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Grove Crane GMK 4080-1 Driving Operating Manual 3302433 – PDF DOWNLOAD
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Description
Grove Crane GMK 4080-1 Driving Operating Manual 3302433 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4080-1 Driving Operating Manual 3302433 – PDF DOWNLOAD
Language : English
Pages : 892
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
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DESCRIPTION:
Grove Crane GMK 4080-1 Driving Operating Manual 3302433 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
The GMK 4080-1 is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 4080-1 truck crane may only be used when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - Without the corresponding special equipment, the GMK 4080-1 truck crane may only be operated within
the permitted temperature range; à Technical
data, p. 1 – 7. - The GMK 4080-1 truck crane is designed solely for lifting loads which are within the permitted GMK
4080-1 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 GMK 4080-1 may only be operated with parts of equipment which are permitted by Manitowoc Crane
Group Germany GmbH and which are labelled with the serial number of the GMK 4080-1. - The manufacturer is not liable for any damage caused by improper or unau- thorized use of the GMK
4080-1 truck crane. The user alone bears the risk.
Improper use:
Manitowoc Crane Group Germany GmbH is not liable for damage resulting
from improper or unauthorized use of the GMK 4080-1 truck crane. The user
alone bears the risk.
Improper use includes:
– Transporting loads on the carrier.
– Pushing, pulling or lifting loads with the level adjustment system, outrigger
beams or outrigger cylinders.
– Pushing or pulling loads or lifting them off the ground using the slewing
gear, derricking gear or telescoping mechanism.
– Pulling off fixed objects with the crane.
– Two-hook operation with the boom extension and two-hook operation on
the main boom head without additional equipment.
– Setting RCL codes that do not correspond to the actual rigging mode.
– Working with an overridden RCL or overridden lifting limit switch.
– After RCL shutdown, increasing the working radius by pulling the raised
load at an angle (e.g. with a chain hoist).
– Misuse of the outrigger pressure display as a safety function to prevent
the crane from overturning (outrigger pressure higher than 0 t).
– On-road driving in an impermissible driving mode (axle load, dimension).
– Moving the rigged crane in an impermissible driving mode.
– Using equipment that is not permitted for the crane.
– Transporting people in any way using the lifting tackle, on the load, or in
the crane cab while driving.
– Transporting passengers outside the driver’s cab.
– Loading and unloading work, i.e. continuous operation without a sufficiently
long break.
– Usage for any kind of sport or recreation event, especially for bungee
jumping.
TABLE OF CONTENTS:
Grove Crane GMK 4080-1 Driving Operating Manual 3302433 – PDF DOWNLOAD
1 Overview.................................................................................... 7 1.1 Accidents............................................................................. 7 1.2 Branch offices........................................................................ 9 1.2.1 Manitowoc Crane Care............................................................ 9 1.2.2 Dealer list..................................................................... 9 1.3 Warranty specifications............................................................... 9 1.4 Terms used............................................................................ 10 1.5 Technical data........................................................................ 13 1.5.1 Maximum lifting capacity (ASME B 30.5).......................................... 13 1.5.2 Dimensions and weights of the truck crane, axle loads........................... 14 Dimensions........................................................................ 15 Weight and axle loads............................................................. 15 1.5.3 Dimensions and weights of removable parts....................................... 16 Spare wheel....................................................................... 16 Outriggers........................................................................ 16 Counterweight combinations........................................................ 16 Counterweight parts............................................................... 17 Hook blocks and hook tackle....................................................... 17 1.5.4 Carrier......................................................................... 19 Engine............................................................................ 19 Transmission...................................................................... 19 Transfer case..................................................................... 19 Axle lines........................................................................ 20 Steering.......................................................................... 20 Tyres............................................................................. 20 Outriggers........................................................................ 21 Electrical system................................................................. 21 Tool.............................................................................. 21 Towing couplings.................................................................. 22 Driving speeds.................................................................... 22 Climbing ability.................................................................. 22 Turning radii..................................................................... 22 1.5.5 Superstructure.................................................................. 23 Main hoist........................................................................ 23 Auxiliary hoist................................................................... 23 Slewing gear...................................................................... 23 Derricking gear................................................................... 23 Main boom......................................................................... 24 Lattice extension................................................................. 24 Operating speeds.................................................................. 24 1.6 Documentation supplied................................................................ 25 1.6.1 Questions on documentation...................................................... 26 1.7 Notes on the operating manual......................................................... 27 1.7.1 What do the symbols used mean?.................................................. 27 1.7.2 How is the operating manual structured?......................................... 29 Division.......................................................................... 29 Structure of the chapters......................................................... 29 Structure of the pages............................................................ 30 1.7.3 How do I find the information I need?........................................... 31 Cross-references example.......................................................... 32 1.7.4 What information is available for operations planning?.......................... 34 1.8 Conversion table for US measuring units............................................... 35 1.9 Training – Information................................................................ 37 1.10 Identification....................................................................... 38 1.11 EC Declaration of Conformity......................................................... 40 2 Basic safety instructions................................................................... 43 2.1 Intended use.......................................................................... 43 2.1.1 Improper use.................................................................... 44 2.2 Organisational measures............................................................... 45 2.3 Personnel qualifications.............................................................. 47 2.4 Safety instructions for driving the truck crane....................................... 48 2.5 Safety instructions for crane operation............................................... 49 2.6 Notes on transporting persons......................................................... 51 Equipment for lifting persons......................................................... 51 Personnel............................................................................. 51 Operation............................................................................. 52 Truck crane........................................................................... 53 3 Operating elements for driving.............................................................. 57 3.1 Overview of the operating elements.................................................... 57 3.1.1 Exterior of the truck crane..................................................... 58 3.1.2 Driver's cab.................................................................... 60 Top view of driver's cab.......................................................... 60 Below in the driver's cab......................................................... 62 Overhead in the driver's cab...................................................... 63 Behind the rest................................................................... 65 3.1.3 Front instrument panel.......................................................... 66 Left.............................................................................. 66 Tachograph........................................................................ 69 Middle............................................................................ 70 Right............................................................................. 72 3.1.4 Side instrument panel........................................................... 74 Transmission display, heating system.............................................. 76 Auxiliary heater.................................................................. 77 3.1.5 Transmission operating elements................................................. 78 3.1.6 Steering wheel/steering column.................................................. 79 3.1.7 Sockets for hand-held control................................................... 80 3.1.8 Outrigger control units......................................................... 81 3.1.9 Hydraulic emergency operation................................................... 83 3.2 Short description of the operating elements........................................... 85 3.2.1 Definition of direction information............................................. 85 Basic rule........................................................................ 85 Switches and buttons.............................................................. 86 3.2.2 General notes on the operating elements......................................... 86 3.2.3 Engine.......................................................................... 87 Steering column................................................................... 87 Multipurpose switch............................................................... 87 Instrument panels................................................................. 88 3.2.4 DEF system...................................................................... 90 Instrument panel.................................................................. 90 3.2.5 Electrical system/electronics................................................... 93 Electrical system................................................................. 93 Electronics....................................................................... 94 3.2.6 Transmission.................................................................... 96 3.2.7 Transfer case...................................................................101 3.2.8 Final drive.....................................................................103 Transverse differential locks.....................................................103 Longitudinal differential lock....................................................103 3.2.9 Reverse camera..................................................................104 3.2.10 Brakes.........................................................................105 Service brake.....................................................................105 Parking brake.....................................................................107 Additional brakes.................................................................108 3.2.11 Steering/separate steering.....................................................109 Instrument panels.................................................................109 Driver's door.....................................................................109 3.2.12 Suspension.....................................................................110 3.2.13 Hydraulic system...............................................................111 3.2.14 Lighting/windscreen wipers/horn................................................111 Steering column...................................................................111 Instrument panels.................................................................112 Overhead in the driver's cab......................................................114 3.2.15 Level adjustment system........................................................115 3.2.16 Tachograph/speedometer.........................................................117 Tachograph........................................................................117 Speedometer.......................................................................117 3.2.17 Diagnostics....................................................................118 3.2.18 Windows, doors, keys...........................................................119 Window winder.....................................................................119 Windows...........................................................................119 Doors.............................................................................120 Keys..............................................................................120 3.2.19 Front flap.....................................................................121 4 Starting/turning off the engine.............................................................125 4.1 Starting the engine from the driver's cab.............................................125 4.1.1 CHECKLIST: Starting the engine..................................................125 4.1.2 CHECKLIST: At low temperatures..................................................128 4.1.3 Ladders and access ladders......................................................129 Ladders...........................................................................129 Access ladders....................................................................130 4.1.4 Operation if equipped with dual tank............................................131 Switching over to the dual tank...................................................131 Switching over to the standard tank...............................................132 4.1.5 Refuel..........................................................................133 Fuel tank.........................................................................133 DEF tank..........................................................................135 Tank – auxiliary heater...........................................................136 4.1.6 Checks before starting the engine...............................................137 On hydraulic tank.................................................................137 Battery master switch.............................................................137 Checking the hand-held control....................................................138 4.1.7 Switching on the ignition.......................................................138 4.1.8 Lamp test/switching state alignment.............................................139 Lamp test.........................................................................139 Switching state alignment.........................................................140 4.1.9 Starting the engine – from the driver's cab.....................................141 Without flame start system........................................................142 With flame start system...........................................................143 4.1.10 Checks after starting the engine...............................................144 4.1.11 Monitoring elements............................................................145 4.1.12 Setting the idling speed.......................................................146 4.2 Turning off the engine................................................................147 4.2.1 On the ignition lock/with hand-held control.....................................147 After turning off.................................................................147 4.2.2 Using the emergency stop switches...............................................148 Resetting the emergency stop switch...............................................148 4.3 Air intake inhibitor..................................................................149 Releasing the air intake inhibitor....................................................149 5 Driving.....................................................................................153 5.1 Before driving........................................................................153 5.1.1 CHECKLIST: Checks before on-road driving........................................153 5.1.2 Checking the condition of the truck crane.......................................159 Electrical system.................................................................159 Adjusting the mirrors.............................................................159 Adjusting the reverse camera......................................................160 Warning plates for vehicle width..................................................161 Vehicle height....................................................................161 Supply pressure...................................................................163 Parking brake.....................................................................164 5.1.3 Adjusting the seat and the steering column......................................165 Driver's seat.....................................................................165 Passenger's seat..................................................................166 Adjusting the steering column.....................................................166 5.1.4 Switching the suspension on/off.................................................167 Switching on the suspension.......................................................167 Switching off the suspension......................................................167 5.1.5 Setting the tachograph..........................................................169 Prerequisites.....................................................................169 In the event of malfunctions......................................................169 Setting the tachograph............................................................170 5.2 Operating the transmission............................................................175 5.2.1 Switching on....................................................................175 5.2.2 Switching the transmission to neutral position..................................176 5.2.3 Selecting the direction of travel and starting gear.............................177 Selecting the driving direction...................................................177 Selecting the starting gear.......................................................178 5.2.4 Changing the operating mode.....................................................179 Changing to automatic mode........................................................179 Changing to manual mode...........................................................179 5.2.5 Starting........................................................................181 5.2.6 Driving and changing gears......................................................183 In automatic operating mode.......................................................183 In manual operating mode..........................................................184 5.2.7 Changing the driving direction..................................................185 5.2.8 Stopping........................................................................185 Stopping for a long period of time................................................185 5.2.9 Transmission mode L.............................................................186 Switching on......................................................................186 Switching off.....................................................................187 5.2.10 On the roller type dynamometer.................................................188 5.2.11 Preheating transmission........................................................188 5.3 Driving and turning off the truck crane...............................................189 5.3.1 Checks while driving............................................................189 Immediately after you start to move...............................................189 While driving.....................................................................190 5.3.2 Tempomat........................................................................192 Switching on the Tempomat.........................................................192 Driving with the Tempomat.........................................................193 Switching off the Tempomat........................................................193 5.3.3 Temposet........................................................................194 Switching on......................................................................194 Driving with the Temposet.........................................................194 Switching off.....................................................................194 5.3.4 Driving downhill................................................................195 Starting..........................................................................195 Inspections when driving downhill.................................................197 Downshifting......................................................................198 Additional brakes.................................................................199 5.3.5 Driving uphill..................................................................200 Starting..........................................................................200 Driving...........................................................................200 5.3.6 Warning messages in driving mode................................................201 Meaning of the lamps..............................................................201 5.3.7 Notes on torque reduction.......................................................205 5.3.8 Turning off the truck crane.....................................................206 Securing the truck crane against moving unintentionally...........................207 When stationary for more than 8hours.............................................208 5.3.9 Fold-up berth...................................................................209 5.4 Off-road driving......................................................................211 Adjustments to the transmission.......................................................211 Connections...........................................................................211 Changing the vehicle level............................................................211 Rocking the vehicle free and towing...................................................211 5.4.1 Transfer case – switching on off-road/on-road gears.............................212 Engaging the off-road gear........................................................212 Switching on the on-road gear.....................................................212 Neutral position..................................................................212 5.4.2 Key-operated switch.............................................................213 When switching on.................................................................213 When switching off................................................................213 5.4.3 Operating the longitudinal differential lock....................................215 5.4.4 Operating of the transverse differential locks..................................217 5.4.5 Operating the level adjustment system...........................................219 Setting the on-road level.........................................................219 Preselecting lifting/lowering.....................................................221 Inclining the truck crane.........................................................221 Changing the overall level........................................................221 After level adjustment............................................................222 5.4.6 Separate steering/normal steering mode..........................................223 Switching to separate steering....................................................224 Steering with separate steering...................................................225 Switching to normal steering mode.................................................226 5.4.7 Freeing truck crane stuck in terrain............................................227 Rocking the truck crane free......................................................227 Towing free forwards..............................................................228 Towing free in reverse gear.......................................................228 5.5 Heating and air-conditioning system...................................................229 5.5.1 Standard heating system.........................................................229 Switching on......................................................................229 Heating...........................................................................229 Air distribution..................................................................231 Examples..........................................................................232 Switching off.....................................................................232 5.5.2 Auxiliary water heating system..................................................233 Preheating theengine.............................................................233 Preheating thedriver's cab.......................................................234 Switching on......................................................................235 Setting the day and time..........................................................236 Storing the heating start.........................................................237 Setting the heating period........................................................238 Switching the heating start on and off............................................239 Switching off.....................................................................239 Setting the remaining time........................................................240 5.5.3 Air-conditioning system.........................................................241 Information.......................................................................241 Switching on/off..................................................................241 Cooling...........................................................................242 Drying............................................................................242 5.6 Towing a trailer......................................................................243 Effects on the axle loads.............................................................243 Coupling the trailer..................................................................244 Connecting the supply lines...........................................................245 Removing the supply lines.............................................................246 Uncoupling the trailer................................................................246 Checking the braking force............................................................248 6 Driving modes...............................................................................251 6.1 Driving modes.........................................................................251 Information about the axle loads......................................................251 6.1.1 Information on how to use the tables............................................252 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs)..............................253 For 385/95 R25 tyres..............................................................253 For 445/95 R25 tyres..............................................................254 For 525/80 R25 tyres..............................................................255 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)............257 6.2 Rigging work for driving with a trailer...............................................259 6.2.1 Switching on the slewing gear freewheel.........................................259 6.2.2 Switching on the boom floating position.........................................261 6.2.3 Switching on boom pre-tensioning................................................262 6.2.4 Switching the superstructure driving lights on/off..............................264 Switching off.....................................................................264 Switching on......................................................................264 7 Malfunctions in driving mode................................................................267 7.1 Emergency stop switch.................................................................267 7.2 What to do when a malfunction occurs in road traffic..................................269 7.3 Towing the truck crane................................................................271 7.3.1 Towing after engine/transmission damage.........................................272 Compressed-air supply.............................................................272 Electric power supply.............................................................272 On the transmission...............................................................273 Axle drives.......................................................................273 Transfer case.....................................................................273 Parking brake.....................................................................274 Towing the truck crane out of the danger area.....................................275 7.3.2 Tow starting....................................................................275 7.4 Wheels and tyres......................................................................277 7.4.1 Wheel change....................................................................277 Removing a damaged wheel..........................................................277 On the spare wheel holder.........................................................278 Mounting a wheel..................................................................279 7.4.2 Inflating the tyres yourself....................................................280 Connecting the filling hose.......................................................280 Inflating the tyres...............................................................281 Removing the filling hose.........................................................281 7.5 Tilting/lowering the driver's cab.....................................................283 7.5.1 Prerequisites and information on tilting........................................283 7.5.2 With mechanical tilt mechanism..................................................284 Unlocking/ locking the driver's cab...............................................284 Tilting the driver's cab..........................................................285 Lowering the driver's cab.........................................................287 7.5.3 Tilting and lowering the driver's cab...........................................288 Operating the hand pump...........................................................288 Tilting the driver's cab..........................................................289 Lowering the driver's cab.........................................................290 7.6 Fuses on the carrier..................................................................291 Notes on changing fuses...............................................................291 7.6.1 Fuses in the driver's cab.......................................................292 Front cover.......................................................................292 7.6.2 Fuses on the I/Oboards.........................................................297 7.6.3 Fuses in the battery box........................................................299 7.6.4 Fuse on the battery charger.....................................................300 7.7 Troubleshooting.......................................................................301 7.7.1 Malfunctions on the engine......................................................301 When operating with the dual tank.................................................303 7.7.2 Malfunctions in the DEF system..................................................304 7.7.3 Malfunctions in the transmission................................................305 7.7.4 Malfunctions of the service brake...............................................307 7.7.5 Malfunctions of the outriggers..................................................308 7.7.6 Malfunctions of the steering....................................................309 7.7.7 Transfer case malfunctions......................................................310 7.7.8 Malfunctions in the differential locks..........................................310 7.7.9 Malfunctions in the hydraulic system/hydraulic oil cooler.......................311 7.7.10 Malfunctions on the suspension.................................................311 7.7.11 Malfunctions of the level adjustment system....................................312 7.7.12 Malfunctions of the reverse camera.............................................312 7.7.13 Malfunctions in the lighting and indicators....................................313 7.7.14 Various malfunctions on the carrier............................................314 7.7.15 Malfunctions on the ECOS carrier...............................................316 In the driver's cab...............................................................316 On the control units..............................................................319 7.8 Procedure during malfunctions.........................................................321 7.8.1 Switching the engine fan to emergency mode......................................321 7.8.2 Switching the fan thermostat to emergency mode..................................322 7.8.3 Procedure during transmission malfunctions......................................323 Error messages....................................................................323 Displaying error codes............................................................324 7.9 Emergency operations..................................................................327 7.9.1 External starting socket........................................................327 Performing a jump start...........................................................328 8 Index.......................................................................................331 A.........................................................................................333 B.........................................................................................333 C.........................................................................................333 D.........................................................................................336 E.........................................................................................338 F.........................................................................................340 H.........................................................................................340 I.........................................................................................341 K.........................................................................................342 L.........................................................................................342 M.........................................................................................342 O.........................................................................................344 P.........................................................................................345 R.........................................................................................345 S.........................................................................................346 T.........................................................................................347 V.........................................................................................349 W.........................................................................................349 9 Operating elements for crane operation......................................................359 9.1 Overview of the operating elements....................................................359 9.1.1 Exterior of the truck crane.....................................................360 9.1.2 Crane cab.......................................................................364 9.1.3 Front panel.....................................................................366 9.1.4 Side panel......................................................................367 Bottom............................................................................367 Top...............................................................................368 Console, rear.....................................................................370 Heating system....................................................................371 9.1.5 Control panels..................................................................372 Left..............................................................................372 Right.............................................................................373 9.1.6 Control lever configuration.....................................................374 Version 1.........................................................................374 Version 2.........................................................................375 9.1.7 ECOS control unit...............................................................376 9.1.8 ECOS display – main menu........................................................378 9.1.9 ECOS display – submenus.........................................................381 Counterweight submenu.............................................................381 Outriggers submenu................................................................382 Telescoping submenu...............................................................384 Power unit speeds submenu.........................................................386 Monitoring submenu................................................................387 Settings submenu..................................................................388 Operating hours submenu...........................................................389 Error submenu.....................................................................390 Warning submenu...................................................................391 Working range limiter submenu....................................................392 Enter slewing angle submenu.......................................................393 Enter objects submenu.............................................................394 Driving submenu...................................................................395 9.1.10 RCL control unit...............................................................396 9.1.11 Hand-held control..............................................................401 Outriggers control panel.........................................................403 9.1.12 Outrigger control units........................................................404 Outrigger.........................................................................405 Outrigger pressure display........................................................405 Inclination indicator.............................................................405 9.1.13 Hydraulic emergency operation..................................................406 9.2 Short description of the operating elements...........................................407 9.2.1 Definition of direction information.............................................407 Basic rule........................................................................407 Switches..........................................................................408 9.2.2 General rules for buttons and symbols on the display............................409 9.2.3 Engine..........................................................................411 Side panel........................................................................411 ECOS display......................................................................411 9.2.4 Seat contact switch and dead man's switch.......................................412 9.2.5 ECOS crane control..............................................................413 Control unit......................................................................413 9.2.6 Outrigger.......................................................................416 Hand-held control.................................................................416 In the Outrigger submenu..........................................................417 In the Settings submenu...........................................................418 On the outrigger control units....................................................419 9.2.7 Inclination indicators..........................................................421 9.2.8 Outrigger pressure displays.....................................................422 Outriggers submenu................................................................422 Outrigger control units...........................................................422 9.2.9 Anemometer display..............................................................422 9.2.10 Counterweight submenu..........................................................423 Counterweight submenu.............................................................423 9.2.11 Main hoist.....................................................................426 9.2.12 Auxiliary hoist................................................................427 9.2.13 Slewing gear...................................................................429 9.2.14 Houselock......................................................................430 ECOS Display......................................................................430 Side panel........................................................................430 9.2.15 Derricking gear................................................................431 9.2.16 Telescoping mechanism..........................................................432 Control panels....................................................................432 Submenu...........................................................................433 In the Settings submenu...........................................................437 9.2.17 Hydraulic system...............................................................439 9.2.18 Rated capacity limiter (RCL)...................................................441 Input elements with displays......................................................441 Display elements..................................................................444 RCL override......................................................................447 External displays.................................................................448 9.2.19 Electrical system..............................................................449 9.2.20 Lighting, windscreen wiper/washing system......................................450 Lighting..........................................................................450 Windscreen wiper/washing system...................................................451 9.2.21 Hand-held control..............................................................453 Sockets for hand- held control....................................................453 Engine control panel..............................................................454 Horn..............................................................................454 Outrigger control panel...........................................................455 Hand-held control bracket.........................................................457 9.2.22 Diagnostics....................................................................457 9.2.23 Windows, doors, keys...........................................................458 Windscreen........................................................................458 Rear window.......................................................................458 Crane cab door....................................................................459 Keys..............................................................................460 9.3 Short description of the operating elements – driving from the crane cab..............461 9.3.1 Driving submenu.................................................................461 9.3.2 Engine..........................................................................461 9.3.3 Transmission....................................................................462 9.3.4 Final drive.....................................................................463 9.3.5 Brakes..........................................................................464 Side panel........................................................................464 9.3.6 Steering........................................................................465 Normal steering...................................................................465 Separate steering.................................................................466 10 Starting/turning off the engine – for crane operation......................................469 10.1 CHECKLIST: When starting the engine for the first time of the day....................469 10.2 CHECKLIST: Starting the engine from the crane cab....................................471 10.2.1 CHECKLIST: At low temperatures.................................................473 10.2.2 Refuelling.....................................................................473 Tank for superstructure heater....................................................473 10.2.3 Checks before starting the engine..............................................474 Checking the hand-held control....................................................474 10.2.4 Switching on the ignition......................................................474 10.2.5 Lamp test/switching state equalisation.........................................475 Lamp test.........................................................................475 Equalisation of the switching states..............................................476 10.2.6 Adjusting display brightness...................................................477 10.2.7 Starting the engine – from the crane cab.......................................478 Without flame start system........................................................478 With flame start system...........................................................479 10.2.8 Checks after starting the engine...............................................480 10.2.9 Monitoring submenu.............................................................481 10.2.10 Setting idling speed..........................................................482 10.3 Starting the engine – with the hand-held control.....................................483 Prerequisites.........................................................................483 In the driver's cab...................................................................483 Start the engine......................................................................483 10.4 Turning off the engine...............................................................485 10.4.1 During normal operation, with the ignition lock/with the hand- held control....485 After turning off.................................................................485 10.4.2 In emergencies, with the emergency stop switches...............................486 Resetting the emergency stop switch...............................................486 10.5 Air intake inhibitor.................................................................487 11 Crane operation............................................................................491 11.1 Before operating the crane...........................................................491 11.1.1 CHECKLIST: Checks before operating the crane...................................491 11.1.2 Checking the condition of the truck crane......................................495 Visual inspection.................................................................495 Checking the position of the hoist ropes..........................................495 Checking the electrical system....................................................496 11.1.3 Adjusting the crane cab seat and front control panel...........................497 Crane cab seat....................................................................497 Front panel.......................................................................498 11.1.4 Checking the safety equipment..................................................499 Rated capacity limiter............................................................499 Lifting limit switch..............................................................499 Emergency stop switch.............................................................500 Seat contact switch...............................................................501 11.1.5 Earthing the load..............................................................502 11.1.6 Preheating the hydraulic oil...................................................503 11.1.7 Switching the houselock on/off.................................................504 Switching on the houselock........................................................504 Switching off the houselock.......................................................506 11.2 Operation of the rated capacity limiter..............................................507 11.2.1 Switching on the RCL...........................................................508 Switching on......................................................................508 Lamp test on the RCL..............................................................510 Brightness of the displays........................................................510 11.2.2 Enter rigging mode.............................................................511 Entering the RCL code.............................................................512 Entering the reeving..............................................................515 Entering individual components....................................................516 11.2.3 Checks before operating the crane..............................................520 11.2.4 Displays during crane operation................................................522 Continuous displays...............................................................522 Optional displays.................................................................524 11.2.5 RCL early warning..............................................................526 11.2.6 RCL shutdown...................................................................526 Shutdown due to overload..........................................................526 11.2.7 Error message..................................................................528 11.2.8 RCL override – version A.......................................................529 11.2.9 RCL override – version B.......................................................530 Overview status display...........................................................530 When rigging......................................................................531 To raise the boom.................................................................532 In emergencies....................................................................533 11.2.10 Displaying and entering the time and date.....................................534 Display...........................................................................534 Input.............................................................................535 11.3 Crane operation with main boom.......................................................537 11.3.1 Checks during crane operation..................................................537 Horizontal alignment..............................................................537 Safe distances....................................................................537 Checking the wind speed...........................................................538 11.3.2 Permissible slewing ranges and working positions...............................539 360 slewing range................................................................539 0 to the rear working position...................................................539 180 to the front rigging position................................................540 Free-on-wheels working position...................................................540 11.3.3 Main hoist.....................................................................541 Switching on the main hoist.......................................................542 Lifting and lowering..............................................................542 Switching off the main hoist......................................................543 11.3.4 Auxiliary hoist................................................................545 Switching on the auxiliary hoist..................................................546 Lifting and lowering..............................................................546 Switching off the auxiliary hoist.................................................547 11.3.5 Lifting limit switch, lowering limit switch, height contact switch.............549 Lifting limit switch..............................................................549 Lowering limit switch.............................................................551 11.3.6 Derricking gear................................................................551 Switching on the derricking gear..................................................552 Raising and lowering..............................................................552 Re-enable raising function........................................................553 Switching off the derricking gear.................................................554 Lowering the main boom to a horizontal position...................................554 11.3.7 Telescoping mechanism..........................................................555 Overview..........................................................................556 Telescoping process...............................................................556 Assignment for display............................................................558 Fixed length, intermediate length, telescoping length.............................560 Telescoping.......................................................................561 Telescoping sequence..............................................................561 Checks before starting work.......................................................562 Switching on the telescoping mechanism............................................562 Function of the control lever.....................................................563 Switching off the telescoping mechanism...........................................565 Manual telescoping................................................................565 Checking the initial position.....................................................566 Unlocking the telescoping cylinder................................................568 Extending/retracting the telescoping cylinder.....................................570 Lock telescoping cylinder.........................................................571 Unlocking the telescopic section..................................................572 Telescoping the telescopic section................................................574 Locking the telescopic section....................................................575 Locking the telescopic section for on-road driving................................576 Telescoping with teleautomation...................................................577 Telescoping the main boom when horizontal.........................................581 11.3.8 High-speed mode................................................................582 Switch on function................................................................582 Derricking gear/ telescoping mechanism............................................582 Hoist.............................................................................583 11.3.9 Slewing gear...................................................................584 Switching on the slewing gear.....................................................584 Slew..............................................................................585 Braking the slewing movement......................................................588 Slewing gear freewheel............................................................589 Switching off the slewing gear....................................................589 11.3.10 Possible movement combinations................................................590 11.3.11 Hydraulic oil cooling.........................................................590 11.4 Settings and displays for crane operation............................................591 11.4.1 Inclining the crane cab........................................................591 11.4.2 Setting idling speed...........................................................592 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................592 11.4.4 Limiting the power unit speeds.................................................593 11.4.5 Setting the characteristic curves for the control levers.......................594 11.4.6 Using the slewable spotlights..................................................595 11.4.7 Displaying the operating hours.................................................596 11.4.8 Warning submenu................................................................597 Meaning of the symbols............................................................597 Exiting the submenu...............................................................600 11.4.9 Error submenu..................................................................600 11.5 Working range limiter................................................................601 11.5.1 Opening the working range limiter submenu......................................602 11.5.2 Viewing current settings.......................................................603 11.5.3 Entering limit values..........................................................605 Overall height/ Working radius....................................................605 Slewing angle.....................................................................606 Entering objects..................................................................608 11.5.4 Entering limit values/objects manually.........................................611 Limit values......................................................................611 Objects...........................................................................612 11.5.5 Switching monitoring functions on/off..........................................613 11.5.6 Shutdown by working range limiter..............................................614 11.6 Work break...........................................................................615 11.6.1 In case of short work breaks...................................................615 11.6.2 In case of work breaks of more than 8 hours....................................616 To secure the truck crane.........................................................616 11.7 Heating and air-conditioning system..................................................617 11.7.1 Heating system.................................................................617 Switching on......................................................................618 Heating...........................................................................619 Air distribution..................................................................620 Switching off.....................................................................621 Setting the day and time..........................................................621 Storing the heating start.........................................................622 Setting the heating period........................................................623 Switching heating start on/off....................................................624 Switching off.....................................................................625 Setting the remaining time........................................................625 11.7.2 Air-conditioning system........................................................627 Information.......................................................................627 Switching on/off..................................................................628 Cooling...........................................................................628 Drying the air....................................................................629 11.8 CraneSTAR system.....................................................................631 11.8.1 Overview.......................................................................631 11.8.2 Position of the components.....................................................631 12 Rigging work...............................................................................635 12.1 Rigging work checklists for crane operation with the main boom.......................635 12.1.1 CHECKLIST: Rigging.............................................................635 12.1.2 CHECKLIST: Unrigging...........................................................641 12.2 Choosing a suitable site.............................................................645 12.2.1 Determining the required ground bearing area...................................645 12.2.2 Safe distance from slopes and pits.............................................648 12.2.3 Earthing the truck crane.......................................................649 12.2.4 Safe distance from electrical cables...........................................650 12.3 Rigging work after driving with a trailer............................................653 12.3.1 Switching off the boom floating position.......................................653 12.3.2 Switching off the slewing gear freewheel.......................................654 Before slewing....................................................................654 12.3.3 Switching off boom pre-tensioning..............................................655 12.4 Connecting/disconnecting the hand-held control.......................................657 12.5 Outrigger............................................................................659 12.5.1 CHECKLIST: Extending the outriggers............................................659 12.5.2 CHECKLIST: Retracting the outriggers...........................................661 12.5.3 Permissible outrigger spans....................................................662 12.5.4 Preparing the truck crane......................................................663 In the driver's cab...............................................................663 Outrigger control units...........................................................663 12.5.5 Setting the outrigger spans....................................................664 For on-road driving...............................................................667 12.5.6 Extending/retracting outrigger beams...........................................669 From the control units............................................................670 With the hand- held control.......................................................671 From the crane cab................................................................673 12.5.7 Moving the outrigger pads into working/driving position........................675 12.5.8 Enlarging the ground bearing area..............................................676 12.5.9 Extending/retracting supporting cylinders......................................677 From the control units............................................................678 With the hand- held control.......................................................679 From the crane cab................................................................681 12.5.10 Level the truck crane on outriggers...........................................683 Inclination indicators............................................................683 Prerequisites.....................................................................684 Manual alignment..................................................................685 Automatic alignment...............................................................686 12.5.11 Levelling the free-on-wheels truck crane......................................688 When rigging......................................................................688 During crane operation............................................................689 12.5.12 Outrigger pressure display....................................................691 12.6 Rigging/unrigging the counterweight..................................................693 12.6.1 Counterweight sections.........................................................693 Counterweight sections............................................................693 12.6.2 Identification.................................................................694 12.6.3 Slinging points on the counterweight sections..................................695 12.6.4 CHECKLIST: Rigging the counterweight...........................................696 12.6.5 CHECKLIST: Unrigging the counterweight.........................................697 12.6.6 Assembling counterweight versions – on the turntable...........................699 12.6.7 Assembling counterweight versions – on the counterweight platform..............700 Setting down the 2.5 t base plate.................................................701 Note on 19.3 t....................................................................701 With 1.8 t on the turntable.......................................................702 With 4.3 t on the turntable.......................................................704 With 6.8 t on the turntable.......................................................706 With 9.3 t on the turntable.......................................................708 12.6.8 Counterweight hoist unit.......................................................709 Checks............................................................................710 Counterweight submenu.............................................................711 Extending/retracting the lifting cylinders........................................711 Locking/Unlocking counterweight...................................................712 12.6.9 Removing/installing the counterweight on the turntable.........................713 Removing..........................................................................713 Installing........................................................................714 12.6.10 Setting down counterweight for driving the truck crane........................715 12.6.11 Slewing with rigged counterweight.............................................717 12.7 Rigging work on the main boom........................................................719 12.7.1 Hook block on the bumper.......................................................719 Picking up the hook block.........................................................719 Attaching the hook block..........................................................720 12.7.2 Hook block on a separate vehicle...............................................721 Picking up the hook block.........................................................722 Setting down the hook block.......................................................722 12.7.3 Reeving and unreeving the hoist rope...........................................724 Pocket lock.......................................................................724 Fork..............................................................................725 Rope end clamp....................................................................726 Reeving the hoist rope............................................................727 Unreeving the hoist rope..........................................................731 12.7.4 Possible reeving methods on the main boom......................................733 With 6 head sheaves...............................................................733 With 7 head sheaves...............................................................736 With 8 head sheaves...............................................................738 12.7.5 Installing/removing the lifting limit switch...................................739 Installing the lifting limit switch...............................................739 Removing the lifting limit switch.................................................742 12.7.6 Locking/unlocking the lifting limit switch.....................................743 Locking...........................................................................743 Releasing locking.................................................................744 12.7.7 Anemometer and air traffic control light.......................................745 Installing........................................................................745 Removing..........................................................................746 12.8 Other rigging work...................................................................747 12.8.1 Rigging in free on wheels working position.....................................747 12.8.2 Mirror for crane operation.....................................................751 12.8.3 Cameras for crane operation....................................................752 Cameras on the hoists.............................................................752 Camera on main boom...............................................................752 Turning the monitor on/off and switching between cameras..........................756 13 Driving with rigged truck crane............................................................759 13.1 Safety instructions..................................................................759 13.2 Driving distance.....................................................................761 13.3 Before driving the rigged truck crane................................................761 13.3.1 Check the tyre pressure and the wind speed.....................................761 13.4 Permissible rigging modes and axle loads.............................................763 13.4.1 Axle loads.....................................................................763 13.4.2 To drive without a load........................................................763 13.4.3 To drive with a load...........................................................764 13.5 Driving from the driver's cab........................................................765 13.5.1 Preparing to drive.............................................................765 Transmission......................................................................765 Switching on separate steering....................................................765 Connections.......................................................................765 13.5.2 While driving..................................................................766 13.6 Driving from the crane cab...........................................................767 13.6.1 Preparing to drive.............................................................767 In the driver's cab...............................................................767 In the crane cab..................................................................768 13.6.2 Opening/closing the Driving mode submenu.......................................769 Automatic.........................................................................769 Manual............................................................................770 Closing...........................................................................771 13.6.3 Steering system................................................................771 Switching on......................................................................771 Adjusting the steering direction..................................................772 Normal steering...................................................................772 Separate steering.................................................................773 13.6.4 Operating the transmission.....................................................775 Driving direction.................................................................775 Selecting the transmission mode...................................................776 13.6.5 Cameras for driving from the crane cab.........................................777 13.6.6 Starting.......................................................................778 13.6.7 While driving..................................................................778 Transmission mode L, R............................................................778 Transmission mode D...............................................................779 Warning messages..................................................................779 13.6.8 Possible connections...........................................................780 Longitudinal/ transverse differential locks.......................................780 13.6.9 After driving..................................................................782 14 Malfunctions during crane operation........................................................785 14.1 Emergency stop switch................................................................785 14.2 What to do when malfunctions occur during crane operation............................787 Load can be lowered...................................................................787 Load cannot be lowered................................................................787 14.3 Fuses on the superstructure..........................................................789 Notes on changing fuses...............................................................789 14.3.1 Fuses on the turntable.........................................................790 Fuse groups F1/F8.................................................................790 Fuses on the circuit board........................................................791 On I/O-3 circuit board............................................................791 14.3.2 Fuses in the crane cab.........................................................792 14.3.3 RCL fuses......................................................................794 14.4 Finding and eliminating malfunctions.................................................795 14.4.1 Malfunctions on the engine.....................................................795 14.4.2 Malfunctions when inclining the crane cab......................................795 14.4.3 Malfunctions when operating with the hand-held control.........................796 14.4.4 Malfunctions when inclining the crane cab......................................796 14.4.5 Malfunctions on the main hoist/auxiliary hoist.................................797 14.4.6 Malfunctions in the hoist cameras..............................................799 14.4.7 Malfunctions in the main boom camera...........................................799 14.4.8 Malfunctions on the derricking gear............................................801 14.4.9 Malfunctions in the telescoping mechanism......................................803 Telescoping mechanism error messages..............................................805 14.4.10 Malfunctions on the slewing gear..............................................807 14.4.11 Malfunctions on the counterweight hoist unit..................................809 14.4.12 Malfunctions in the hydraulic system/hydraulic oil cooler.....................810 14.4.13 Malfunctions when driving from the crane cab..................................811 14.4.14 Malfunctions of the outriggers................................................812 14.4.15 Various crane cab malfunctions................................................813 14.4.16 Troubleshooting the RCL.......................................................815 General malfunctions..............................................................815 Error messages....................................................................816 Table of error codes..............................................................818 Switching off the sensor/tachogenerator...........................................821 14.4.17 Malfunctions ECOS – superstructure............................................822 ECOS programme version............................................................822 General malfunctions..............................................................822 Error messages....................................................................823 Exiting the submenu...............................................................824 14.4.18 Malfunctions on CraneSTAR system..............................................825 14.5 Emergency operations and programmes..................................................829 14.5.1 Mechanical emergency activation for retracting.................................830 Prior to the emergency activation, check..........................................830 Procedure.........................................................................830 Mechanical emergency activation...................................................831 14.5.2 Telescoping emergency programme................................................833 Start the emergency program.......................................................833 Determining the error type........................................................834 Error on length indicator.........................................................835 If there is an error at a proximity switch........................................838 Terminating the emergency program.................................................840 Tables for approaching the locking points.........................................841 14.5.3 Entering the current telescoping...............................................843 14.5.4 Emergency operation with the hand-held control.................................845 Preparations......................................................................845 Operating a power unit............................................................846 Stopping movements................................................................848 Stopping movements in emergencies.................................................848 Turning off the engine............................................................848 14.6 Hydraulic emergency operation........................................................849 14.6.1 Connect/disconnect hoses.......................................................849 14.6.2 Establishing the required hydraulic circuits...................................850 Switching over valves.............................................................850 For lifting/lowering..............................................................852 14.6.3 Performing emergency operation.................................................853 14.6.4 After the emergency activation.................................................853 14.7 Hydraulic emergency operation BGR 159................................................855 14.7.1 Operating principle............................................................855 14.7.2 Connecting/disconnecting hoses.................................................857 For transformers..................................................................857 For the hand pump.................................................................858 14.7.3 Establishing the hydraulic circuits required...................................859 Switching positions of the valves.................................................859 Switching over valves.............................................................859 For lifting/lowering..............................................................861 For slewing.......................................................................862 14.7.4 Performing emergency operation.................................................863 Derricking........................................................................864 Lifting/lowering..................................................................865 Slew..............................................................................865 14.7.5 After emergency operation......................................................866 Switching off emergency operation.................................................866 Switching over to crane operation.................................................866 Disconnecting the hoses...........................................................866 14.7.6 Emergency supply of another crane..............................................867 After emergency supply............................................................868 15 Index......................................................................................871 A.........................................................................................873 B.........................................................................................873 C.........................................................................................873 D.........................................................................................876 E.........................................................................................878 F.........................................................................................880 H.........................................................................................880 I.........................................................................................881 K.........................................................................................882 L.........................................................................................882 M.........................................................................................882 O.........................................................................................884 P.........................................................................................885 R.........................................................................................885 S.........................................................................................886 T.........................................................................................887 V.........................................................................................889 W.........................................................................................889
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