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Grove Crane GMK 4080-1 Driving Operating Manual 3302434 – PDF DOWNLOAD
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Description
Grove Crane GMK 4080-1 Driving Operating Manual 3302434 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4080-1 Driving Operating Manual 3302434 – PDF DOWNLOAD
Language : English
Pages : 908
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
DESCRIPTION:
Grove Crane GMK 4080-1 Driving Operating Manual 3302434 – 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; àTechnical
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 unauthorized
use of the GMK 4080-1 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 4080-1 Driving Operating Manual 3302434 – 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.........................................................................................344 R.........................................................................................345 S.........................................................................................346 T.........................................................................................347 V.........................................................................................349 W.........................................................................................350 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 RCL display – main menu........................................................398 9.1.12 RCL display – submenus.........................................................399 Submenu Rigging mode entry........................................................399 Monitoring submenu................................................................400 Rigging mode monitoring submenu...................................................402 Submenu Lifting capacity table....................................................403 Working range submenu.............................................................404 Error submenu.....................................................................405 Settings submenu.................................................................406 9.1.13 Hand-held control..............................................................407 Outriggers control panel.........................................................409 9.1.14 Outrigger control units........................................................410 Outrigger.........................................................................411 Outrigger pressure display........................................................411 Inclination indicator.............................................................411 9.1.15 Hydraulic emergency operation..................................................412 9.2 Short description of the operating elements...........................................413 9.2.1 Definition of direction information.............................................413 Basic rule........................................................................413 Switches..........................................................................414 9.2.2 General rules for buttons and symbols on the display............................415 9.2.3 Engine..........................................................................417 Side panel........................................................................417 ECOS display......................................................................417 9.2.4 Seat contact switch and dead man's switch.......................................418 9.2.5 ECOS crane control..............................................................419 Control unit......................................................................419 9.2.6 Outrigger.......................................................................422 Hand-held control.................................................................422 In the Outrigger submenu..........................................................423 In the Settings submenu...........................................................424 On the outrigger control units....................................................425 9.2.7 Inclination indicators..........................................................427 9.2.8 Outrigger pressure displays.....................................................428 Outriggers submenu................................................................428 Outrigger control units...........................................................428 9.2.9 Anemometer display..............................................................428 9.2.10 Counterweight submenu..........................................................429 Counterweight submenu.............................................................429 9.2.11 Main hoist.....................................................................432 9.2.12 Auxiliary hoist................................................................433 9.2.13 Slewing gear...................................................................435 9.2.14 Houselock......................................................................436 ECOS Display......................................................................436 Side panel........................................................................436 9.2.15 Derricking gear................................................................437 9.2.16 Telescoping mechanism..........................................................438 Control panels....................................................................438 Submenu...........................................................................439 In the Settings submenu...........................................................443 9.2.17 Hydraulic system...............................................................445 9.2.18 Rated capacity limiter (RCL)...................................................447 Control unit......................................................................447 Main menu.........................................................................449 Submenu Rigging mode entry........................................................450 Monitoring submenu...............................................................453 Submenu Lifting capacity table....................................................457 Working range submenu.............................................................458 RCL override......................................................................459 External displays.................................................................460 9.2.19 Electrical system..............................................................461 9.2.20 Lighting, windscreen wiper/washing system......................................462 Lighting..........................................................................462 Windscreen wiper/washing system...................................................463 9.2.21 Hand-held control..............................................................465 Sockets for hand- held control....................................................465 Engine control panel..............................................................466 Horn..............................................................................466 Outrigger control panel...........................................................467 Hand-held control bracket.........................................................469 9.2.22 Diagnostics....................................................................469 9.2.23 Windows, doors, keys...........................................................470 Windscreen........................................................................470 Rear window.......................................................................470 Crane cab door....................................................................471 Keys..............................................................................472 9.3 Short description of the operating elements – driving from the crane cab..............473 9.3.1 Driving submenu.................................................................473 9.3.2 Engine..........................................................................473 9.3.3 Transmission....................................................................474 9.3.4 Final drive.....................................................................475 9.3.5 Brakes..........................................................................476 Side panel........................................................................476 9.3.6 Steering........................................................................477 Normal steering...................................................................477 Separate steering.................................................................478 10 Starting/turning off the engine – for crane operation......................................481 10.1 CHECKLIST: When starting the engine for the first time of the day....................481 10.2 CHECKLIST: Starting the engine from the crane cab....................................483 10.2.1 CHECKLIST: At low temperatures.................................................485 10.2.2 Refuelling.....................................................................485 Tank for superstructure heater....................................................485 10.2.3 Checks before starting the engine..............................................486 Checking the hand-held control....................................................486 10.2.4 Switching on the ignition......................................................486 10.2.5 Lamp test/switching state equalisation.........................................487 Lamp test.........................................................................487 Equalisation of the switching states..............................................488 10.2.6 Adjusting display brightness...................................................489 10.2.7 Starting the engine – from the crane cab.......................................490 Without flame start system........................................................490 With flame start system...........................................................491 10.2.8 Checks after starting the engine...............................................492 10.2.9 Monitoring submenu.............................................................493 10.2.10 Setting idling speed..........................................................494 10.3 Starting the engine – with the hand-held control.....................................495 Prerequisites.........................................................................495 In the driver's cab...................................................................495 Start the engine......................................................................495 10.4 Turning off the engine...............................................................497 10.4.1 During normal operation, with the ignition lock/with the hand- held control....497 After turning off.................................................................497 10.4.2 In emergencies, with the emergency stop switches...............................498 Resetting the emergency stop switch...............................................498 10.5 Air intake inhibitor.................................................................499 11 Crane operation............................................................................503 11.1 Before operating the crane...........................................................503 11.1.1 CHECKLIST: Checks before operating the crane...................................503 11.1.2 Checking the condition of the truck crane......................................507 Visual inspection.................................................................507 Checking the position of the hoist ropes..........................................507 Checking the electrical system....................................................508 11.1.3 Adjusting the crane cab seat and front control panel...........................509 Crane cab seat....................................................................509 Front panel.......................................................................510 11.1.4 Checking the safety equipment..................................................511 Rated capacity limiter............................................................511 Lifting limit switch..............................................................511 Emergency stop switch.............................................................512 Seat contact switch...............................................................513 11.1.5 Earthing the load..............................................................514 11.1.6 Preheating the hydraulic oil...................................................515 11.1.7 Switching the houselock on/off.................................................516 Switching on the houselock........................................................516 Switching off the houselock.......................................................518 11.2 Operation of the rated capacity limiter..............................................519 11.2.1 Switching on the RCL...........................................................520 Switching on......................................................................520 Brightness of the displays........................................................522 11.2.2 Enter rigging mode.............................................................523 Entering individual components....................................................524 Entering the RCL code.............................................................528 Entering the reeving..............................................................529 Accepting the rigging mode........................................................529 11.2.3 Checks before operating the crane..............................................531 Opening the submenu...............................................................531 Checks............................................................................532 11.2.4 Displays during crane operation................................................535 11.2.5 RCL early warning..............................................................538 11.2.6 RCL shutdown...................................................................538 Shutdown due to overload..........................................................538 11.2.7 Display in the event of errors.................................................540 11.2.8 RCL override – version A.......................................................541 11.2.9 RCL override – version B.......................................................543 Overview status display...........................................................543 When rigging......................................................................544 To raise the boom.................................................................545 In emergencies....................................................................546 11.2.10 Displaying the lifting capacity tables........................................547 11.2.11 Entering the time/date........................................................549 11.3 Crane operation with main boom.......................................................551 11.3.1 Checks during crane operation..................................................551 Horizontal alignment..............................................................551 Safe distances....................................................................551 Checking the wind speed...........................................................552 11.3.2 Permissible slewing ranges and working positions...............................553 360 slewing range................................................................553 0 to the rear working position...................................................553 180 to the front rigging position................................................554 Free-on-wheels working position...................................................554 11.3.3 Main hoist.....................................................................555 Switching on the main hoist.......................................................556 Lifting and lowering..............................................................556 Switching off the main hoist......................................................557 11.3.4 Auxiliary hoist................................................................559 Switching on the auxiliary hoist..................................................560 Lifting and lowering..............................................................560 Switching off the auxiliary hoist.................................................561 11.3.5 Lifting limit switch, lowering limit switch, height contact switch.............563 Lifting limit switch..............................................................563 Lowering limit switch.............................................................565 11.3.6 Derricking gear................................................................565 Switching on the derricking gear..................................................566 Raising and lowering..............................................................566 Re-enable raising function........................................................567 Switching off the derricking gear.................................................568 Lowering the main boom to a horizontal position...................................568 11.3.7 Telescoping mechanism..........................................................569 Overview..........................................................................570 Telescoping process...............................................................570 Assignment for display............................................................572 Fixed length, intermediate length, telescoping length.............................574 Telescoping.......................................................................575 Telescoping sequence..............................................................575 Checks before starting work.......................................................576 Switching on the telescoping mechanism............................................576 Function of the control lever.....................................................577 Switching off the telescoping mechanism...........................................579 Manual telescoping................................................................579 Checking the initial position.....................................................580 Unlocking the telescoping cylinder................................................582 Extending/retracting the telescoping cylinder.....................................584 Lock telescoping cylinder.........................................................585 Unlocking the telescopic section..................................................586 Telescoping the telescopic section................................................588 Locking the telescopic section....................................................589 Locking the telescopic section for on-road driving................................590 Telescoping with teleautomation...................................................591 Telescoping the main boom when horizontal.........................................595 11.3.8 High-speed mode................................................................596 Switch on function................................................................596 Derricking gear/ telescoping mechanism............................................596 Hoist.............................................................................597 11.3.9 Slewing gear...................................................................598 Switching on the slewing gear.....................................................598 Slew..............................................................................599 Braking the slewing movement......................................................602 Slewing gear freewheel............................................................603 Switching off the slewing gear....................................................603 11.3.10 Possible movement combinations................................................604 11.3.11 Hydraulic oil cooling.........................................................604 11.4 Settings and displays for crane operation............................................605 11.4.1 Inclining the crane cab........................................................605 11.4.2 Setting idling speed...........................................................606 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................606 11.4.4 Limiting the power unit speeds.................................................607 11.4.5 Setting the characteristic curves for the control levers.......................608 11.4.6 Using the slewable spotlights..................................................609 11.4.7 Displaying the operating hours.................................................610 11.4.8 Warning submenu................................................................611 Meaning of the symbols............................................................611 Exiting the submenu...............................................................614 11.4.9 Error submenu..................................................................614 11.5 Working range limiter................................................................615 11.5.1 Opening the working range limiter submenu......................................616 11.5.2 Viewing current settings.......................................................617 11.5.3 Entering limit values..........................................................619 Overall height/ Working radius....................................................619 Slewing angle.....................................................................620 Entering objects..................................................................622 11.5.4 Entering limit values/objects manually.........................................625 Limit values......................................................................625 Objects...........................................................................626 11.5.5 Switching monitoring functions on/off..........................................627 11.5.6 Shutdown by working range limiter..............................................628 11.6 Work break...........................................................................629 11.6.1 In case of short work breaks...................................................629 11.6.2 In case of work breaks of more than 8 hours....................................630 To secure the truck crane.........................................................630 11.7 Heating and air-conditioning system..................................................631 11.7.1 Heating system.................................................................631 Switching on......................................................................632 Heating...........................................................................633 Air distribution..................................................................634 Switching off.....................................................................635 Setting the day and time..........................................................635 Storing the heating start.........................................................636 Setting the heating period........................................................637 Switching heating start on/off....................................................638 Switching off.....................................................................639 Setting the remaining time........................................................639 11.7.2 Air-conditioning system........................................................641 Information.......................................................................641 Switching on/off..................................................................642 Cooling...........................................................................642 Drying the air....................................................................643 11.8 CraneSTAR system.....................................................................645 11.8.1 Overview.......................................................................645 11.8.2 Position of the components.....................................................645 12 Rigging work...............................................................................649 12.1 Rigging work checklists for crane operation with the main boom.......................649 12.1.1 CHECKLIST: Rigging.............................................................649 12.1.2 CHECKLIST: Unrigging...........................................................655 12.2 Choosing a suitable site.............................................................659 12.2.1 Determining the required ground bearing area...................................659 12.2.2 Safe distance from slopes and pits.............................................662 12.2.3 Earthing the truck crane.......................................................663 12.2.4 Safe distance from electrical cables...........................................664 12.3 Rigging work after driving with a trailer............................................667 12.3.1 Switching off the boom floating position.......................................667 12.3.2 Switching off the slewing gear freewheel.......................................668 Before slewing....................................................................668 12.3.3 Switching off boom pre-tensioning..............................................669 12.4 Connecting/disconnecting the hand-held control.......................................671 12.5 Outrigger............................................................................673 12.5.1 CHECKLIST: Extending the outriggers............................................673 12.5.2 CHECKLIST: Retracting the outriggers...........................................675 12.5.3 Permissible outrigger spans....................................................676 12.5.4 Preparing the truck crane......................................................677 In the driver's cab...............................................................677 Outrigger control units...........................................................677 12.5.5 Setting the outrigger spans....................................................678 For on-road driving...............................................................681 12.5.6 Extending/retracting outrigger beams...........................................683 From the control units............................................................684 With the hand- held control.......................................................685 From the crane cab................................................................687 12.5.7 Moving the outrigger pads into working/driving position........................689 12.5.8 Enlarging the ground bearing area..............................................690 12.5.9 Extending/retracting supporting cylinders......................................691 From the control units............................................................692 With the hand- held control.......................................................693 From the crane cab................................................................695 12.5.10 Level the truck crane on outriggers...........................................697 Inclination indicators............................................................697 Prerequisites.....................................................................698 Manual alignment..................................................................699 Automatic alignment...............................................................700 12.5.11 Levelling the free-on-wheels truck crane......................................702 When rigging......................................................................702 During crane operation............................................................703 12.5.12 Outrigger pressure display....................................................705 12.6 Rigging/unrigging the counterweight..................................................707 12.6.1 Counterweight sections.........................................................707 Counterweight sections............................................................707 12.6.2 Identification.................................................................708 12.6.3 Slinging points on the counterweight sections..................................709 12.6.4 CHECKLIST: Rigging the counterweight...........................................710 12.6.5 CHECKLIST: Unrigging the counterweight.........................................711 12.6.6 Assembling counterweight versions – on the turntable...........................713 12.6.7 Assembling counterweight versions – on the counterweight platform..............714 Setting down the 2.5 t base plate.................................................715 Note on 19.3 t....................................................................715 With 1.8 t on the turntable.......................................................716 With 4.3 t on the turntable.......................................................718 With 6.8 t on the turntable.......................................................720 With 9.3 t on the turntable.......................................................722 12.6.8 Counterweight hoist unit.......................................................723 Checks............................................................................724 Counterweight submenu.............................................................725 Extending/retracting the lifting cylinders........................................725 Locking/Unlocking counterweight...................................................726 12.6.9 Removing/installing the counterweight on the turntable.........................727 Removing..........................................................................727 Installing........................................................................728 12.6.10 Setting down counterweight for driving the truck crane........................729 12.6.11 Slewing with rigged counterweight.............................................731 12.7 Rigging work on the main boom........................................................733 12.7.1 Hook block on the bumper.......................................................733 Picking up the hook block.........................................................733 Attaching the hook block..........................................................734 12.7.2 Hook block on a separate vehicle...............................................735 Picking up the hook block.........................................................736 Setting down the hook block.......................................................736 12.7.3 Reeving and unreeving the hoist rope...........................................738 Pocket lock.......................................................................738 Fork..............................................................................739 Rope end clamp....................................................................740 Reeving the hoist rope............................................................741 Unreeving the hoist rope..........................................................745 12.7.4 Possible reeving methods on the main boom......................................747 With 6 head sheaves...............................................................747 With 7 head sheaves...............................................................750 With 8 head sheaves...............................................................752 12.7.5 Installing/removing the lifting limit switch...................................753 Installing the lifting limit switch...............................................753 Removing the lifting limit switch.................................................756 12.7.6 Locking/unlocking the lifting limit switch.....................................757 Locking...........................................................................757 Releasing locking.................................................................758 12.7.7 Anemometer and air traffic control light.......................................759 Installing........................................................................759 Removing..........................................................................760 12.8 Other rigging work...................................................................761 12.8.1 Rigging in free on wheels working position.....................................761 12.8.2 Mirror for crane operation.....................................................765 12.8.3 Cameras for crane operation....................................................766 Cameras on the hoists.............................................................766 Camera on main boom...............................................................766 Turning the monitor on/off and switching between cameras..........................770 13 Driving with rigged truck crane............................................................773 13.1 Safety instructions..................................................................773 13.2 Driving distance.....................................................................775 13.3 Before driving the rigged truck crane................................................775 13.3.1 Check the tyre pressure and the wind speed.....................................775 13.4 Permissible rigging modes and axle loads.............................................777 13.4.1 Axle loads.....................................................................777 13.4.2 To drive without a load........................................................777 13.4.3 To drive with a load...........................................................778 13.5 Driving from the driver's cab........................................................779 13.5.1 Preparing to drive.............................................................779 Transmission......................................................................779 Switching on separate steering....................................................779 Connections.......................................................................779 13.5.2 While driving..................................................................780 13.6 Driving from the crane cab...........................................................781 13.6.1 Preparing to drive.............................................................781 In the driver's cab...............................................................781 In the crane cab..................................................................782 13.6.2 Opening/closing the Driving mode submenu.......................................783 Automatic.........................................................................783 Manual............................................................................784 Closing...........................................................................785 13.6.3 Steering system................................................................785 Switching on......................................................................785 Adjusting the steering direction..................................................786 Normal steering...................................................................786 Separate steering.................................................................787 13.6.4 Operating the transmission.....................................................789 Driving direction.................................................................789 Selecting the transmission mode...................................................790 13.6.5 Cameras for driving from the crane cab.........................................791 13.6.6 Starting.......................................................................792 13.6.7 While driving..................................................................792 Transmission mode L, R............................................................792 Transmission mode D...............................................................793 Warning messages..................................................................793 13.6.8 Possible connections...........................................................794 Longitudinal/ transverse differential locks.......................................794 13.6.9 After driving..................................................................796 14 Malfunctions during crane operation........................................................799 14.1 Emergency stop switch................................................................799 14.2 What to do when malfunctions occur during crane operation............................801 Load can be lowered...................................................................801 Load cannot be lowered................................................................801 14.3 Fuses on the superstructure..........................................................803 Notes on changing fuses...............................................................803 14.3.1 Fuses on the turntable.........................................................804 Fuse groups F1/F8.................................................................804 Fuses on the circuit board........................................................805 On I/O-3 circuit board............................................................805 14.3.2 Fuses in the crane cab.........................................................806 14.3.3 RCL fuses......................................................................808 14.4 Finding and eliminating malfunctions.................................................809 14.4.1 Malfunctions on the engine.....................................................809 14.4.2 Malfunctions when inclining the crane cab......................................809 14.4.3 Malfunctions when operating with the hand-held control.........................810 14.4.4 Malfunctions when inclining the crane cab......................................810 14.4.5 Malfunctions on the main hoist/auxiliary hoist.................................811 14.4.6 Malfunctions in the hoist cameras..............................................813 14.4.7 Malfunctions in the main boom camera...........................................813 14.4.8 Malfunctions on the derricking gear............................................815 14.4.9 Malfunctions in the telescoping mechanism......................................817 Telescoping mechanism error messages..............................................819 14.4.10 Malfunctions on the slewing gear..............................................821 14.4.11 Malfunctions on the counterweight hoist unit..................................823 14.4.12 Malfunctions in the hydraulic system/hydraulic oil cooler.....................824 14.4.13 Malfunctions when driving from the crane cab..................................825 14.4.14 Malfunctions of the outriggers................................................826 14.4.15 Various crane cab malfunctions................................................827 14.4.16 Troubleshooting the RCL.......................................................829 General malfunctions..............................................................829 Error messages in the Monitoring submenu..........................................830 Displays in the Error submenu.....................................................832 Table of error codes..............................................................834 Switching off the sensor/tachogenerator...........................................837 14.4.17 Malfunctions ECOS – superstructure............................................838 ECOS programme version............................................................838 General malfunctions..............................................................838 Error messages....................................................................839 Exiting the submenu...............................................................840 14.4.18 Malfunctions on CraneSTAR system..............................................841 14.5 Emergency operations and programmes..................................................845 14.5.1 Mechanical emergency activation for retracting.................................846 Prior to the emergency activation, check..........................................846 Procedure.........................................................................846 Mechanical emergency activation...................................................847 14.5.2 Telescoping emergency programme................................................849 Start the emergency program.......................................................849 Determining the error type........................................................850 Error on length indicator.........................................................851 If there is an error at a proximity switch........................................854 Terminating the emergency program.................................................856 Tables for approaching the locking points.........................................857 14.5.3 Entering the current telescoping...............................................859 14.5.4 Emergency operation with the hand-held control.................................861 Preparations......................................................................861 Operating a power unit............................................................862 Stopping movements................................................................864 Stopping movements in emergencies.................................................864 Turning off the engine............................................................864 14.6 Hydraulic emergency operation........................................................865 14.6.1 Connect/disconnect hoses.......................................................865 14.6.2 Establishing the required hydraulic circuits...................................866 Switching over valves.............................................................866 For lifting/lowering..............................................................868 14.6.3 Performing emergency operation.................................................869 14.6.4 After the emergency activation.................................................869 14.7 Hydraulic emergency operation BGR 159................................................871 14.7.1 Operating principle............................................................871 14.7.2 Connecting/disconnecting hoses.................................................873 For transformers..................................................................873 For the hand pump.................................................................874 14.7.3 Establishing the hydraulic circuits required...................................875 Switching positions of the valves.................................................875 Switching over valves.............................................................875 For lifting/lowering..............................................................877 For slewing.......................................................................878 14.7.4 Performing emergency operation.................................................879 Derricking........................................................................880 Lifting/lowering..................................................................881 Slew..............................................................................881 14.7.5 After emergency operation......................................................882 Switching off emergency operation.................................................882 Switching over to crane operation.................................................882 Disconnecting the hoses...........................................................882 14.7.6 Emergency supply of another crane..............................................883 After emergency supply............................................................884 15 Index......................................................................................887 A.........................................................................................889 B.........................................................................................889 C.........................................................................................889 D.........................................................................................892 E.........................................................................................894 F.........................................................................................896 H.........................................................................................896 I.........................................................................................897 K.........................................................................................898 L.........................................................................................898 M.........................................................................................898 O.........................................................................................900 P.........................................................................................900 R.........................................................................................901 S.........................................................................................902 T.........................................................................................903 V.........................................................................................905 W.........................................................................................906
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