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Grove Crane GMK 4090 Operating Manual 3302736 – PDF DOWNLOAD
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Description
Grove Crane GMK 4090 Operating Manual 3302736 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4090 Operating Manual 3302736 – PDF DOWNLOAD
Language : English
Pages : 998
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 4090 Operating Manual 3302736 – PDF DOWNLOAD
Intended use:
- The GMK4090 truck crane is constructed in accordance with the latest tech- nology and the
recognised safety regulations. Nevertheless, the operator or third parties can still be endangered
and the crane or other property put at risk while using it. - The truck crane may be modified only with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK4090 truck crane may be used only when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK4090 truck crane may only be operated without the corresponding special equipment within the
permitted temperature range; à Technical
data, p. 1 – 7. - The GMK4090 truck crane is designed solely for lifting loads which are within the permitted GMK4090
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 GMK4090 may only be operated with parts of equipment which have been approved by Manitowoc
Crane Group Germany GmbH and which are labelled with the serial number of the GMK4090.
The manufacturer is not liable for any damage caused by improper or unau-
thorized use of the GMK4090 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 4090 Operating Manual 3302736 – PDF DOWNLOAD
Operating manual ....................................................................................................... 1 Correction sheets................................................................................................... 3 Hook blocks – Change............................................................................................ 3 Driving from the crane cab...................................................................................... 5 Additional pages.................................................................................................... 7 MAXbase......................................................................................................... 7 Additional outrigger spans.................................................................................. 7 Telescoping emergency programe.................................................................................. 9 Mounting counterweight on the turntable......................................................................... 11 Crane cab heating and air-conditioning system................................................................... 13 Operation from the driver's cab............................................................................. 13 Table of contents .................................................................................................. 17 General ............................................................................................................ 47 1 Overview...................................................................................................... 47 1.1 Accidents............................................................................................... 47 1.2 Branch offices.......................................................................................... 49 1.2.1 Manitowoc Crane Care.............................................................................. 49 1.2.2 Dealer list....................................................................................... 49 1.3 Warranty specifications................................................................................. 49 1.4 Terms used.............................................................................................. 50 1.5 Technical data.......................................................................................... 53 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................................. 53 1.5.2 Maximum lifting capacity (ASME B 30.5)............................................................ 53 1.5.3 Dimensions and weights of the truck crane, axle loads............................................. 54 Dimensions.......................................................................................... 55 Weight and axle loads............................................................................... 55 1.5.4 Dimensions and weights of removable parts......................................................... 56 Spare wheel......................................................................................... 56 Outrigger........................................................................................... 56 Hook blocks and hook tackle......................................................................... 57 Counterweight parts................................................................................ 60 Auxiliary hoist..................................................................................... 60 1.5.5 Carrier........................................................................................... 61 Engine.............................................................................................. 61 Transmission........................................................................................ 61 Transfer case....................................................................................... 61 Axle lines.......................................................................................... 61 Steering............................................................................................ 62 Tyres............................................................................................... 62 Turning turning radii............................................................................... 62 Outrigger........................................................................................... 63 Electrical system................................................................................... 64 Tool................................................................................................ 64 Towing couplings................................................................................... 64 Driving speeds...................................................................................... 64 Climbing ability.................................................................................... 64 1.5.6 Superstructure.................................................................................... 65 Main hoist.......................................................................................... 65 Auxiliary hoist..................................................................................... 65 Slewing gear........................................................................................ 65 Derricking gear..................................................................................... 65 Main boom........................................................................................... 66 Lattice extension................................................................................... 66 Operating speeds.................................................................................... 66 Noise emission...................................................................................... 66 1.6 Documentation supplied.................................................................................. 67 1.6.1 Questions on documentation........................................................................ 68 1.7 Notes on the operating manual........................................................................... 69 1.7.1 What do the symbols used mean?.................................................................... 69 1.7.2 How is the operating manual structured?........................................................... 71 Division............................................................................................ 71 Structure of the chapters........................................................................... 71 Structure of the pages.............................................................................. 72 1.7.3 How do I find the information I need?............................................................. 73 Cross-references example............................................................................ 74 1.7.4 What information is available for operations planning?............................................ 76 1.8 Conversion table for US measuring units................................................................. 77 1.9 Training - Information.................................................................................. 79 1.10 Identification......................................................................................... 80 1.11 EC Declaration of Conformity........................................................................... 82 1.12 Notes on the engine data card.......................................................................... 83 2 Basic safety instructions..................................................................................... 85 2.1 Intended use............................................................................................ 85 2.1.1 Improper use...................................................................................... 86 2.2 Organisational measures................................................................................. 87 2.3 Personnel qualifications................................................................................ 89 2.4 Safety instructions for driving the truck crane......................................................... 90 2.5 Safety instructions for crane operation................................................................. 91 2.6 Instructions on transporting persons.................................................................... 94 Equipment for lifting persons........................................................................... 94 Personnel............................................................................................... 94 Operation............................................................................................... 95 Truck crane............................................................................................. 96 Driving............................................................................................................. 97 3 Operating elements for driving................................................................................ 97 3.1 Overview of the operating elements...................................................................... 97 3.1.1 On the outside of the truck crane................................................................. 98 3.1.2 Driver's cab......................................................................................102 Front overview......................................................................................102 Rear overview.......................................................................................104 Behind the cover...................................................................................105 3.1.3 Steering column/steering wheel....................................................................106 3.1.4 Instrument panel..................................................................................107 Left/right..........................................................................................107 Middle..............................................................................................108 3.1.5 Transmission operating elements...................................................................110 3.1.6 On-board computer.................................................................................111 3.1.7 Tachograph........................................................................................112 3.1.8 Heating and air-conditioning system...............................................................113 Standard............................................................................................113 Auxiliary water heating system....................................................................114 Auxiliary air heater...............................................................................115 3.1.9 CCS control unit..................................................................................117 3.1.10 CCS – menu-dependent displays....................................................................118 3.1.11 CCS – Start menu.................................................................................119 3.1.12 CCS – Overview menu groups.......................................................................120 3.1.13 Carrier menu group...............................................................................122 Suspension/level adjustment menu...................................................................123 Driving menu.......................................................................................124 3.1.14 Menu group, settings.............................................................................125 Set display brightness and date/ time menu..........................................................126 Switch units menu...................................................................................127 3.1.15 Menu group Information...........................................................................128 Operating hours menu...............................................................................129 Engine/transmission error menu.....................................................................130 Crane operation error menu.........................................................................131 3.1.16 Various controls menu group......................................................................132 3.1.17 Emergency operations menu group..................................................................133 3.1.18 Outrigger control units..........................................................................134 3.2 Short description of the operating elements.............................................................135 3.2.1 Definition of information relating to directions of movement......................................136 Basic rule..........................................................................................136 3.2.2 General rules for buttons and symbols on the display..............................................137 3.2.3 Engine............................................................................................138 Steering column.....................................................................................138 On the steering wheel...............................................................................138 Instrument panel....................................................................................139 3.2.4 AdBlue system.....................................................................................140 Instrument panel....................................................................................140 CCS display.........................................................................................141 3.2.5 Battery master switch.............................................................................141 3.2.6 Electrical system.................................................................................142 3.2.7 Crane control CCS.................................................................................143 3.2.8 Transmission......................................................................................145 Transmission control unit...........................................................................145 Driving position display............................................................................147 3.2.9 Reverse camera....................................................................................148 3.2.10 BirdView system 270 .............................................................................149 3.2.11 Transfer case....................................................................................151 3.2.12 Final drive......................................................................................152 3.2.13 Brakes...........................................................................................153 Service brake.......................................................................................153 Additional brakes...................................................................................153 Parking brake.......................................................................................154 3.2.14 Steering/separate steering.......................................................................155 Instrument panel....................................................................................155 CCS display.........................................................................................157 3.2.15 Suspension.......................................................................................159 CCS display.........................................................................................159 3.2.16 Lighting/windscreen wipers/horn..................................................................160 Steering column.....................................................................................160 Steering wheel......................................................................................160 Instrument panel....................................................................................160 CCS display.........................................................................................162 Roof................................................................................................162 3.2.17 Level adjustment system..........................................................................163 3.2.18 Trip recorder/speedometer........................................................................165 Tachograph..........................................................................................165 Cover...............................................................................................165 Speedometer.........................................................................................165 3.2.19 Diagnostics......................................................................................166 3.2.20 Push-up roof.....................................................................................166 3.2.21 On-board computer................................................................................167 3.2.22 Front flap.......................................................................................168 3.2.23 Windows and doors................................................................................169 Window winder.......................................................................................169 Doors...............................................................................................170 3.2.24 Access ladders and ladders.......................................................................171 4 Starting the engine for driving – switching it off............................................................175 4.1 Starting the engine from the driver's cab...............................................................175 4.1.1 CHECKLIST: Starting the engine....................................................................175 4.1.2 CHECKLIST: At low temperatures....................................................................178 4.1.3 Filling up........................................................................................179 Fuel tank...........................................................................................179 AdBlue tank.........................................................................................181 4.1.4 Checks before starting the engine.................................................................182 At the hydraulic tank...............................................................................182 Battery master switch...............................................................................183 Checking the hand-held control......................................................................183 4.1.5 Switching the ignition on.........................................................................183 4.1.6 Lamp test/equalisation of the switching states....................................................185 Lamp test...........................................................................................185 Switching the switching state.......................................................................185 4.1.7 Display – setting the brightness..................................................................186 4.1.8 Starting the engine...............................................................................188 4.1.9 Checks after starting the engine..................................................................190 Start menu and on-board computer....................................................................190 Instrument panel....................................................................................191 4.1.10 Setting the idling speed.........................................................................192 4.2 Switch off the engine...................................................................................193 4.2.1 At the ignition lock and with the outrigger control units.........................................193 After switching off................................................................................193 4.2.2 Using the emergency stop switches.................................................................194 Emergency stop switch, resetting....................................................................194 4.3 Air intake inhibitor....................................................................................195 Opening the air intake inhibitor........................................................................195 5 Driving.......................................................................................................197 5.1 Before driving..........................................................................................197 5.1.1 CHECKLIST: Checks before on-road driving..........................................................197 5.1.2 Check the condition of the truck crane............................................................203 Electrical system...................................................................................203 Mirror, adjusting...................................................................................203 Warning plates for vehicle width....................................................................204 Checking the vehicle height.........................................................................205 Supply pressure.....................................................................................206 Parking brake.......................................................................................207 5.1.3 Adjusting the seat and the steering column........................................................209 Adjusting the driver's seat........................................................................209 Adjusting the passenger seat.......................................................................210 Adjusting the steering column......................................................................211 5.1.4 Switching the suspension on/off...................................................................212 Opening the menu....................................................................................212 Switching the suspension on........................................................................213 Switching the suspension off.......................................................................213 5.1.5 Setting the tachograph............................................................................214 Prerequisites.......................................................................................214 In the event of malfunctions........................................................................214 Setting the tachograph.............................................................................215 5.1.6 Time, setting.....................................................................................219 5.1.7 Displaying and resetting operating hours..........................................................220 5.2 Operating the transmission..............................................................................221 5.2.1 Switching on......................................................................................221 5.2.2 Switching the transmission to the neutral position................................................222 5.2.3 Selecting the direction of travel and starting gear...............................................223 Selecting the driving direction....................................................................223 Selecting the starting gear ......................................................................224 5.2.4 Changing operating mode...........................................................................225 Changing to automatic mode..........................................................................225 Change to manual mode...............................................................................225 5.2.5 Starting..........................................................................................226 5.2.6 Driving and changing gears........................................................................227 In automatic operating mode.........................................................................227 In manual operating mode............................................................................228 5.2.7 Changing the driving direction....................................................................229 5.2.8 Stopping..........................................................................................229 Stopping for longer periods........................................................................229 5.2.9 On the roller type dynamometer....................................................................230 5.2.10 Preheating transmission..........................................................................230 5.3 Driving the truck crane and switching it off............................................................231 5.3.1 Checks whilst driving.............................................................................231 Brakes..............................................................................................231 ABS system..........................................................................................231 Steering............................................................................................232 Warning messages....................................................................................232 Monitoring elements.................................................................................233 5.3.2 Cruise control....................................................................................234 Switching on........................................................................................234 Switching off.......................................................................................235 5.3.3 Temposet..........................................................................................236 Switching on........................................................................................236 Switching off.......................................................................................236 5.3.4 Driving downhill..................................................................................237 Starting............................................................................................237 Checks when driving downhill.......................................................................238 Downshifting........................................................................................238 Additional brakes...................................................................................239 5.3.5 Driving uphill....................................................................................240 Starting............................................................................................240 Driving.............................................................................................240 5.3.6 Overriding torque reduction.......................................................................241 5.3.7 Switching the truck crane off.....................................................................242 Secure it against rolling away......................................................................242 When stationary for more than 8hours...............................................................243 5.3.8 Fold-up berth.....................................................................................244 5.4 Off-road driving........................................................................................245 Adjustments to the transmission.........................................................................245 Connections.............................................................................................245 Changing the vehicle level..............................................................................245 Rocking the vehicle free and towing.....................................................................245 5.4.1 Transfer case – switching the off-road gear on/off................................................246 5.4.2 Longitudinal and transverse differential locks....................................................247 5.4.3 Operating the level adjustment system.............................................................249 Opening the menu....................................................................................249 Setting the on- road level.........................................................................250 Pre-selecting suspension struts....................................................................250 Changing the vehicle level..........................................................................251 Viewing the current inclination.....................................................................252 Exiting the menu...................................................................................252 5.4.4 Freeing truck crane stuck in terrain..............................................................253 Rocking the truck crane free.......................................................................253 Towing free forwards...............................................................................254 Towing free to the rear............................................................................254 5.5 Separate steering.......................................................................................255 5.5.1 Switching to separate steering....................................................................256 5.5.2 Switching to normal steering mode.................................................................259 5.5.3 Switching units of measure........................................................................260 5.6 Radio...................................................................................................260 5.7 Heating and air-conditioning system.....................................................................261 5.7.1 Standard heating system...........................................................................261 Switching on........................................................................................261 Heating.............................................................................................261 Air distribution....................................................................................262 Examples............................................................................................263 Switching off.......................................................................................263 5.7.2 Air-conditioning system...........................................................................264 Notes...............................................................................................264 Switching on/off....................................................................................264 Cooling.............................................................................................265 Drying..............................................................................................265 5.7.3 Auxiliary water heating system....................................................................266 Preheating the engine..............................................................................266 Preheating the driver's cab........................................................................267 Switching on........................................................................................267 Setting the date and time...........................................................................269 Storing the heating start..........................................................................270 5.7.4 Auxiliary air heater..............................................................................272 Switching on........................................................................................272 Setting the heating level..........................................................................273 Setting the day and time...........................................................................274 Setting the preselection time.......................................................................274 Preselection times Delete...........................................................................276 Switching off.......................................................................................276 5.8 Towing a trailer........................................................................................277 Effects on the axle loads...............................................................................277 Coupling the trailer...................................................................................278 Connecting the supply lines............................................................................279 Removing supply lines.................................................................................280 Uncoupling the trailer.................................................................................280 Checking the braking force..............................................................................282 6 Driving modes.................................................................................................283 6.1 Driving modes...........................................................................................283 Information about the axle loads........................................................................283 6.1.1 Information on how to use the tables.............................................................284 6.1.2 Table for maximum axle load 12 t (26 500 lbs).....................................................285 Tyres 385/95 R25....................................................................................285 Tyres 445/95 R25....................................................................................286 Tyres 525/80 R25....................................................................................287 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)..............................288 6.2 Weighing the truck crane................................................................................289 Axle groups.............................................................................................290 Weighing procedure......................................................................................291 Evaluation..............................................................................................292 6.3 Rigging work for driving with a dolly...................................................................293 6.3.1 Switching on the slewing gear freewheel...........................................................294 6.3.2 Switching on the boom floating position...........................................................295 6.3.3 Switching on boom pre-tensioning..................................................................296 6.4 Installing/removing the outrigger beams.................................................................297 6.4.1 CHECKLIST: Removing the outrigger beams...........................................................298 6.4.2 CHECKLIST: Installing the outrigger beams.........................................................300 6.4.3 Centre of gravity data............................................................................302 6.4.4 Preparations – for removal........................................................................302 6.4.5 Preparations – on the truck crane.................................................................303 Prerequisites.......................................................................................303 6.4.6 Removing/attaching outrigger pads.................................................................304 Removing the outrigger pads........................................................................304 Attaching the outrigger pads.......................................................................305 6.4.7 Disconnecting/establishing hydraulic connection...................................................306 6.4.8 Disconnecting/establishing the electrical connection..............................................307 6.4.9 Unscrewing/screwing in the spacers................................................................308 Unscrewing..........................................................................................308 Screwing in.........................................................................................309 6.4.10 Disconnecting/establishing the connections to the supporting box.................................310 6.4.11 Pulling out/Inserting the outrigger beam.........................................................310 Extending the outrigger beam.......................................................................310 Inserting the outrigger beam........................................................................312 6.4.12 Transporting the outrigger beams.................................................................314 6.4.13 Note on error messages with removed outrigger beams..............................................314 7 Transport.....................................................................................................315 7.1 Transport with transport vehicle........................................................................315 7.1.1 CHECKLIST: Checks before transport................................................................316 7.1.2 Drive the truck crane on to the transport vehicle.................................................318 Driving on..........................................................................................319 Lashing.............................................................................................319 7.2 Transport by ship.......................................................................................320 8 Malfunctions in driving mode..................................................................................321 8.1 Emergency stop switch...................................................................................321 8.2 Procedure during malfunctions...........................................................................322 8.2.1 What to do when a malfunction occurs in road traffic..............................................322 8.2.2 Procedure during engine malfunctions..............................................................323 8.2.3 Procedure during transmission malfunctions........................................................324 8.3 Warning and error messages..............................................................................325 8.3.1 Warning or malfunction messages on the instrument panel...........................................325 Meaning of the lamps................................................................................325 8.3.2 Warning and malfunction messages on the on-board computer display.................................329 Messages............................................................................................329 Symbols.............................................................................................330 8.3.3 Warning messages on the CCS display...............................................................333 Symbols in the display area.........................................................................333 8.3.4 Error messages on the CCS display.................................................................337 Exiting the menu....................................................................................338 Special error messages..............................................................................338 8.4 Troubleshooting.........................................................................................339 8.4.1 Malfunctions on the engine........................................................................339 When operating with the dual tank...................................................................341 8.4.2 Faults on the Adblue system.......................................................................341 8.4.3 Differential lock malfunctions....................................................................342 8.4.4 Transfer case malfunctions........................................................................342 8.4.5 Malfunctions in the transmission..................................................................343 8.4.6 Malfunctions of the steering......................................................................344 8.4.7 Malfunctions of the service brake.................................................................345 8.4.9 Malfunctions of the level adjustment system.......................................................346 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler........................................346 8.4.11 Malfunction in the CCS control unit..............................................................346 8.5 Emergency operation and breakdown assistance............................................................347 8.5.1 Starting the truck crane externally...............................................................347 8.5.2 Battery charger...................................................................................348 Prerequisites.......................................................................................348 8.5.3 Towing the truck crane............................................................................349 In the case of engine/transmission damage...........................................................349 Longer towing distances.............................................................................352 Tow starting........................................................................................352 8.5.4 Wheel change......................................................................................353 Removing a damaged wheel............................................................................354 On the spare wheel holder...........................................................................354 Mounting a wheel....................................................................................355 8.5.5 Inflating the tyres yourself......................................................................357 Connecting the filling hose.........................................................................357 Inflating the tyres.................................................................................358 Remove the filling hose............................................................................358 8.5.6 Emergency operation, steering 3rd axle line.......................................................359 Performing emergency operation.....................................................................359 After emergency operation..........................................................................361 8.6 Tilting/lowering the driver's cab.......................................................................363 8.6.1 Prerequisites and information on tilting..........................................................363 8.6.2 Tilting and lowering the driver's cab.............................................................364 Operating the hand pump.............................................................................364 Tilting the driver's cab............................................................................365 Lowering the driver's cab..........................................................................366 8.7 Fuses on the carrier....................................................................................369 Information on changing fuses.........................................................................369 8.7.1 Fuses in the driver's cab.........................................................................370 8.7.2 Fuses in the battery box..........................................................................376 Crane operation ....................................................................................................377 9 Operating elements for crane operation........................................................................377 9.1 Overview of the operating elements......................................................................377 9.1.1 Exterior of the truck crane.......................................................................378 9.1.2 Crane cab.........................................................................................382 Side panel..........................................................................................384 Crane cab, rear.....................................................................................386 9.1.3 Control panels....................................................................................388 Left................................................................................................388 Right...............................................................................................389 9.1.4 Control lever assignment..........................................................................390 Version 1...........................................................................................390 Version 2...........................................................................................391 9.1.5 CCS control unit..................................................................................392 9.1.6 Menu-independent displays.........................................................................394 9.1.7 CCS – Start menu..................................................................................395 RCL display.........................................................................................396 Display Slewing ranges/working radii...............................................................397 9.1.8 CCS – Overview menu groups........................................................................398 9.1.9 Superstructure menu group.........................................................................402 Superstructure lock sub-menu......................................................................403 Counterweight menu..................................................................................404 9.1.10 Menu group outrigger/driving....................................................................405 Outrigger menu.....................................................................................406 Outrigger cylinders menu...........................................................................408 Driving menu........................................................................................410 9.1.11 RCL/Telescoping menu group.......................................................................413 Menu enter rigging mode/ telescope.................................................................414 Pre-selection telescoping menu.....................................................................418 Lifting capacity tables menu........................................................................420 Telescoping semi- automation menu..................................................................421 Manual telescoping menu...........................................................................422 9.1.12 Active working range limiter menu group..........................................................423 Overall height menu................................................................................424 Working radius menu.................................................................................425 Slewing angle menu..................................................................................426 Hoist rope travel limitation menu...................................................................427 9.1.13 Information1 menu group.........................................................................428 Hydraulic pressure and fuel consumption menu........................................................429 9.1.14 Heating/Engine/Additional equipment menu group...................................................431 Economy menu........................................................................................432 Remote control menu.................................................................................433 Heating/air- conditioning menu......................................................................434 Spotlights menu.....................................................................................435 9.1.15 Telescoping emergency program menu group.......................................................436 Telescoping emergency program menu.................................................................437 Unknown telescoping menu...........................................................................438 9.1.16 Settings menu group..............................................................................439 Crane cab menu......................................................................................440 Set display brightness and date/time menu...........................................................441 Switch units menu...................................................................................442 Set control lever characteristic curve menu.........................................................443 Power unit speeds menu............................................................................444 9.1.17 Information2 menu group.........................................................................445 Operating hours menu................................................................................446 Engine/ transmission error menu.....................................................................447 Crane operation error menu..........................................................................448 Program version menu................................................................................449 9.1.18 Various controls.................................................................................450 9.1.19 RCL control unit.................................................................................451 9.1.20 Menu-independent displays........................................................................453 9.1.21 RCL – menus......................................................................................454 Monitoring menu....................................................................................454 Lifting capacity tables menu........................................................................456 Datalogger menu.....................................................................................457 9.1.22 Hand-held control................................................................................458 9.1.23 Outriggers control units.........................................................................459 Menu- independent buttons..........................................................................459 Outrigger menu......................................................................................460 Raise axle menu....................................................................................462 9.2 Short description of the operating elements.............................................................463 9.2.1 Definition of information relating to directions of movement......................................463 Basic rule..........................................................................................463 9.2.2 General rules for buttons and symbols on the display..............................................464 9.2.3 Engine............................................................................................465 Side panel.........................................................................................465 Left control lever..................................................................................465 Economy mode menu...................................................................................466 9.2.4 AdBlue system.....................................................................................466 CCS display.........................................................................................466 9.2.5 Seat contact switch and dead man's switch.........................................................468 9.2.6 Crane control CCS.................................................................................469 9.2.7 Outrigger – crane cab.............................................................................474 Control panels......................................................................................474 CCS display.........................................................................................475 9.2.8 Outrigger control units...........................................................................477 General information.................................................................................477 Outrigger menu......................................................................................478 9.2.9 Raise axle........................................................................................480 9.2.10 Inclination indicators...........................................................................482 9.2.11 Outrigger pressure displays......................................................................483 Outriggers submenu.................................................................................483 Outriggers control units...........................................................................483 9.2.12 Anemometer displays..............................................................................483 9.2.13 Counterweight menu...............................................................................484 Counterweight submenu..............................................................................484 9.2.14 Main hoist.......................................................................................488 Control panels......................................................................................488 CCS display.........................................................................................488 9.2.15 Auxiliary hoist..................................................................................490 Control panels......................................................................................490 CCS display.........................................................................................491 9.2.16 Slewing gear.....................................................................................492 Control panels......................................................................................492 CCS display.........................................................................................493 9.2.17 Derricking gear..................................................................................494 Control panels......................................................................................494 CCS display.........................................................................................495 Side panel..........................................................................................495 9.2.18 Telescoping mechanism............................................................................496 Control panels......................................................................................496 CCS display.........................................................................................497 Telescoping semi- automation menu...................................................................497 Manual telescoping menu.............................................................................499 9.2.19 Hydraulic system.................................................................................502 9.2.20 Superstructure lock menu.........................................................................503 Turntable locking..................................................................................503 Houselock...........................................................................................505 9.2.21 Remote control...................................................................................506 9.2.22 Rated capacity limiter (RCL).....................................................................507 CCS display.........................................................................................507 RCL display.........................................................................................516 RCL override – version A............................................................................517 RCL override – version B............................................................................518 9.2.23 Electrical system................................................................................519 9.2.24 Lighting, windscreen wiper/washing system........................................................520 Lighting............................................................................................520 Windscreen wiper/washing system....................................................................522 Horn................................................................................................523 9.2.25 Hand-held control................................................................................524 Sockets for hand- held control......................................................................524 Engine control panel................................................................................525 Horn................................................................................................525 9.2.26 Windows and doors................................................................................528 Window..............................................................................................528 Rear window.........................................................................................528 Crane cab door......................................................................................529 9.2.27 Diagnostics......................................................................................530 9.2.28 Other............................................................................................530 9.3 Short description of the operating elements – driving from the crane cab................................531 9.3.1 Driving menu......................................................................................531 9.3.2 Transmission......................................................................................533 9.3.3 Final drive.......................................................................................535 9.3.4 Brakes............................................................................................536 CCS display.........................................................................................536 Side panel from above...............................................................................536 9.3.5 Steering..........................................................................................537 CCS display.........................................................................................538 Control panels......................................................................................540 10 Starting/switching off the engine – for crane operation......................................................541 10.1 When starting the engine for the first time in the day.................................................541 10.2 Starting the engine – from the crane cab...............................................................543 10.2.1 Check the fuel level and AdBlue level............................................................543 Fuel................................................................................................543 AdBlue..............................................................................................543 10.2.2 Checks before starting the engine................................................................544 Checks on the carrier..............................................................................544 Checking the hand-held control......................................................................544 At the hydraulic tank...............................................................................544 10.2.3 Switching the ignition on........................................................................545 10.2.4 Comparison of switching states...................................................................546 10.2.5 Display – setting the brightness.................................................................546 10.2.6 Starting the engine..............................................................................547 10.2.7 Checks after starting the engine.................................................................548 10.2.8 Setting the idling speed.........................................................................549 10.3 Starting the engine – with the hand-held control.......................................................550 10.4 Switch off the engine..................................................................................551 10.4.1 At the ignition lock and with hand-held control..................................................551 After switching off................................................................................551 10.4.2 With the idling button...........................................................................551 10.4.3 Using the emergency stop switches................................................................552 Emergency stop switch, resetting....................................................................552 11 Crane operation..............................................................................................553 11.1 Before operating the crane.............................................................................553 11.1.1 CHECKLIST: Checks before operating the crane.....................................................553 11.1.2 Check the condition of the truck crane...........................................................557 Fuel tank auxiliary heater..........................................................................557 Visual inspection...................................................................................557 Checking the position of the hoist ropes............................................................558 Checking the electrical system......................................................................559 11.1.3 Adjusting the crane cab seat and front control panel.............................................560 Crane cab seat......................................................................................560 Front control panel.................................................................................561 11.1.4 Checking the safety equipment....................................................................561 Rated capacity limiter..............................................................................561 Lifting limit switch...............................................................................562 Emergency stop switch...............................................................................562 Seat contact switch................................................................................563 11.1.5 Earthing the load................................................................................564 11.1.6 Preheating hydraulic oil.........................................................................565 Prerequisites.......................................................................................565 Preheating..........................................................................................565 11.1.7 Locking/unlocking the superstructure.............................................................566 Locking points......................................................................................566 Locking the turntable..............................................................................567 Unlocking the turntable............................................................................567 11.1.8 Switching the houselock on/off...................................................................568 Switching on the houselock.........................................................................568 Switching off the houselock........................................................................570 11.2 Standard slewing range type............................................................................571 11.2.1 Permissible slewing ranges and working positions.................................................571 360 slewing range..................................................................................571 Working position 0 to the rear.....................................................................571 180 to the front rigging position..................................................................571 11.3 MAXbase slewing range type.............................................................................573 11.3.1 Specifications in the lifting capacity tables....................................................574 11.3.2 Enabled slewing ranges...........................................................................575 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit.......578 11.4 Operation of the rated capacity limiter................................................................579 11.4.1 Switch on the RCL................................................................................580 Switching on........................................................................................580 11.4.2 Enter rigging mode...............................................................................582 Notes on Input.....................................................................................582 Enter the slewing range type........................................................................583 Entering individual components......................................................................584 Entering the RCL code..............................................................................590 11.4.3 Pre-selecting telescoping........................................................................590 11.4.4 Confirm the rigging mode and lifting capacity table..............................................591 Slewing range type Standard.........................................................................591 Slewing range type MAXbase..........................................................................593 11.4.5 Checks before operating the crane................................................................595 Monitoring menu.....................................................................................595 Checking the rigging mode...........................................................................595 Hoist checking......................................................................................597 11.4.6 Display during the crane operation...............................................................599 On the RCL dislay...................................................................................599 On the CCSdisplay...................................................................................603 11.4.7 RCL early warning................................................................................607 11.4.8 RCL shutdown.....................................................................................607 Shutdown due to overload............................................................................607 11.4.9 Displaying the lifting capacity tables...........................................................609 Slewing range type Standard.........................................................................609 Slewing range type MAXbase..........................................................................611 11.4.10 RCL override – version A........................................................................613 Overview status display.............................................................................613 When rigging........................................................................................614 To raise the boom...................................................................................615 In emergencies......................................................................................616 11.4.11 RCL override – version B........................................................................617 11.4.12 Datalogger......................................................................................618 Export data.........................................................................................618 Display the data....................................................................................619 11.5 Crane operation with main boom.........................................................................623 11.5.1 Checks during crane operation....................................................................623 Horizontal alignment................................................................................623 Safe distances.....................................................................................623 Checking the wind speed.............................................................................624 Deformation of the main boom due to direct sunlight.................................................625 11.5.2 Main hoist.......................................................................................626 Switching on the main hoist.........................................................................627 Lifting and lowering...............................................................................627 Maximum permissible hoist rope speed................................................................628 Switching off the main hoist.......................................................................629 11.5.3 Auxiliary hoist..................................................................................630 Switching on the auxiliary hoist...................................................................630 Lifting and lowering...............................................................................631 Maximum permissible hoist rope speed................................................................632 Switching off the auxiliary hoist..................................................................632 11.5.4 Lifting limit switch and lowering limit switch...................................................633 Lifting limit switch................................................................................633 Lowering limit switch...............................................................................635 11.5.5 Derricking gear..................................................................................636 Switching on the derricking gear...................................................................636 Raising and lowering................................................................................637 Maximum derricking speed............................................................................638 Re-enable raising function..........................................................................638 Switching off the derricking gear...................................................................639 Lowering the main boom to a horizontal position.....................................................639 11.5.6 Telescoping mechanism............................................................................640 Overview............................................................................................641 Telescoping process.................................................................................642 Assignment for display..............................................................................644 Fixed length, intermediate length, telescoping length..............................................645 Telescoping.........................................................................................646 Telescoping sequence...............................................................................646 Inspections prior to starting operations...........................................................647 Switching on the telescoping mechanism..............................................................648 Function of the control lever.......................................................................648 Switching off the telescoping mechanism.............................................................650 Manual telescoping.................................................................................651 Checking the initial position.......................................................................651 Unlocking the telescoping cylinder..................................................................653 Extending/retracting the telescoping cylinder.......................................................655 Lock telescoping cylinder...........................................................................656 Unlocking the telescopic section...................................................................657 Telescoping the telescopic section.................................................................658 Locking the telescopic section.....................................................................659 Locking the telescopic section for on-road driving.................................................660 Telescoping with semi-automaton.....................................................................660 Telescoping with pre-selection......................................................................662 11.5.7 High-speed mode..................................................................................663 Derricking gear telescoping mechanism..............................................................663 Hoists..............................................................................................663 11.5.8 Slewing gear.....................................................................................665 Slewing gear brake..................................................................................665 Switching on the slewing gear......................................................................666 Releasing the slewing gear brake....................................................................666 Applying the slewing gear brake.....................................................................666 Releasing locked slewing gear.......................................................................666 Slewing.............................................................................................667 Permissible slewing speed..........................................................................668 Braking the slewing movement........................................................................669 Slewing gear freewheel..............................................................................669 Switching off the slewing gear.....................................................................670 11.5.9 Switching the reduction of slewing speed on and off..............................................671 Switching reduction off.............................................................................671 11.5.10 Possible movement combinations..................................................................672 11.6 Settings and displays for crane operation..............................................................673 11.6.1 Inclining the crane cab..........................................................................673 11.6.2 Setting the idling speed.........................................................................674 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper......................................674 11.6.4 Limiting the power unit speeds...................................................................675 11.6.5 Economy mode.....................................................................................676 Switching on........................................................................................676 Ending/switching off................................................................................678 11.6.6 Switching units of measure.......................................................................678 11.6.7 Setting the characteristic curves for the control levers.........................................679 11.6.8 Using the slewable spotlights....................................................................680 Manually swinging...................................................................................681 Automatic load tracking.............................................................................681 11.6.9 Overriding torque reduction......................................................................682 11.6.10 Displaying the operating hours..................................................................683 11.7 Working range limiter..................................................................................685 11.7.1 Viewing current settings.........................................................................686 On the RCL dislay...................................................................................686 In the CCS Start menu...............................................................................687 11.7.2 Opening the working range limiter menu...........................................................687 11.7.3 Enter limit values – for the overall height......................................................688 11.7.4 Enter limit values – for the working radius......................................................690 11.7.5 Enter limit values – for the slewing range.......................................................692 11.7.6 Enter limit values – for the hoist rope travel...................................................695 11.7.7 Shutdown by working range limiter................................................................697 11.8 Work break.............................................................................................699 11.8.1 In case of short work breaks.....................................................................699 11.8.2 In case of work breaks of more than 8 hours......................................................700 To secure the truck crane...........................................................................700 11.9 Heating and air-conditioning system....................................................................701 11.9.1 Standard heating system..........................................................................701 Switching on........................................................................................701 Heating.............................................................................................701 Air distribution....................................................................................702 Switching off.......................................................................................702 11.9.2 Air-conditioning system..........................................................................703 Notes...............................................................................................703 Switching on/off....................................................................................703 Cooling, automatic..................................................................................704 Cooling, maximum....................................................................................704 11.9.3 Auxiliary heater.................................................................................705 Switching on........................................................................................705 Setting the temperature.............................................................................706 Setting the heating start/heating duration..........................................................706 Switching heating start on/off......................................................................707 11.10 CraneSTAR system......................................................................................708 11.10.1 Overview........................................................................................708 11.10.2 Position of the components......................................................................708 12 Rigging work.................................................................................................709 12.1 Rigging work checklists for crane operation with the main boom.........................................709 12.1.1 CHECKLIST: Rigging...............................................................................709 12.1.2 CHECKLIST: Unrigging.............................................................................715 12.2 Choice of a suitable positioning site..................................................................719 12.2.1 Determining the required load-bearing area.......................................................719 12.2.2 Safe distance from slopes and pits...............................................................722 12.2.3 Earthing the truck crane.........................................................................723 12.2.4 Safe distance from overhead power lines..........................................................724 12.3 Rigging work after driving with a dolly................................................................727 12.3.1 Switching off the boom floating position.........................................................727 12.3.2 Switching off the slewing gear freewheel.........................................................728 Before slewing......................................................................................728 12.3.3 Switching off boom pre-tensioning................................................................729 12.4 Connecting/disconnecting the hand-held control.........................................................731 12.5 Starting the engine for rigging........................................................................735 12.5.1 Starting/shutoff the engine – with the hand-held control.........................................735 Prerequisites.......................................................................................735 Starting the engine.................................................................................736 Turning off the engine..............................................................................736 12.5.2 Starting/shutoff the engine – from the outrigger control units...................................737 Prerequisites.......................................................................................737 Starting the engine.................................................................................737 Turning off the engine..............................................................................737 12.6 Slewing range – only with the Standard slewing range type..............................................739 12.6.1 Representation in the lifting capacity tables....................................................739 12.6.2 Enabled outrigger spans..........................................................................740 12.7 Outriggers – Overview – MAXbase slewing range type.....................................................741 12.7.1 Definitions......................................................................................741 12.7.2 Representation in the lifting capacity tables....................................................743 12.7.3 Enabled outrigger spans..........................................................................744 12.8 Outrigger operation....................................................................................749 12.8.1 CHECKLIST: Extending the outriggers..............................................................749 12.8.2 CHECKLIST: Retracting the outriggers.............................................................751 12.8.3 Preparing the truck crane........................................................................752 Driver's cab........................................................................................752 Crane cab...........................................................................................752 12.8.4 Setting the outrigger spans......................................................................754 For on-road driving.................................................................................757 12.8.5 Extending/retracting outrigger beams.............................................................757 From the control units..............................................................................758 From the cranecab..................................................................................759 12.8.6 Moving the outrigger pads into operating/driving position........................................761 12.8.7 Enlarging the load-bearing area..................................................................763 12.8.8 Extending/retracting supporting cylinders........................................................764 From the control units..............................................................................765 From the crane cab..................................................................................766 12.8.9 Levelling the truck crane on outriggers horizontally.............................................768 Inclination indicators..............................................................................768 Prerequisites.......................................................................................769 Manual alignment...................................................................................770 Automatic alignment.................................................................................770 12.8.10 Levelling the free-standing truck crane.........................................................772 12.8.11 Operating the axle raising system...............................................................774 12.8.12 Outrigger pressure display......................................................................776 12.9 Rigging/unrigging the counterweight....................................................................779 12.9.1 Information on rigging...........................................................................779 When rigging........................................................................................779 When unrigging......................................................................................780 12.9.2 Counterweight sections...........................................................................781 12.9.3 Identification...................................................................................782 12.9.4 Slinging points on the counterweight sections....................................................783 12.9.5 CHECKLIST: Rigging the counterweight.............................................................784 12.9.6 CHECKLIST: Unrigging the counterweight...........................................................786 12.9.7 Assembling counterweight combination.............................................................787 Setting down the top counterweight section..........................................................788 Version A...........................................................................................789 Version B...........................................................................................791 12.9.8 Removing/installing the counterweight on the turntable...........................................793 Removing............................................................................................793 Installing..........................................................................................796 Other combinations..................................................................................799 Other combinations, version A.......................................................................803 Further combinations, version B.....................................................................809 12.9.9 Counterweight hoist unit.........................................................................813 Counterweight menu.................................................................................813 Extending/retracting the lifting cylinders..........................................................814 Automatic mode rigging.............................................................................816 Automatic mode unrigging...........................................................................818 Cancel automatic mode..............................................................................819 12.9.10 Setting down counterweight for driving..........................................................821 Version A...........................................................................................821 Version B...........................................................................................822 12.9.11 Slewing with rigged counterweight...............................................................823 12.10 Rigging work on the main boom.........................................................................825 12.10.1 Hook block on the bumper........................................................................825 Picking up the hook block...........................................................................825 Attaching the hook block............................................................................826 12.10.2 Hook block on a separate vehicle................................................................827 Picking up the hook block..........................................................................828 Setting down the hook block........................................................................828 12.10.3 Hook block, separable...........................................................................830 Rigging for on- road driving........................................................................830 Rigging for crane operation.........................................................................831 12.10.4 Hook block with ballast plates..................................................................832 Removing............................................................................................832 Installing..........................................................................................833 Information on crane operation......................................................................833 12.10.5 Reeving and unreeving the hoist rope............................................................834 hoist rope, reeving.................................................................................835 Unreeving hoist rope...............................................................................839 12.10.6 Rigging aid for the hoist rope..................................................................840 With 6 head sheaves.................................................................................842 With 7 head sheaves.................................................................................845 With 8 head sheaves.................................................................................847 12.10.8 Installing/removing the lifting limit switch....................................................849 Installing the lifting limit switch.................................................................849 Removing the lifting limit switch...................................................................852 12.10.9 Locking/unlocking the lifting limit switch......................................................854 Locking.............................................................................................854 Removing the lock..................................................................................854 12.10.10 Anemometer and air traffic control light.......................................................855 Installing..........................................................................................855 Switching on/off....................................................................................856 Removing............................................................................................856 12.11 Other rigging work....................................................................................859 12.11.1 Railings on the turntable.......................................................................859 12.11.2 Open/close coverings at the turntable...........................................................860 12.11.3 Folding the mirrors in and out, and adjusting them..............................................861 12.11.4 Cameras for crane operation.....................................................................862 Camera on main boom.................................................................................862 Camera on the hoists................................................................................865 Camera on the driver's cab..........................................................................865 Operating the camera................................................................................866 12.11.5 Step at the crane cab...........................................................................867 12.11.6 Storage compartments............................................................................869 12.11.7 Slinging points for personal protective equipment...............................................870 13 Driving with a rigged truck crane............................................................................871 13.1 Driving distance.......................................................................................871 13.2 Permissible rigging modes and axle loads...............................................................872 Axle load table........................................................................................872 13.2.1 To drive without a load..........................................................................875 13.2.2 To drive with a load.............................................................................875 13.2.3 Axle loads.......................................................................................875 13.3 Before driving the rigged truck crane..................................................................876 13.3.1 Check the tyre pressures and wind speed..........................................................876 13.3.2 Secure the superstructure against slewing........................................................876 13.3.3 Putting the truck crane on the wheels – with Raise axle function.................................877 13.3.4 Putting the truck crane on the wheels – with the outriggers......................................879 13.4 Driving from the driver's cab..........................................................................881 13.4.1 Preparing to drive...............................................................................881 Transmission........................................................................................881 Switching on separate steering......................................................................881 Connections.........................................................................................881 13.4.2 Whilst driving...................................................................................882 13.4.3 After driving....................................................................................883 13.5 Driving from the crane cab.............................................................................885 13.5.1 Preparing to drive...............................................................................886 13.5.2 Opening/closing the driving menu.................................................................886 Opening the menu....................................................................................886 Selecting the operating mode.......................................................................887 Crane's hydraulic system Driving mode...............................................................889 Closing menu........................................................................................889 13.5.3 Steering.........................................................................................890 Switching on........................................................................................890 Display and steering direction......................................................................890 Switching the steering direction...................................................................891 Displays when steering..............................................................................891 Separate steering...................................................................................892 Normal steering mode................................................................................895 13.5.4 Operating the transmission.......................................................................896 Selecting the transmission mode....................................................................896 13.5.5 Whilst driving...................................................................................897 DMand RM transmission mode.........................................................................897 Transmission mode D.................................................................................897 Warning messages....................................................................................897 13.5.6 Possible connections.............................................................................898 Longitudinal/ transverse differential locks.........................................................898 13.5.7 After driving....................................................................................900 14 Malfunctions during crane operation..........................................................................901 14.1 Emergency stop switch..................................................................................901 14.2 What to do when malfunctions occur during crane operation..............................................902 The load can be set down................................................................................902 Load cannot be set down.................................................................................902 14.3 Warning and error messages.............................................................................903 Program version.........................................................................................903 14.3.1 Warning messages on the CCS display..............................................................903 Meaning of the symbols..............................................................................904 14.3.2 Error messages on the CCS display................................................................907 14.3.3 Warning messages on the RCL display..............................................................909 14.4 Troubleshooting........................................................................................913 14.4.1 Malfunctions on the engine.......................................................................913 14.4.2 Malfunctions on the main hoist/auxiliary hoist...................................................913 14.4.3 Malfunctions in the hoist cameras................................................................915 14.4.4 Malfunctions in the main boom camera.............................................................915 14.4.5 Malfunctions on the derricking gear..............................................................916 14.4.6 Malfunctions in the telescoping mechanism........................................................917 14.4.7 Malfunctions on the slewing gear.................................................................918 14.4.8 Malfunctions on the counterweight hoist unit.....................................................920 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler........................................920 14.4.10 Malfunctions when operating with the hand-held control..........................................921 14.4.11 Malfunctions when inclining the crane cab.......................................................921 14.4.12 Malfunctions of the outriggers..................................................................922 14.4.13 Malfunctions when raising the axles.............................................................922 14.4.14 Malfunctions on the CCS/RCL control units.......................................................923 14.4.15 Malfunctions when driving from the crane cab....................................................923 14.4.16 Malfunctions on the turntable lock..............................................................924 14.4.17 Malfunctions on the CraneSTAR system............................................................924 14.5 Emergency operations and programs......................................................................927 14.5.1 Mechanical emergency activation for retracting...................................................928 Prior to the emergency operation, check.............................................................928 Procedure...........................................................................................928 Mechanical emergency activation....................................................................929 14.5.2 Telescoping emergency program....................................................................931 Open the Emergency program submenu.................................................................931 Determining the type of error......................................................................932 Error at the length indicator.......................................................................933 Tables for approaching the locking points...........................................................937 14.5.3 Entering the current telescoping.................................................................939 14.5.4 Emergency operation with the hand-held control...................................................941 To pre-select a power unit..........................................................................942 Operating a power unit..............................................................................942 Stopping movements.................................................................................943 Stopping movements in emergencies...................................................................944 Switch off the engine...............................................................................944 14.5.5 Notes on slewing in emergency operation..........................................................944 For the Standard slewing range type.................................................................944 For the MAXbase slewing range type..................................................................946 14.5.6 Rotate for overridden slewing gear shutdown......................................................947 14.6 Hydraulic emergency operation with the hand pump.......................................................949 14.6.2 Switching over the crane's hydraulic system......................................................950 14.6.3 Establishing the required hydraulic circuits.....................................................951 Releasing/securing valves...........................................................................951 Switching over valves...............................................................................952 For lowering........................................................................................953 14.6.4 Performing emergency activation..................................................................954 14.6.5 After emergency activation.......................................................................954 14.7 Hydraulic emergency operation as per BGR 159...........................................................956 14.7.1 Applications and function........................................................................956 14.7.2 CHECKLIST: Emergency operation...................................................................958 14.7.3 CHECKLIST: After emergency operation.............................................................959 14.7.4 Connecting/removing transformer – for self-sufficiency...........................................960 Connecting..........................................................................................960 Removing............................................................................................961 14.7.5 Switching emergency operation on/off.............................................................962 14.7.6 Connecting/removing transformer – for external energy source.....................................963 14.7.7 Establishing the required hydraulic circuits.....................................................964 Switching over valves...............................................................................964 For lifting/ lowering...............................................................................966 For slewing.........................................................................................967 14.7.8 Performing emergency operation...................................................................968 Slewing.............................................................................................968 Derricking..........................................................................................969 Lifting/lowering....................................................................................969 14.7.9 Emergency supply of another crane................................................................970 For emergency supply................................................................................970 After emergency supply..............................................................................970 14.8 Fuses in the crane cab.................................................................................972 Information on changing fuses.........................................................................972 Index..............................................................................................................977 A...............................................................................................................979 B...............................................................................................................979 C...............................................................................................................979 D...............................................................................................................982 E...............................................................................................................984 F...............................................................................................................985 H...............................................................................................................986 I...............................................................................................................987 L...............................................................................................................987 M...............................................................................................................988 O...............................................................................................................989 P...............................................................................................................990 R...............................................................................................................990 S...............................................................................................................992 T...............................................................................................................993 V...............................................................................................................995 W...............................................................................................................995
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