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Grove Crane GMK 4100 Part 1 Driving Operating Manual 3113126 – PDF DOWNLOAD
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Description
Grove Crane GMK 4100 Part 1 Driving Operating Manual 3113126 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100 Part 1 Driving Operating Manual 3113126 – PDF DOWNLOAD
Language : English
Pages : 938
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 4100 Part 1 Driving Operating Manual 3113126 – PDF DOWNLOAD
Intended use:
- The GMK 4100 is a state-of-the-art truck crane, designed in accordance with approved safety regulations. Nevertheless, the operator or third parties can still be endangered and the crane or other property put at risk while using it.
- The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 4100 truck crane may only be used when it is in perfect technical condition and for its intended purpose and with due attention paid to safe operation and possible hazards.
- Any malfunctions that could impair safety must be eliminated immediately. Without the corresponding special equipment, the GMK 4100 truck crane may only be operated within the permitted temperature range; àTechnical data, p. 1 – 7.
- The GMK 4100 truck crane is designed solely for lifting loads which are within the permitted GMK 4100 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
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
- The GMK 4100 may only be operated with parts of equipment which are permitted by Manitowoc Crane Group Germany GmbH and which are labelled with the serial number of the GMK 4100.
- The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK 4100 truck crane. The user alone bears the risk.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 4100 Part 1 Driving Operating Manual 3113126 – PDF DOWNLOAD
Correction sheets .......................................................................... 3 Round outrigger pads made of synthetic material.......................................... 3 1 Overview................................................................................... 9 1.1 Accidents............................................................................ 9 1.2 Branch offices....................................................................... 11 1.2.1 Manitowoc Crane Care........................................................... 11 1.2.2 Dealer list.................................................................... 11 1.3 Warranty specifications.............................................................. 11 1.4 Terms used........................................................................... 12 1.5 Technical data....................................................................... 15 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 15 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 16 Dimensions....................................................................... 17 Weight and axle loads............................................................ 17 1.5.3 Dimensions and weights of removable parts...................................... 18 Spare wheel...................................................................... 18 Outriggers....................................................................... 18 Counterweight combinations....................................................... 18 Counterweight parts.............................................................. 19 Hook blocks and hook tackle...................................................... 19 1.5.4 Carrier........................................................................ 21 Engine........................................................................... 21 Transmission..................................................................... 22 Transfer case.................................................................... 22 Axle lines....................................................................... 22 Steering......................................................................... 22 Tyres............................................................................ 22 Outriggers....................................................................... 23 Electrical system................................................................ 23 Tool............................................................................. 23 Towing couplings................................................................. 23 Driving speeds................................................................... 24 Climbing ability................................................................. 24 Turning radii.................................................................... 24 1.5.5 Superstructure................................................................. 25 Engine........................................................................... 25 Main hoist....................................................................... 25 Auxiliary hoist.................................................................. 26 Slewing gear..................................................................... 26 Derricking gear.................................................................. 26 Main boom........................................................................ 27 Lattice extension................................................................ 27 Operating speeds................................................................. 27 1.6 Documentation supplied............................................................... 29 1.6.1 Questions on documentation..................................................... 30 1.7 Notes on the operating instructions.................................................. 31 1.7.1 What do the symbols used mean?................................................. 31 1.7.2 How are the operating instructions structured?................................. 33 Division......................................................................... 33 Structure of the chapters........................................................ 33 Structure of the pages........................................................... 34 1.7.3 How do I find the information I need?.......................................... 35 Cross-references example......................................................... 36 1.7.4 What information is available for operations planning?......................... 38 1.8 Conversion table for US measuring units.............................................. 39 1.9 Training – Information............................................................... 41 1.10 Identification...................................................................... 42 1.11 EC Declaration of Conformity........................................................ 44 2 Basic safety instructions.................................................................. 47 2.1 Intended use......................................................................... 47 2.1.1 Improper use................................................................... 47 2.2 Organisational measures.............................................................. 49 2.3 Personnel qualifications............................................................. 51 2.4 Safety instructions for driving the truck crane...................................... 52 2.5 Safety instructions for crane operation.............................................. 53 2.6 Notes on transporting persons........................................................ 55 Equipment for lifting persons........................................................ 55 Personnel............................................................................ 55 Operation............................................................................ 56 Truck crane.......................................................................... 57 3 Operating elements for driving............................................................. 61 3.1 Overview of the operating elements................................................... 63 3.1.1 On the outside of the truck crane.............................................. 64 3.1.2 Driver's cab................................................................... 66 Overview......................................................................... 66 Behind the cover................................................................. 68 3.1.3 Instrument panel............................................................... 69 Left/right....................................................................... 69 Middle........................................................................... 70 3.1.4 On-board computer.............................................................. 72 Display, driving mode............................................................ 72 On-board computer time correction................................................ 73 3.1.5 Steering column/steering wheel................................................. 74 3.1.6 Transmission operating elements................................................ 75 3.1.7 Tachograph..................................................................... 77 3.1.8 ECOS control unit.............................................................. 78 3.1.9 ECOS display – main menu....................................................... 80 3.1.10 ECOS display – submenus....................................................... 82 Level adjustment system submenu................................................. 82 Settings submenu................................................................ 83 Operating hours submenu.......................................................... 84 Warning submenu.................................................................. 85 Transmission emergency program submenu........................................... 86 Error submenu.................................................................... 87 3.1.11 Heating/Air-conditioning system............................................... 88 Standard heating system.......................................................... 88 Auxiliary air heater............................................................. 89 Auxiliary water heater........................................................... 91 3.1.12 Sockets for hand-held control................................................. 92 3.1.13 Outrigger control units....................................................... 93 3.2 Short description of the operating elements.......................................... 95 3.2.1 Definition of direction information............................................ 95 Basic rule....................................................................... 95 Switches and buttons............................................................. 96 3.2.2 General rules for buttons and symbols on the display........................... 96 3.2.3 Engine......................................................................... 97 Steering column.................................................................. 97 Multipurpose switch.............................................................. 97 Instrument panel................................................................. 99 Main menu........................................................................ 99 3.2.4 DEF system.....................................................................100 Instrument panel.................................................................100 3.2.5 Electrical system..............................................................101 3.2.6 ECOS crane control.............................................................102 Control unit.....................................................................102 3.2.7 Transmission...................................................................105 Transmission display.............................................................105 ECOS display.....................................................................105 Operating elements...............................................................106 Instrument panel.................................................................107 3.2.8 Transfer case..................................................................108 Main menu........................................................................108 3.2.9 Final drive....................................................................109 3.2.10 Reverse camera................................................................110 3.2.11 Brakes........................................................................111 Service brake....................................................................111 Parking brake....................................................................112 Additional brakes................................................................113 3.2.12 Steering/separate steering....................................................114 ECOS display.....................................................................114 Driver's door....................................................................115 3.2.13 Suspension....................................................................115 3.2.14 Lighting/windscreen wipers/horn...............................................116 Steering column..................................................................116 Instrument panel.................................................................116 Roof.............................................................................118 3.2.15 Level adjustment system.......................................................118 3.2.16 Tachograph/speedometer........................................................120 Tachograph.......................................................................120 Speedometer......................................................................120 3.2.17 Diagnostics...................................................................121 Displays/ submenu................................................................121 3.2.18 On-board computer.............................................................122 3.2.19 Push-up roof..................................................................124 3.2.20 Windows, doors, keys..........................................................124 Window winder....................................................................124 Doors............................................................................125 Keys.............................................................................125 3.2.21 Front flap....................................................................126 3.2.22 Storage compartment...........................................................126 3.2.23 Hand-held control bracket.....................................................127 4 Starting/turning off the engine for driving................................................131 4.1 Starting the engine from the driver's cab............................................131 4.1.1 CHECKLIST: Starting the engine.................................................131 4.1.2 CHECKLIST: At low temperatures.................................................134 4.1.3 Ladders and access ladders.....................................................135 Ladders..........................................................................135 Access ladders...................................................................136 4.1.4 Refuel.........................................................................137 Fuel tank........................................................................137 DEF tank.........................................................................138 4.1.5 Checks before starting the engine..............................................139 On hydraulic tank................................................................139 Battery master switch............................................................139 Checking hand- held control......................................................140 4.1.6 Switching on the ignition......................................................140 4.1.7 Lamp test/equalisation of the switching states.................................141 Lamp test........................................................................141 Equalisation of the switching states.............................................142 4.1.8 Display – setting the brightness...............................................143 4.1.9 Starting the engine............................................................144 Without flame start system.......................................................145 With flame start system..........................................................146 4.1.10 Checks after starting the engine..............................................147 4.1.11 Monitoring elements...........................................................148 Instrument panel.................................................................148 ECOS display.....................................................................149 Display driving mode............................................................149 4.1.12 Setting idling speed..........................................................150 4.2 Turning off the engine...............................................................151 4.2.1 On the ignition lock/with hand-held control....................................151 After turning off................................................................151 4.2.2 Using the emergency stop switches..............................................152 Resetting the emergency stop switch..............................................152 4.3 Air intake inhibitor.................................................................153 Releasing the air intake inhibitor...................................................153 5 Driving....................................................................................157 5.1 Before driving.......................................................................157 5.1.1 CHECKLIST: Checks before on-road driving.......................................157 5.1.2 Checking the condition of the truck crane......................................163 Electrical system................................................................163 Adjusting the mirrors............................................................163 Adjusting the reverse camera.....................................................164 Warning plates for vehicle width.................................................165 Displaying vehicle height........................................................165 Supply pressure..................................................................166 Parking brake....................................................................167 5.1.3 Adjusting the seat and the steering column.....................................168 Driver's seat....................................................................168 Passenger's seat.................................................................169 Adjusting the steering column....................................................169 5.1.4 Switching the suspension on/off................................................170 Opening the submenu..............................................................170 Switching on the suspension......................................................171 Switching off the suspension.....................................................171 5.1.5 Setting the tachograph.........................................................172 Prerequisites....................................................................172 In the event of malfunctions.....................................................172 Setting the tachograph...........................................................173 Additional displays..............................................................176 5.1.6 Displaying the operating hours.................................................177 5.1.7 Settings/displays with the on-board computer...................................178 Operation........................................................................178 Overview.........................................................................179 Monitoring information...........................................................179 Error information................................................................180 Alarm clock......................................................................181 Language.........................................................................181 Settings.........................................................................182 Diagnostics......................................................................182 5.2 Operating the transmission...........................................................185 5.2.1 Switching on...................................................................185 5.2.2 Switching the transmission to neutral position.................................186 5.2.3 Changing the operating mode....................................................186 Change to automatic mode.........................................................186 Change to manual mode............................................................187 5.2.4 Display of the selected gears..................................................187 5.2.5 Selecting the direction of travel and starting gear............................189 Selecting the driving direction..................................................189 Selecting the starting gear......................................................190 5.2.6 Starting.......................................................................191 5.2.7 Driving and changing gears.....................................................192 In automatic operating mode......................................................192 In manual operating mode.........................................................193 5.2.8 Changing the driving direction.................................................194 Quick change of gear.............................................................194 5.2.9 Stopping.......................................................................195 Stopping for a long period of time...............................................195 5.2.10 On the roller type dynamometer................................................195 5.3 Driving and turning off the truck crane..............................................197 5.3.1 Checks while driving...........................................................197 Immediately after you start to move..............................................197 While driving....................................................................198 5.3.2 Tempomat.......................................................................200 Switching on.....................................................................200 Switching off....................................................................201 5.3.3 Temposet.......................................................................201 Switching on.....................................................................201 Switching off....................................................................202 5.3.4 Driving downhill...............................................................203 Starting.........................................................................203 Inspections when driving downhill................................................203 Downshifting.....................................................................204 Additional brakes................................................................205 5.3.5 Driving uphill.................................................................206 Starting.........................................................................206 Driving..........................................................................206 5.3.6 Warning submenu................................................................206 Meaning of the symbols...........................................................207 Exiting the submenu..............................................................208 5.3.7 Notes on torque reduction......................................................209 5.3.8 Error submenu..................................................................210 5.3.9 Messages on the on-board computer display......................................210 Information......................................................................211 Warning messages.................................................................212 Error messages...................................................................213 Information......................................................................215 5.3.10 Turning off the truck crane...................................................219 Securing against rolling away....................................................219 When stationary for more than 8hours............................................220 5.4 Off-road driving.....................................................................221 Adjustments to the transmission......................................................221 Connections..........................................................................221 Changing the vehicle level...........................................................221 Rocking the vehicle free and towing..................................................221 5.4.1 Transfer case – switching the off-road gear on/off.............................222 Neutral position.................................................................222 5.4.2 Longitudinal and transverse differential locks.................................223 5.4.3 Operating the level adjustment system..........................................225 Opening the submenu..............................................................225 Setting the on-road level........................................................225 Pre-selecting suspension struts..................................................226 Changing the vehicle level.......................................................227 Viewing the current inclination..................................................227 Exiting the submenu..............................................................228 5.4.4 Freeing truck crane stuck in terrain...........................................229 Rocking the truck crane free.....................................................229 Towing free forwards.............................................................230 Towing free in reverse gear......................................................230 5.4.5 Separate steering..............................................................231 Switching to separate steering...................................................231 Steering.........................................................................232 Switching to normal steering mode................................................233 5.5 Heating and air-conditioning system..................................................235 5.5.1 Standard heating system........................................................235 Switching on.....................................................................235 Heating..........................................................................235 Air distribution.................................................................236 Examples.........................................................................237 Switching off....................................................................237 5.5.2 Air-conditioning system........................................................238 Information......................................................................238 Switching on/off.................................................................238 Cooling..........................................................................239 Drying...........................................................................239 5.5.3 Auxiliary air heater – Version A...............................................240 Switching on.....................................................................240 Temperature......................................................................241 Setting the day and time.........................................................241 Storing the heating start........................................................242 Setting the heating period.......................................................243 Switching the heating start on and off...........................................244 Switching off....................................................................244 Setting the remaining time.......................................................245 5.5.4 Auxiliary air heater – Version B...............................................247 Switching on.....................................................................247 Setting the heating level........................................................248 Setting the day and time.........................................................249 Setting the preselection time..................................................249 Deleting preselection times......................................................251 Switching off....................................................................251 5.5.5 Auxiliary water heater.........................................................252 Preheating the engine............................................................252 Preheating the driver's cab......................................................253 Switching on.....................................................................253 Setting the day and time.........................................................254 Storing the heating start........................................................255 Switching heating start on/off...................................................256 Switching off....................................................................257 Additional functions.............................................................257 5.6 Towing a trailer.....................................................................259 Effects on the axle loads............................................................259 Coupling the trailer.................................................................260 Connecting the supply lines..........................................................261 Removing the supply lines............................................................262 Uncoupling the trailer...............................................................262 Checking the braking force...........................................................264 6 Driving modes..............................................................................267 6.1 Driving modes........................................................................267 Information about the axle loads.....................................................267 6.1.1 Information on how to use the tables...........................................268 6.1.2 Table for a maximum axle load of 12 t..........................................269 For 14.00 R25 tyres..............................................................269 For 16.00 R25 tyres..............................................................270 For 20.5 R25 tyres...............................................................271 6.1.3 Maximum permitted speeds with an axle load of over 12 t........................272 6.2 Rigging work for driving with a trailer..............................................273 6.2.1 Switching on the slewing gear freewheel........................................274 6.2.2 Switching on boom floating position............................................275 6.2.3 Switching on boom pre-tensioning...............................................276 6.2.4 Switching the superstructure driving lights on/off.............................278 Switching off....................................................................278 Switching on.....................................................................278 7 Malfunctions in driving mode...............................................................281 7.1 Emergency stop switch................................................................281 7.2 What to do when a malfunction occurs in road traffic.................................283 7.3 Towing the truck crane...............................................................285 7.3.1 Towing after engine/transmission damage........................................286 Compressed-air supply............................................................286 Electric power supply............................................................286 On the transmission..............................................................287 Axle drives......................................................................288 Transfer case....................................................................288 Parking brake....................................................................288 Towing the truck crane out of the danger area....................................289 7.3.2 Tow starting...................................................................290 7.4 Wheels and tyres.....................................................................291 7.4.1 Wheel change...................................................................291 Removing a damaged wheel.........................................................291 On the spare wheel holder........................................................292 Mounting a wheel.................................................................293 7.4.2 Inflating the tyres yourself...................................................295 Connecting the filling hose......................................................295 Inflating the tyres..............................................................296 Removing the filling hose........................................................296 7.5 Fuses on the carrier.................................................................297 Notes on changing fuses..............................................................297 7.5.1 Fuses in the driver's cab......................................................298 F1 to F 41.......................................................................298 A1 to A3.........................................................................300 7.5.2 Fuses in the battery box.......................................................302 7.6 Troubleshooting......................................................................303 7.6.1 Malfunctions on the engine.....................................................303 7.6.2 Malfunctions on the DEF system.................................................305 7.6.3 Malfunctions in the transmission...............................................306 7.6.4 Malfunctions of the service brake..............................................307 7.6.5 Malfunctions of the steering...................................................308 7.6.6 Malfunctions of transfer case..................................................308 7.6.7 Malfunctions in the differential locks.........................................309 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................309 7.6.9 Malfunctions on the suspension.................................................310 7.6.10 Malfunctions of the level adjustment system...................................310 7.6.11 Malfunctions of the reverse camera............................................310 7.6.12 Malfunctions on the ECOS carrier..............................................311 ECOS programme version...........................................................311 General malfunctions.............................................................311 Error messages...................................................................312 Exiting the submenu..............................................................313 On the control units.............................................................314 7.7 Procedure in the event of malfunctions...............................................315 7.7.1 Switching on emergency operation in coolant circuit............................315 7.7.2 Procedure in the event of malfunctions to the transmission and engine..........316 Engine...........................................................................316 Transmission.....................................................................317 Transmission emergency program submenu...........................................318 Emergency gear shift.............................................................321 Compressed air emergency switching...............................................322 Switching gears mechanically in emergency mode...................................324 ID number of the transmission....................................................327 7.8 Emergency operation..................................................................329 7.8.1 External starting socket.......................................................329 Performing a jump start..........................................................330 7.8.2 Battery charger................................................................330 8 Index......................................................................................333 A........................................................................................335 B........................................................................................335 C........................................................................................335 D........................................................................................337 E........................................................................................339 F........................................................................................341 H........................................................................................342 I........................................................................................343 K........................................................................................343 L........................................................................................343 M........................................................................................344 O........................................................................................345 P........................................................................................346 R........................................................................................346 S........................................................................................347 T........................................................................................348 V........................................................................................350 W........................................................................................350 Corrections sheets ..........................................................................357 Round outrigger pads made of synthetic material..........................................357 9 Operating elements for crane operation.....................................................363 9.1 Overview of the operating elements...................................................365 9.1.1 Exterior of the truck crane....................................................366 9.1.2 Crane cab......................................................................370 9.1.3 Front panel....................................................................372 9.1.4 Side panel.....................................................................373 Bottom...........................................................................373 Top..............................................................................374 Console, rear....................................................................376 Standard heating system..........................................................377 Auxiliary water heater...........................................................378 Auxiliary air heater.............................................................379 9.1.5 Control panels.................................................................380 Left.............................................................................380 Right............................................................................381 9.1.6 Control lever configuration....................................................382 Version 1........................................................................382 Version 2........................................................................383 9.1.7 ECOS control unit..............................................................384 9.1.8 ECOS display – main menu.......................................................386 9.1.9 ECOS display – submenus........................................................388 Counterweight submenu............................................................388 Slewing gear/ Houselock submenu..................................................389 Outriggers submenu...............................................................390 Telescoping submenu..............................................................392 Power unit speeds submenu........................................................393 Monitoring submenu...............................................................394 Settings submenu.................................................................395 Operating hours submenu..........................................................396 Error submenu....................................................................397 Warning submenu..................................................................398 Working range limiter submenu...................................................400 Enter slewing angle submenu......................................................401 Enter objects submenu............................................................402 Driving submenu..................................................................403 9.1.10 RCL control unit..............................................................404 9.1.11 RCL display – main menu.......................................................406 9.1.12 RCL display – submenus........................................................407 Submenu Rigging mode entry.......................................................407 Monitoring submenu...............................................................408 Rigging mode monitoring submenu..................................................410 Submenu Lifting capacity table...................................................411 Working range submenu............................................................412 Error submenu....................................................................413 Settings submenu................................................................414 9.1.13 Hand-held control.............................................................415 Outriggers control panel........................................................417 9.1.14 Outrigger control units.......................................................418 Outrigger........................................................................419 Outrigger pressure display.......................................................419 Inclination indicator............................................................419 9.2 Short description of the operating elements..........................................421 9.2.1 Definition of direction information............................................421 Basic rule.......................................................................421 Switches.........................................................................421 9.2.2 General rules for buttons and symbols on the display...........................422 9.2.3 Engine for crane operation.....................................................423 Side panel.......................................................................423 Console, rear....................................................................424 ECOS display.....................................................................424 9.2.4 DEF system.....................................................................425 Instrument panel.................................................................425 ECOS display.....................................................................425 9.2.5 Engine for driving.............................................................427 Side panel.......................................................................427 Main menu........................................................................427 Outriggers submenu...............................................................428 9.2.6 Seat contact switch and dead man's switch......................................429 9.2.7 ECOS crane control.............................................................431 Control unit.....................................................................431 9.2.8 Outrigger......................................................................434 Hand-held control................................................................434 In the Outrigger submenu.........................................................435 In the Settings submenu..........................................................436 On the outrigger control units...................................................437 9.2.9 Inclination indicators.........................................................439 9.2.10 Outrigger pressure displays...................................................440 Outriggers submenu...............................................................440 Outrigger control units..........................................................440 9.2.11 Anemometer display............................................................440 9.2.12 Counterweight submenu.........................................................441 Counterweight submenu............................................................441 9.2.13 Main hoist....................................................................444 9.2.14 Auxiliary hoist...............................................................446 9.2.15 Slewing gear..................................................................447 Submenu..........................................................................448 9.2.16 Derricking gear...............................................................451 9.2.17 Telescoping mechanism.........................................................452 Control panels...................................................................452 Submenu..........................................................................453 In the Settings submenu..........................................................457 9.2.18 Hydraulic system..............................................................459 9.2.19 Houselock.....................................................................460 9.2.20 Rated capacity limiter (RCL)..................................................461 Control unit.....................................................................461 Main menu........................................................................463 Submenu Rigging mode entry.......................................................464 Monitoring submenu..............................................................467 Submenu Lifting capacity table...................................................471 Working range submenu............................................................472 RCL override.....................................................................473 External displays................................................................474 9.2.21 Electrical system.............................................................475 9.2.22 Lighting, windscreen wiper/washing system.....................................475 Lighting.........................................................................475 Windscreen wiper/washing system..................................................477 9.2.23 Hand-held control.............................................................478 Sockets for hand- held control...................................................478 Engine control panel.............................................................479 Horn.............................................................................479 Outrigger control panel..........................................................480 9.2.24 Diagnostics...................................................................482 9.2.25 Windows, doors, keys..........................................................482 Windscreen.......................................................................482 Rear window......................................................................483 Crane cab door...................................................................483 Keys.............................................................................484 9.3 Short description of the operating elements – driving from the crane cab.............485 9.3.1 Driving submenu................................................................485 9.3.2 Engine for driving.............................................................486 9.3.3 Transmission...................................................................487 9.3.4 Final drive....................................................................488 9.3.5 Brakes.........................................................................489 Side panel.......................................................................489 ECOS display.....................................................................489 9.3.6 Steering.......................................................................490 Normal steering..................................................................491 Separate steering................................................................491 10 Starting/turning off the engine – for crane operation.....................................495 10.1 Starting the engine – from the crane cab............................................495 10.1.1 CHECKLIST: Starting the engine................................................495 10.1.2 CHECKLIST: At low temperatures................................................498 10.1.3 Refuel........................................................................499 Fuel tank........................................................................499 DEF tank.........................................................................501 Tank – auxiliary heater..........................................................502 10.1.4 Checks before starting the engine.............................................503 On hydraulic tank................................................................503 Battery master switch............................................................503 Checking the hand-held control...................................................504 10.1.5 Switching on the ignition.....................................................504 10.1.6 Lamp test/switching state equalisation........................................505 Lamp test........................................................................505 Equalisation of the switching states.............................................506 10.1.7 Adjusting display brightness..................................................507 10.1.8 Starting the engine...........................................................508 Without flame start system.......................................................508 With flame start system..........................................................509 10.1.9 Checks after starting the engine..............................................510 10.1.10 Monitoring submenu...........................................................511 10.1.11 Setting idling speed.........................................................512 10.2 Starting the engine – with the hand-held control....................................513 Prerequisites........................................................................513 Starting the engine..................................................................513 10.3 Turning off the engine..............................................................515 10.3.1 During normal operation, with the ignition lock/with the handheld control....515 After turning off................................................................515 10.3.2 In emergencies, with the emergency stop switches..............................516 Resetting the emergency stop switch..............................................516 10.4 Air intake inhibitor................................................................517 Releasing the air intake inhibitor...................................................517 11 Crane operation...........................................................................521 11.1 Before operating the crane..........................................................521 11.1.1 CHECKLIST: Checks before operating the crane..................................521 11.1.2 Checking the condition of the truck crane.....................................525 Visual inspection................................................................525 Checking the position of the hoist ropes.........................................525 Checking the electrical system...................................................526 11.1.3 Adjusting the crane cab seat and front control panel..........................527 Crane cab seat...................................................................527 Front panel......................................................................528 11.1.4 Checking the safety equipment.................................................529 Rated capacity limiter...........................................................529 Lifting limit switch.............................................................529 Emergency stop switch............................................................530 Seat contact switch..............................................................531 11.1.5 Earthing the load.............................................................532 11.1.6 Preheating the hydraulic oil..................................................533 11.1.7 Switching the Houselock on/off................................................534 Switching on the Houselock.......................................................534 Switching off the Houselock......................................................536 11.2 Operation of the rated capacity limiter.............................................537 11.2.1 Switching on the RCL..........................................................538 Switching on.....................................................................538 Brightness of the displays.......................................................540 11.2.2 Enter rigging mode............................................................541 Entering individual components...................................................542 Entering the RCL code............................................................546 Entering the reeving.............................................................547 Accepting the rigging mode.......................................................547 11.2.3 Checks before operating the crane.............................................549 Opening the submenu..............................................................549 Checks...........................................................................550 11.2.4 Displays during crane operation...............................................553 11.2.5 RCL early warning.............................................................556 11.2.6 RCL shutdown..................................................................556 Shutdown due to overload.........................................................556 11.2.7 Display in the event of errors................................................558 11.2.8 RCL override – version A......................................................559 11.2.9 RCL override – version B......................................................561 Overview status display..........................................................561 When rigging.....................................................................562 To raise the boom................................................................563 In emergencies...................................................................564 11.2.10 Displaying the lifting capacity tables.......................................565 11.2.11 Entering the time/date.......................................................567 11.3 Crane operation with main boom......................................................569 11.3.1 Checks during crane operation.................................................569 Horizontal alignment.............................................................569 Safe distances...................................................................569 Checking the wind speed..........................................................570 11.3.2 Permissible slewing ranges and working positions..............................571 360 slewing range...............................................................571 0 to the rear working position..................................................571 180 to the front rigging position...............................................572 Free-on-wheels working position..................................................572 11.3.3 Main hoist....................................................................573 Switching on the main hoist......................................................574 Lifting and lowering.............................................................574 Switching off the main hoist.....................................................575 11.3.4 Auxiliary hoist...............................................................577 Switching on the auxiliary hoist.................................................578 Lifting and lowering.............................................................578 Switching off the auxiliary hoist................................................579 11.3.5 Lifting limit switch, lowering limit switch, height contact switch............581 Lifting limit switch.............................................................581 Lowering limit switch............................................................583 11.3.6 Derricking gear...............................................................583 Switching on the derricking gear.................................................584 Raising and lowering.............................................................584 Re-enable raising function.......................................................585 Switching off the derricking gear................................................586 Lowering the main boom to a horizontal position..................................586 11.3.7 Telescoping mechanism.........................................................587 Overview.........................................................................588 Telescoping process..............................................................588 Assignment for display...........................................................590 Fixed length, intermediate length, telescoping length............................592 Telescoping......................................................................593 Telescoping sequence.............................................................593 Checks before starting work......................................................594 Switching on the telescoping mechanism...........................................594 Function of the control lever....................................................595 Switching off the telescoping mechanism..........................................597 Manual telescoping...............................................................597 Checking the initial position....................................................598 Unlocking the telescoping cylinder...............................................600 Extending/ retracting the telescoping cylinder...................................602 Lock telescoping cylinder........................................................603 Unlocking the telescopic section.................................................604 Telescoping the telescopic section...............................................606 Locking the telescopic section...................................................607 Locking the telescopic section for on-road driving...............................608 Telescoping with teleautomation..................................................609 Telescoping the main boom when horizontal........................................613 11.3.8 High-speed mode...............................................................614 Switch on function...............................................................614 Derricking gear/ telescoping mechanism...........................................614 Hoist............................................................................615 11.3.9 Slewing gear..................................................................616 Slewing gear brake...............................................................616 Switching on the slewing gear....................................................617 Releasing the slewing gear brake.................................................617 Engaging the slewing gear brake..................................................617 Slew.............................................................................618 Braking the slewing movement.....................................................620 Slewing gear freewheel...........................................................620 Switching off the slewing gear...................................................621 11.3.10 Possible movement combinations...............................................622 11.3.11 Hydraulic oil cooling........................................................622 11.4 Settings and displays for crane operation...........................................623 11.4.1 Inclining the crane cab.......................................................623 11.4.2 Setting idling speed..........................................................624 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................624 11.4.4 Limiting the power unit speeds................................................625 11.4.5 Setting the characteristic curves for the control levers......................626 11.4.6 Critical load control.........................................................627 Function.........................................................................627 Switching on and off.............................................................627 11.4.7 Using the slewable spotlights.................................................628 11.4.8 Displaying the operating hours................................................629 11.4.9 Warning submenu...............................................................630 Meaning of the symbols...........................................................630 Exiting the submenu..............................................................633 11.4.10 Notes on torque reduction....................................................634 11.4.11 Error submenu................................................................635 11.5 Working range limiter...............................................................637 11.5.1 Opening the working range limiter submenu.....................................638 11.5.2 Viewing current settings......................................................639 11.5.3 Entering limit values.........................................................641 Overall height/ working radius...................................................641 Slewing angle....................................................................642 Entering objects.................................................................644 11.5.4 Entering limit values/objects manually........................................647 Limit values.....................................................................647 Objects..........................................................................648 11.5.5 Switching monitoring functions on/off.........................................649 11.5.6 Shutdown by working range limiter.............................................650 11.6 Work break..........................................................................651 11.6.1 In case of short work breaks..................................................651 11.6.2 In case of work breaks of more than 8 hours...................................652 To secure the truck crane........................................................652 11.7 Heating and air-conditioning system.................................................653 11.7.1 Standard heating system.......................................................653 Switching on.....................................................................653 Heating..........................................................................653 Air distribution.................................................................654 Switching off....................................................................655 11.7.2 Air-conditioning system.......................................................657 Information......................................................................657 Switching on/off.................................................................658 Cooling..........................................................................658 Drying the air...................................................................659 11.7.3 Auxiliary water heater........................................................659 Preheating the engine............................................................660 Preheating the crane cab.........................................................660 Switching on.....................................................................661 Setting the day and time.........................................................662 Storing the heating start........................................................663 Setting the heating period.......................................................664 Switching heating start on/off...................................................665 Switching off....................................................................665 Setting the remaining time.......................................................666 11.7.4 Auxiliary air heater..........................................................667 Switching on.....................................................................667 Temperature......................................................................668 Switching off....................................................................668 Other functions.................................................................668 11.8 CraneSTAR system....................................................................669 11.8.1 Overview......................................................................669 11.8.2 Position of the components....................................................669 12 Rigging work..............................................................................673 12.1 Rigging work checklists for crane operation with the main boom......................673 12.1.1 CHECKLIST: Rigging............................................................673 12.1.2 CHECKLIST: Unrigging..........................................................679 12.2 Choosing a suitable site............................................................683 12.2.1 Determining the required ground bearing area..................................683 12.2.2 Safe distance from slopes and pits............................................686 12.2.3 Earthing the truck crane......................................................687 12.2.4 Safe distance from electrical cables..........................................688 12.3 Rigging work after driving with a trailer...........................................691 12.3.1 Switching off the boom floating position......................................691 12.3.2 Switching off the slewing gear freewheel......................................692 Before slewing...................................................................692 12.3.3 Switching off boom pre-tensioning.............................................693 12.4 Connecting/disconnecting the hand-held control......................................695 12.5 Starting the engine for driving for rigging work....................................697 12.5.1 Starting/turning off the engine with the hand-held control....................697 Prerequisites....................................................................697 Starting the engine..............................................................698 Turning off the engine...........................................................698 12.5.2 Starting/turning off the engine from the crane cab............................699 Prerequisites....................................................................699 Starting the engine..............................................................699 After starting the engine........................................................700 Turning off the engine...........................................................700 12.6 Outrigger...........................................................................701 12.6.1 CHECKLIST: Extending the outriggers...........................................701 12.6.2 CHECKLIST: Retracting the outriggers..........................................703 12.6.3 Permissible outrigger spans...................................................704 12.6.4 Preparing the truck crane.....................................................705 In the driver's cab..............................................................705 Outrigger control units..........................................................705 12.6.5 Setting the outrigger spans...................................................706 For on-road driving..............................................................707 12.6.6 Extending/retracting outrigger beams..........................................708 From the control units...........................................................708 With the hand- held control......................................................709 From the crane cab...............................................................711 12.6.7 Moving the outrigger pads into working/driving position.......................713 12.6.8 Enlarging the ground bearing area.............................................714 12.6.9 Extending/retracting supporting cylinders.....................................715 From the control units...........................................................716 With the hand- held control......................................................717 From the crane cab...............................................................718 12.6.10 Level the truck crane on outriggers..........................................720 Inclination indicators...........................................................720 Prerequisites....................................................................721 Manual alignment.................................................................722 Automatic alignment..............................................................723 12.6.11 Levelling the free-on-wheels truck crane.....................................725 12.6.12 Outrigger pressure display...................................................727 12.7 Rigging/unrigging the counterweight.................................................729 12.7.1 Counterweight sections........................................................729 Version A........................................................................729 Version B........................................................................730 Version C........................................................................730 12.7.2 Identification................................................................731 12.7.3 Slinging points on the counterweight sections.................................732 12.7.4 CHECKLIST: Rigging the counterweight..........................................733 12.7.5 CHECKLIST: Unrigging the counterweight........................................734 12.7.6 Assembling counterweight versions – on the turntable..........................736 12.7.7 Assembling counterweight versions – on the counterweight platform.............737 Setting down the 2.2t base plate................................................737 Version..........................................................................738 Notes on the different versions..................................................739 With version A...................................................................742 With version B...................................................................744 With version C...................................................................746 12.7.8 Counterweight hoist unit......................................................750 Counterweight submenu............................................................750 Extending/ retracting the lifting cylinders......................................751 Automatic mode rigging..........................................................752 Automatic mode unrigging........................................................753 Cancel automatic mode............................................................755 12.7.9 Removing/installing the counterweight on the turntable........................756 Installing.......................................................................757 Removing.........................................................................758 12.7.10 Setting down counterweight for driving the truck crane.......................759 12.7.11 Slewing with rigged counterweight............................................762 12.8 Rigging work on the main boom.......................................................763 12.8.1 Hook block on the bumper......................................................763 Picking up the hook block........................................................763 Attaching the hook block.........................................................764 12.8.2 Hook block on a separate vehicle..............................................765 Picking up the hook block........................................................766 Setting down the hook block......................................................766 12.8.3 Reeving and unreeving the hoist rope..........................................768 Pocket lock......................................................................768 Fork.............................................................................769 Rope end clamp...................................................................770 Reeving the hoist rope...........................................................771 Unreeving the hoist rope.........................................................775 12.8.4 Possible reeving methods on the main boom.....................................777 With 7 head sheaves..............................................................777 With 8 head sheaves..............................................................780 12.8.5 Installing/removing the lifting limit switch..................................783 Installing the lifting limit switch..............................................783 Removing the lifting limit switch................................................786 12.8.6 Locking/unlocking the lifting limit switch....................................787 Locking..........................................................................787 Releasing locking................................................................788 12.8.7 Anemometer and air traffic control light......................................789 Installing.......................................................................789 Removing.........................................................................790 12.9 Other rigging work..................................................................791 12.9.1 Rigging in free on wheels working position....................................791 12.9.2 Railings on the turntable.....................................................795 12.9.3 Mirror for crane operation....................................................796 12.9.4 Cameras for crane operation...................................................797 Cameras on the hoists............................................................797 Camera on main boom..............................................................797 Turning the monitor on/off and switching.........................................800 13 Driving with rigged truck crane...........................................................803 13.1 Safety instructions.................................................................803 13.2 Driving distance....................................................................805 13.3 Before driving the rigged truck crane...............................................805 13.3.1 Check the tyre pressure and the wind speed....................................805 13.4 Permissible rigging modes and axle loads............................................807 13.4.1 Axle loads....................................................................807 13.4.2 To drive without a load.......................................................807 13.4.3 To drive with a load..........................................................808 13.5 Driving from the driver's cab.......................................................809 13.5.1 Preparing to drive............................................................809 Transmission.....................................................................809 Switching on separate steering...................................................809 Connections......................................................................809 13.5.2 While driving.................................................................810 13.6 Driving from the crane cab..........................................................811 13.6.1 Preparing to drive............................................................811 13.6.2 Opening/closing the Driving mode submenu......................................812 Automatic........................................................................812 Manual...........................................................................814 Closing..........................................................................814 13.6.3 Starting/turning off the engine for driving...................................815 Start the engine.................................................................815 Turning off the engine...........................................................816 13.6.4 Steering system...............................................................816 Switching on.....................................................................816 Adjusting the steering direction.................................................816 Displays when steering...........................................................817 Normal steering..................................................................817 Separate steering................................................................818 13.6.5 Operating the transmission....................................................819 Driving direction................................................................820 Selecting the transmission mode..................................................820 13.6.6 Camera system for driving from the crane cab..................................821 13.6.7 Starting......................................................................822 13.6.8 While driving.................................................................822 13.6.9 Warning messages..............................................................823 13.6.10 Possible connections.........................................................824 Longitudinal/ transverse differential locks......................................825 13.6.11 After driving................................................................826 13.7 Driving in combined operation.......................................................827 13.7.1 Switching combined operation on/off...........................................827 Prerequisites....................................................................827 Switching on.....................................................................828 Switching off....................................................................828 13.7.2 Starting/turning off the engine...............................................829 13.7.3 Preparing to drive............................................................830 Transmission.....................................................................830 Switching on separate steering...................................................830 Connections......................................................................830 13.7.4 While driving.................................................................831 Without load.....................................................................831 With load........................................................................832 14 Malfunctions during crane operation.......................................................835 14.1 Emergency stop switch...............................................................835 14.2 What to do when malfunctions occur during crane operation...........................837 Load can be lowered..................................................................837 Load cannot be lowered...............................................................837 14.3 Fuses on the superstructure.........................................................839 Notes on changing fuses..............................................................839 14.3.1 Fuses on the turntable........................................................840 Fuse groups F1/F2................................................................840 Fuses on the circuit board.......................................................841 14.3.2 Fuses in the crane cab........................................................842 14.3.3 Fuses in the battery box......................................................844 14.3.4 RCL fuses.....................................................................845 14.4 Finding and eliminating malfunctions................................................847 14.4.1 Malfunctions on the engine for crane operation................................847 14.4.2 Malfunctions on the DEF system................................................849 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................850 14.4.4 Malfunctions in the hoist cameras.............................................851 14.4.5 Malfunctions in the main boom camera..........................................851 14.4.6 Malfunctions on the derricking gear...........................................852 14.4.7 Malfunctions in the telescoping mechanism.....................................853 Telescoping mechanism error messages.............................................855 14.4.8 Malfunctions on the slewing gear..............................................856 14.4.9 Malfunctions on the counterweight hoist unit..................................857 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................858 14.4.11 Malfunctions when inclining the crane cab....................................858 14.4.12 Malfunctions when operating with the hand-held control.......................858 14.4.13 Malfunctions when driving from the crane cab.................................859 14.4.14 Malfunctions of the outriggers...............................................860 14.4.15 Troubleshooting the RCL......................................................861 General malfunctions.............................................................861 Error messages in the Monitoring submenu.........................................862 Displays in the Error submenu....................................................864 Table of error codes.............................................................866 Switching off the sensor/tachogenerator.........................................869 14.4.16 Malfunctions ECOS – superstructure...........................................870 ECOS programme version...........................................................870 General malfunctions.............................................................870 Error messages...................................................................871 Exiting the submenu..............................................................872 14.4.17 Malfunctions on CraneSTAR system.............................................873 14.5 Emergency operations and programmes.................................................877 14.5.1 Mechanical emergency activation for retracting................................878 Prior to the emergency activation, check.........................................878 Procedure........................................................................878 Mechanical emergency activation..................................................879 14.5.2 Telescoping emergency programme...............................................881 Start the emergency program......................................................881 Determining the error type.......................................................882 Error on length indicator........................................................883 If there is an error at a proximity switch.......................................886 Terminating the emergency program................................................888 Tables for approaching the locking points........................................889 14.5.3 Entering the current telescoping..............................................891 14.5.4 Emergency operation with the hand-held control................................893 Preparations.....................................................................893 Operating a power unit...........................................................894 Stopping movements...............................................................896 Stopping movements in emergencies................................................896 Turning off the engine...........................................................896 14.5.5 Switching on emergency operation in coolant circuit...........................897 14.6 Hydraulic emergency operation.......................................................899 14.6.1 Operating principle...........................................................899 14.6.2 Connecting/disconnecting hoses................................................901 Establishing connections.........................................................901 Disconnecting....................................................................902 14.6.3 Switching emergency operation on/off..........................................903 14.6.4 Establishing the hydraulic circuits required..................................904 Switching over valves............................................................904 For lifting/ lowering............................................................906 For slewing......................................................................907 14.6.5 Performing emergency operation................................................908 Slew.............................................................................908 Derricking.......................................................................909 Lifting/lowering.................................................................909 14.6.6 After emergency operation.....................................................910 Switching off emergency operation................................................910 Switching over to crane operation................................................910 Disconnecting the hoses..........................................................910 14.6.7 Emergency supply of another crane.............................................911 For emergency supply.............................................................911 After emergency supply...........................................................911 14.7 Other emergency operations..........................................................913 14.7.1 External starting socket......................................................913 Performing a jump start..........................................................914 14.7.2 Battery charger...............................................................914 15 Index.....................................................................................917 A........................................................................................919 B........................................................................................919 C........................................................................................919 D........................................................................................921 E........................................................................................923 F........................................................................................925 H........................................................................................926 I........................................................................................927 K........................................................................................927 L........................................................................................927 M........................................................................................928 O........................................................................................929 P........................................................................................930 R........................................................................................930 S........................................................................................931 T........................................................................................932 V........................................................................................934 W........................................................................................934
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