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Grove Crane GMK 4100L-1 Operating Manual 3302689 – PDF DOWNLOAD
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Description
Grove Crane GMK 4100L-1 Operating Manual 3302689 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100L-1 Operating Manual 3302689 – PDF DOWNLOAD
Language : English
Pages : 1020
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 4100L-1 Operating Manual 3302689 – PDF DOWNLOAD
Intended use:
The GMK4100L-1 truck crane is constructed in accordance with the latest technology and the
recognised safety regulations. Nevertheless, the opera- tor or third parties can still be
endangered and the crane or other property put at risk while using it.
- The truck crane may be modified only with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK4100L-1 truck crane may be used only when it is in perfect techni- cal condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK4100L-1 truck crane may only be operated without the correspond- ing special equipment
within thepermitted temperature range; à Technical
data, p. 1 – 7. - The GMK4100L-1 truck crane is designed solely for lifting loads which are within the permitted
GMK4100L-1 lifting capacities. The load must be slung as prescribed to a hook block which is
positioned vertically over the load prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating manual(s), the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.
The GMK4100L-1 may only be operated with parts of equipment which have been approved by Manitowoc
Crane Group Germany GmbH and which are labelled with the serial number of the GMK4100L-1.
The manufacturer is not liable for any damage caused by improper or unau- thorized use of the
GMK4100L-1 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 4100L-1 Operating Manual 3302689 – PDF DOWNLOAD
Operating manual........................................................................................................ 1 Table of contents................................................................................................... 41 Additional pages.................................................................................................... 5 Outrigger spans................................................................................................. 3 Driving from the crane cab...................................................................................... 5 Overview of Driving menu.................................................................................... 6 Brief description of the operating elements................................................................. 9 Driving menu............................................................................................ 9 Transmission............................................................................................ 11 Final drive............................................................................................. 13 Brakes.................................................................................................. 14 CCS display......................................................................................... 14 Side panel from above............................................................................... 14 Steering................................................................................................ 15 CCS display......................................................................................... 16 Control panels...................................................................................... 18 Driving from the crane cab.................................................................................. 19 Preparing to drive...................................................................................... 20 Opening/closing the Driving menu........................................................................ 21 Selecting the operating mode....................................................................... 21 Crane's hydraulic system Driving mode............................................................... 23 Closing menu........................................................................................ 23 Steering................................................................................................ 24 Switching on........................................................................................ 24 Display and steering direction...................................................................... 24 Switching the steering direction................................................................... 25 Displays when steering.............................................................................. 25 Separate steering................................................................................... 26 Normal steering..................................................................................... 29 Operating the transmission.............................................................................. 30 Selecting the transmission mode.................................................................... 30 While driving........................................................................................... 31 Warning messages.................................................................................... 31 Possible connections.................................................................................... 32 Longitudinal/transverse differential locks.......................................................... 32 After driving........................................................................................... 34 Telescoping emergency programe.................................................................................. 35 Hook blocks - Change / Correction............................................................................... 37 General............................................................................................................. 71 1 Overview...................................................................................................... 71 1.1 Accidents............................................................................................... 71 1.2 Branch offices.......................................................................................... 73 1.2.1 Manitowoc Crane Care.............................................................................. 73 1.2.2 Dealer list....................................................................................... 73 1.3 Warranty specifications................................................................................. 73 1.4 Terms used.............................................................................................. 74 1.5 Technical data.......................................................................................... 77 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................................. 77 1.5.2 Dimensions and weights of the truck crane, axle loads............................................. 78 Dimensions.......................................................................................... 79 Weight and axle loads............................................................................... 79 1.5.3 Dimensions and weights of removable parts......................................................... 80 Spare wheel......................................................................................... 80 Outrigger........................................................................................... 80 Hook blocks and hook tackle......................................................................... 0 Counterweight parts................................................................................ 84 Auxiliary hoist..................................................................................... 84 1.5.4 Carrier........................................................................................... 85 Motor............................................................................................... 85 Transmission........................................................................................ 85 Transfer case....................................................................................... 85 Axle lines.......................................................................................... 85 Steering............................................................................................ 86 Tyres............................................................................................... 86 Turning turning radii............................................................................... 86 Outrigger........................................................................................... 87 Electrical system................................................................................... 88 Tool................................................................................................ 88 Towing couplings................................................................................... 88 Driving speeds...................................................................................... 88 Climbing ability.................................................................................... 88 1.5.5 Superstructure.................................................................................... 89 Main hoist.......................................................................................... 89 Auxiliary hoist..................................................................................... 89 Slewing gears....................................................................................... 89 Derricking gear..................................................................................... 89 Main boom........................................................................................... 90 Lattice extension................................................................................... 90 Operating speeds.................................................................................... 90 1.6 Documentation supplied.................................................................................. 91 1.6.1 Questions on documentation........................................................................ 92 1.7 Notes on the operating manual........................................................................... 93 1.7.1 What do the symbols used mean?.................................................................... 93 1.7.2 How is the operating manual structured?........................................................... 95 Division............................................................................................ 95 Structure of thechapters........................................................................... 95 Structure of thepages.............................................................................. 96 1.7.3 How do I find the information I need?............................................................. 97 Cross-references example............................................................................ 98 1.7.4 What information is available for operations planning?............................................ 100 1.8 Conversion table for US measuring units................................................................. 101 1.9 Training – Information.................................................................................. 103 1.10 Identification......................................................................................... 104 1.11 EC Declaration of Conformity........................................................................... 106 2 Basic safety instructions..................................................................................... 107 2.1 Intended use............................................................................................ 107 2.1.1 Improper use...................................................................................... 108 2.2 Organisational measures................................................................................. 109 2.3 Personnel qualifications................................................................................ 111 2.4 Safety instructions for driving the truck crane......................................................... 112 2.5 Safety instructions for crane operation................................................................. 113 2.6 Instructions on transporting persons.................................................................... 116 Equipment for lifting persons........................................................................... 116 Personnel............................................................................................... 116 Operation............................................................................................... 117 Truck crane............................................................................................. 118 Driving............................................................................................................. 119 3 Operating elements for driving................................................................................ 119 3.1 Overview of the operating elements...................................................................... 119 3.1.1 On the outside of the truck crane................................................................. 120 3.1.2 Driver's cab...................................................................................... 124 Front overview...................................................................................... 124 Rear overview....................................................................................... 126 Behind the cover................................................................................... 127 3.1.3 Steering column/steering wheel.................................................................... 128 3.1.4 Instrument panel.................................................................................. 129 Left/right.......................................................................................... 129 Middle.............................................................................................. 130 3.1.5 Transmission operating elements................................................................... 132 3.1.6 On-board computer................................................................................. 133 3.1.7 Tachograph........................................................................................ 134 3.1.8 Heating and air-conditioning system............................................................... 135 Standard............................................................................................ 135 Auxiliary water heating system.................................................................... 136 Auxiliary air heater............................................................................... 137 3.1.9 CCS control unit.................................................................................. 139 3.1.10 CCS – menu-dependent displays.................................................................... 140 3.1.11 CCS – Start menu................................................................................. 141 3.1.12 CCS – Overview menu groups....................................................................... 142 3.1.13 Carrier menu group............................................................................... 144 Suspension/ level adjustment menu.................................................................. 145 Driving menu....................................................................................... 146 3.1.14 Settings menu group.............................................................................. 147 Set display brightness and date/time menu........................................................... 148 Switch units menu................................................................................... 149 3.1.15 Menu group Information........................................................................... 150 Operating hours menu............................................................................... 151 Engine/transmission error menu..................................................................... 152 Crane operation error menu......................................................................... 153 3.1.16 Various controls menu group...................................................................... 154 3.1.17 Emergency operations menu group.................................................................. 155 3.1.18 Outrigger control units.......................................................................... 156 3.2 Short description of the operating elements............................................................. 157 3.2.1 Definition of information relating to directions of movement...................................... 158 Basic rule.......................................................................................... 158 3.2.2 General rules for buttons and symbols on the display.............................................. 159 3.2.3 Motor............................................................................................. 160 Steering column..................................................................................... 160 On the steering wheel............................................................................... 160 Instrument panel.................................................................................... 161 3.2.4 AdBlue system..................................................................................... 162 Instrument panel.................................................................................... 162 CCS display......................................................................................... 163 3.2.5 Battery master switch............................................................................. 163 3.2.6 Electrical system................................................................................. 164 3.2.7 Crane control CCS................................................................................. 165 3.2.8 Transmission...................................................................................... 167 Transmission control unit........................................................................... 167 Display, driving mode,.............................................................................. 169 3.2.9 Reverse camera.................................................................................... 170 3.2.10 BirdView system 270 ............................................................................. 171 3.2.11 Transfer case.................................................................................... 173 3.2.12 Final drive...................................................................................... 174 3.2.13 Brakes........................................................................................... 176 Service brake....................................................................................... 176 Parking brake....................................................................................... 176 Additional brakes................................................................................... 177 3.2.14 Steering/separate steering....................................................................... 178 Instrument panel.................................................................................... 178 CCS display......................................................................................... 179 3.2.15 Suspension....................................................................................... 182 CCS display......................................................................................... 182 3.2.16 Lighting/windscreen wipers/horn.................................................................. 183 Steering column..................................................................................... 183 Steering wheel...................................................................................... 183 Instrument panel.................................................................................... 183 CCS display......................................................................................... 185 Roof................................................................................................ 185 3.2.17 Level adjustment system.......................................................................... 186 3.2.18 Tachograph/speedometer........................................................................... 188 Tachograph.......................................................................................... 188 Covers.............................................................................................. 188 Speedometer......................................................................................... 188 3.2.19 Diagnostics...................................................................................... 189 3.2.20 Push-up roof..................................................................................... 189 3.2.21 On-board computer................................................................................ 190 3.2.22 Front flap....................................................................................... 191 3.2.23 Windows and doors................................................................................ 192 Window winder....................................................................................... 192 Doors............................................................................................... 193 3.2.24 Access ladders and ladders....................................................................... 195 4 Starting the engine for driving / switching it off............................................................ 199 4.1 Starting the engine from the driver's cab............................................................... 199 4.1.1 CHECKLIST: Starting the engine.................................................................... 199 4.1.2 CHECKLIST: At low temperatures.................................................................... 202 4.1.3 Filling up........................................................................................ 203 Fuel tank........................................................................................... 203 AdBlue tank......................................................................................... 205 4.1.4 Checks before starting the engine................................................................. 206 At the hydraulic tank............................................................................... 206 Battery master switch............................................................................... 207 Checking the hand-held control...................................................................... 207 4.1.5 Switch the ignition on............................................................................ 207 4.1.6 Lamp test/equalisation of the switching states.................................................... 208 Lamp test........................................................................................... 208 Switching state alignment........................................................................... 208 4.1.7 Display – setting the brightness.................................................................. 209 4.1.8 Starting the engine............................................................................... 211 4.1.9 Checks after starting the engine.................................................................. 213 Start menu and on-board computer.................................................................... 213 Instrument panel.................................................................................... 214 4.1.10 Setting the idling speed......................................................................... 215 4.2 Switch off the engine................................................................................... 216 4.2.1 At the ignition lock and with the outrigger control units......................................... 216 After switching off................................................................................ 216 4.2.2 Using the emergency stop switches................................................................. 217 Resetting the emergency stop switch................................................................. 217 4.3 Air intake inhibitor.................................................................................... 218 Releasing the air intake inhibitor...................................................................... 218 5 Driving....................................................................................................... 219 5.1 Before driving.......................................................................................... 219 5.1.1 CHECKLIST: Checks before on-road driving.......................................................... 219 5.1.2 Check the condition of the truck crane............................................................ 225 Electrical system................................................................................... 225 Adjusting the mirrors............................................................................... 225 Warning plates for vehicle width.................................................................... 226 Checking the vehicle height......................................................................... 227 Supply pressure..................................................................................... 228 Parking brake....................................................................................... 229 5.1.3 Adjusting the seat and the steering column........................................................ 231 Adjusting the driver's seat........................................................................ 231 Adjusting the passenger seat....................................................................... 232 Adjusting the steering column...................................................................... 233 5.1.4 Switching the suspension on/off................................................................... 234 Open menu........................................................................................... 234 Switching the suspension on........................................................................ 235 Switching the suspension off....................................................................... 235 5.1.5 Setting the tachograph............................................................................ 236 Prerequisites....................................................................................... 236 In the event of malfunctions........................................................................ 236 Setting the tachograph............................................................................. 237 5.1.6 Setting the time.................................................................................. 241 5.1.7 Displaying and resetting operating hours.......................................................... 242 5.2 Operating the transmission.............................................................................. 243 5.2.1 Switching on...................................................................................... 243 5.2.2 Switching the transmission to the neutral position................................................ 244 5.2.3 Selecting the direction of travel and starting gear............................................... 245 Selecting the driving direction.................................................................... 245 Selecting the starting gear ...................................................................... 246 5.2.4 Changing the operating mode....................................................................... 247 Changing to automatic mode.......................................................................... 247 Change to manualmode............................................................................... 247 5.2.5 Starting.......................................................................................... 248 5.2.6 Driving and changing gears........................................................................ 249 In automatic operating mode......................................................................... 249 In manual operating mode............................................................................ 250 5.2.7 Changing the driving direction.................................................................... 251 5.2.8 Stopping.......................................................................................... 251 Stopping for longer periods........................................................................ 251 5.2.9 On the roller type dynamometer.................................................................... 252 5.2.10 Preheating transmission.......................................................................... 252 5.3 Driving the truck crane and switching it off............................................................ 253 5.3.1 Checks whilst driving............................................................................. 253 Brakes.............................................................................................. 253 ABS system.......................................................................................... 253 Steering............................................................................................ 254 Warning messages.................................................................................... 254 Monitoring elements................................................................................. 255 5.3.2 Cruise control.................................................................................... 256 Switching on........................................................................................ 256 Switching off....................................................................................... 257 5.3.3 Temposet.......................................................................................... 258 Switching on........................................................................................ 258 Switching off....................................................................................... 258 5.3.4 Driving downhill.................................................................................. 259 Starting............................................................................................ 259 Checks when driving downhill....................................................................... 260 Downshifting........................................................................................ 260 Additional brakes................................................................................... 261 5.3.5 Driving uphill.................................................................................... 262 Starting............................................................................................ 262 Driving............................................................................................. 262 5.3.6 Overriding torque reduction....................................................................... 263 5.3.7 Switching the truck crane off..................................................................... 264 Secure it against rolling away...................................................................... 264 When stationary for more than 8 hours............................................................... 265 5.3.8 Fold-up berth..................................................................................... 266 5.4 Off-road driving........................................................................................ 267 Adjustments to the transmission......................................................................... 267 Connections............................................................................................. 267 Changing the vehicle level.............................................................................. 267 Rocking the vehicle free and towing..................................................................... 267 5.4.1 Transfer case – switching the off-road gear on/off................................................ 268 Neutral position.................................................................................... 268 5.4.2 Longitudinal and transverse differential locks.................................................... 269 5.4.3 Operating the level adjustment system............................................................. 271 Open menu........................................................................................... 271 Setting the on-road level.......................................................................... 272 Pre-selecting suspension struts.................................................................... 272 Changing the vehicle level.......................................................................... 273 Viewing the current inclination..................................................................... 274 Exiting the menu................................................................................... 274 5.4.4 Freeing truck crane stuck in terrain.............................................................. 275 Rocking the truck crane free....................................................................... 275 Towing free forwards............................................................................... 276 Towing free totherear............................................................................ 276 5.5 Separate steering....................................................................................... 277 5.5.1 Switching to separate steering.................................................................... 278 5.5.2 Switching to normal steering mode................................................................. 281 5.5.3 Switching units of measure........................................................................ 282 5.6 Heating and air-conditioning system..................................................................... 283 5.6.1 Standard heating system........................................................................... 283 Switching on........................................................................................ 283 Heating............................................................................................. 283 Air distribution.................................................................................... 284 Examples............................................................................................ 285 Switching off....................................................................................... 285 5.6.2 Air-conditioning system........................................................................... 286 Information......................................................................................... 286 Switching on/off.................................................................................... 286 Cooling............................................................................................. 287 Drying.............................................................................................. 287 5.6.3 Auxiliary water heating system.................................................................... 288 Preheating theengine.............................................................................. 288 Preheating the driver's cab........................................................................ 289 Switching on........................................................................................ 289 Setting the date and time........................................................................... 291 Storing the heating start.......................................................................... 292 5.6.4 Auxiliary air heater.............................................................................. 294 Switching on........................................................................................ 294 Setting the heating level.......................................................................... 295 Setting the day and time........................................................................... 296 Setting the preselection time....................................................................... 296 Deleting preselection times......................................................................... 298 Switching off....................................................................................... 298 5.7 Radio................................................................................................... 298 5.8 Towing a trailer........................................................................................ 299 Effects on theaxleloads............................................................................... 299 Coupling the trailer................................................................................... 300 Connecting the supply lines............................................................................ 301 Removing supply lines................................................................................. 302 Uncoupling thetrailer................................................................................. 302 Checking the braking force.............................................................................. 304 6 Driving modes................................................................................................. 305 6.1 Driving modes........................................................................................... 305 Information about the axle loads........................................................................ 305 6.1.1 How to use the tables............................................................................ 306 6.1.2 Table for a maximum axle load of 12 t............................................................. 307 385/95 R25 tyres.................................................................................... 307 445/95 R25 tyres.................................................................................... 309 525/80 R25 tyres.................................................................................... 310 6.1.3 Maximum permitted speeds with an axle load of over 12 t........................................... 311 6.2 Weighing the truck crane................................................................................ 313 Axle groups............................................................................................. 314 Weighing procedure...................................................................................... 315 Evaluation.............................................................................................. 316 6.3 Rigging work for driving with a dolly................................................................... 317 6.3.1 Switching on the slewing gear freewheel........................................................... 318 6.3.2 Switching on the boom floating position........................................................... 319 6.3.3 Switching on boom pre-tensioning.................................................................. 320 6.4 Rigging the auxiliary hoist............................................................................. 321 6.4.1 Slinging the auxiliary hoist...................................................................... 321 6.4.2 CHECKLIST: Installing the auxiliary hoist......................................................... 322 6.4.3 CHECKLIST: Removing the auxiliary hoist........................................................... 323 6.4.4 Making/breaking the connection between the auxiliary hoist and the turntable...................... 324 6.4.5 Establishing/disconnecting the hydraulic connections.............................................. 325 6.4.6 Disconnecting/establishing the electrical connection.............................................. 326 6.4.7 Making/breaking the connection to the central lubrication......................................... 327 6.4.8 Transporting the auxiliary hoist.................................................................. 328 6.4.9 Check that the auxiliary hoist is functioning properly............................................ 329 Slewing direction................................................................................... 329 Slewing indicator................................................................................... 329 6.4.10 Rigging aid for the hoist rope................................................................... 330 6.5 Installing/removing the outrigger beams................................................................. 333 6.5.1 CHECKLIST: Removing the outrigger beams........................................................... 334 6.5.2 CHECKLIST: Installing the outrigger beams......................................................... 336 6.5.3 Centre of gravity data............................................................................ 338 6.5.4 Preparations – for removal........................................................................ 338 6.5.5 Preparations – on the truck crane................................................................. 339 Prerequisites....................................................................................... 339 6.5.6 Removing/attaching outrigger pads................................................................. 340 Removing the outrigger pads........................................................................ 340 Attaching the outrigger pads....................................................................... 341 6.5.7 Disconnecting/establishing hydraulic connection................................................... 342 6.5.8 Disconnecting/establishing the electrical connection.............................................. 343 6.5.9 Unscrewing/screwing in the spacers................................................................ 344 Unscrewing.......................................................................................... 344 Screwing in......................................................................................... 345 6.5.10 Disconnecting/establishing the connections to the supporting box................................. 346 6.5.11 Pulling out/Inserting the outrigger beam......................................................... 346 Extending the outrigger beam....................................................................... 346 Inserting the outrigger beam........................................................................ 348 6.5.12 Transporting the outrigger beams................................................................. 350 6.5.13 Note on error messages with removed outrigger beams.............................................. 351 7 Transport..................................................................................................... 353 7.1 Transport with transport vehicle........................................................................ 353 7.1.1 CHECKLIST: Checks before transport................................................................ 354 7.1.2 Drive the truck crane on to the transport vehicle................................................. 356 Driving on.......................................................................................... 357 Lashing............................................................................................. 357 7.2 Transport by ship....................................................................................... 358 8 Malfunctions in driving mode.................................................................................. 359 8.1 Emergency stop switch................................................................................... 359 8.2 Procedure during malfunctions........................................................................... 360 8.2.1 What to do when a malfunction occurs in road traffic.............................................. 360 8.2.2 Procedure during engine malfunctions.............................................................. 361 8.2.3 Procedure during transmission malfunctions........................................................ 362 8.3 Warning and error messages.............................................................................. 363 8.3.1 Warning or malfunction messages on the instrument panel........................................... 363 Meaning of thelamps................................................................................ 363 8.3.2 Warning and malfunction messages on the on-board computer display................................. 367 Messages............................................................................................ 367 Symbols............................................................................................. 368 8.3.3 Warning messages on the CCS display............................................................... 371 Symbols in the display area......................................................................... 371 8.3.4 Engine/transmission error messages................................................................ 375 Open menu........................................................................................... 375 Exiting the menu.................................................................................... 375 8.4 Troubleshooting......................................................................................... 377 8.4.1 Malfunctions on the engine........................................................................ 377 When operating with the dual tank................................................................... 379 8.4.2 Faults on the Adblue system....................................................................... 379 8.4.3 Differential lock malfunctions.................................................................... 380 8.4.4 Transfer case malfunctions........................................................................ 380 8.4.5 Malfunctions in the transmission.................................................................. 381 8.4.6 Malfunctions of the steering...................................................................... 382 8.4.7 Malfunctions of the service brake................................................................. 383 8.4.8 Malfunctions on the suspension.................................................................... 383 8.4.9 Malfunctions of the level adjustment system....................................................... 384 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 384 8.5 Emergency operation and breakdown assistance............................................................ 385 8.5.1 Starting the truck crane externally............................................................... 385 8.5.2 Battery charger................................................................................... 386 Prerequisites....................................................................................... 386 8.5.3 Towing the truck crane............................................................................ 387 In the case of engine/ transmission damage.......................................................... 387 Compressed-air supply............................................................................... 387 Longer towing distances............................................................................. 390 Tow starting........................................................................................ 390 8.5.4 Wheel change...................................................................................... 391 Removing a damaged wheel............................................................................ 392 On the spare wheel holder........................................................................... 392 Mounting a wheel.................................................................................... 393 8.5.5 Inflating the tyres yourself...................................................................... 395 Connecting thefilling hose......................................................................... 395 Inflating the tyres................................................................................. 396 Remove the fillinghose............................................................................ 396 8.5.6 Emergency operation, steering 3rd axle line....................................................... 397 Performing emergency operation..................................................................... 397 After emergency operation.......................................................................... 399 8.6 Tilting/lowering the driver's cab....................................................................... 401 8.6.1 Prerequisites and information on tilting.......................................................... 401 8.6.2 Tilting and lowering the driver's cab............................................................. 402 Operating the hand pump............................................................................. 402 Tilting the driver's cab............................................................................ 403 Lowering the driver's cab.......................................................................... 404 8.7 Fuses on the carrier.................................................................................... 407 Information on changing fuses......................................................................... 407 8.7.1 Fuses in the driver's cab......................................................................... 408 8.7.2 Fuses in the battery box.......................................................................... 414 Crane operation..................................................................................................... 415 9 Operating elements for crane operation........................................................................ 415 9.1 Overview of the operating elements...................................................................... 415 9.1.1 Exterior of the truck crane....................................................................... 416 9.1.2 Crane cab......................................................................................... 420 Side panel.......................................................................................... 422 Crane cab, rear..................................................................................... 424 9.1.3 Control panels.................................................................................... 426 Left................................................................................................ 426 Right............................................................................................... 427 9.1.4 Control lever assignment.......................................................................... 428 Version 1........................................................................................... 428 Version 2........................................................................................... 429 9.1.5 CCS control unit.................................................................................. 430 9.1.6 Menu-independent displays......................................................................... 432 9.1.7 CCS – Start menu.................................................................................. 433 RCL display......................................................................................... 434 Display Slewing ranges/working radii............................................................... 435 9.1.8 CCS – Overview menu groups........................................................................ 436 9.1.9 Superstructure menu group......................................................................... 440 Superstructure lock sub-menu...................................................................... 441 Counterweight menu.................................................................................. 442 9.1.10 Menu group outrigger/driving.................................................................... 443 Outrigger menu..................................................................................... 444 Outrigger cylinders menu........................................................................... 446 Driving mode menu.................................................................................. 448 9.1.11 RCL/Telescoping menu group....................................................................... 451 Menu enter rigging mode/ telescope................................................................. 452 Pre-selection telescoping menu..................................................................... 456 Lifting capacity tables menu........................................................................ 458 Telescoping semi- automation menu.................................................................. 459 Manual telescoping menu........................................................................... 460 9.1.12 Active working range limiter menu group.......................................................... 461 Overall height menu................................................................................ 462 Working radius menu................................................................................. 463 Slewing angle menu.................................................................................. 464 Hoist rope travel limitation menu................................................................... 465 9.1.13 Information menu group 1......................................................................... 466 Hydraulic pressure and fuel consumption menu........................................................ 467 9.1.14 Heating/Engine/Additional equipment menu group................................................... 468 Economy menu........................................................................................ 469 Remote control menu................................................................................. 470 Heating/ air-conditioning menu...................................................................... 471 Spotlights menu..................................................................................... 472 9.1.15 Telescoping emergency program menu group....................................................... 473 Telescoping emergency program menu................................................................ 474 Unknown telescoping menu........................................................................... 476 Swinging the swing-away lattice emergency operation menu............................................ 477 9.1.16 Settings menu group.............................................................................. 478 Crane cab menu...................................................................................... 479 Set display brightness and date/time menu........................................................... 480 Switch units menu................................................................................... 481 Set control lever characteristic curve menu......................................................... 482 Power unit speedsmenu............................................................................ 483 9.1.17 Information menu group 2......................................................................... 484 Operating hours menu................................................................................ 485 Engine/transmission errormenu...................................................................... 486 Crane operation error menu.......................................................................... 487 Program version menu................................................................................ 488 9.1.18 Various controls................................................................................. 489 9.1.19 RCL control unit................................................................................. 490 9.1.20 Menu-independent displays........................................................................ 491 9.1.21 RCL – menus...................................................................................... 492 Monitoring menu.................................................................................... 492 Lifting capacity tables menu........................................................................ 494 Datalogger menu..................................................................................... 495 9.1.22 Hand-held control................................................................................ 497 9.1.23 Outriggers control units......................................................................... 499 Menu- independent buttons.......................................................................... 499 Outrigger menu...................................................................................... 500 Raise axle menu.................................................................................... 502 9.2 Short description of the operating elements............................................................. 503 9.2.1 Definition of information relating to directions of movement...................................... 503 Basic rule.......................................................................................... 503 9.2.2 General rules for buttons and symbols on the display.............................................. 504 9.2.3 Engine............................................................................................ 505 Side panel......................................................................................... 505 Left control lever.................................................................................. 505 Economy mode menu................................................................................... 506 9.2.4 AdBlue system..................................................................................... 506 CCS display......................................................................................... 506 9.2.5 Seat contact switch and dead man's switch......................................................... 508 9.2.6 Crane control CCS................................................................................. 509 9.2.7 Outrigger – crane cab............................................................................. 514 Control panels...................................................................................... 514 CCS display......................................................................................... 515 9.2.8 Outrigger control units........................................................................... 517 General information................................................................................. 517 Outrigger menu...................................................................................... 518 9.2.9 Raise axle........................................................................................ 520 9.2.10 Inclination indicators........................................................................... 522 9.2.11 Outrigger pressure displays...................................................................... 523 Outrigger menu..................................................................................... 523 Outriggers control units........................................................................... 523 9.2.12 Anemometer displays.............................................................................. 523 9.2.13 Counterweight menu............................................................................... 524 9.2.14 Main hoist....................................................................................... 528 Control panels...................................................................................... 528 CCS display......................................................................................... 528 9.2.15 Auxiliary hoist.................................................................................. 530 Control panels...................................................................................... 530 CCS display......................................................................................... 530 9.2.16 Slewing gear..................................................................................... 532 Control panels...................................................................................... 532 CCS display......................................................................................... 533 9.2.17 Derricking gear.................................................................................. 534 Control panels...................................................................................... 534 CCS display......................................................................................... 535 Side panel.......................................................................................... 535 9.2.18 Telescoping mechanism............................................................................ 536 Control panels...................................................................................... 536 CCS display......................................................................................... 537 Telescoping semi- automation menu................................................................... 537 Manual telescoping menu............................................................................. 539 9.2.19 Hydraulic system................................................................................. 542 9.2.20 Superstructure lock/house lock menu.............................................................. 543 Superstructure lock................................................................................ 543 Houselock........................................................................................... 545 9.2.21 Remote control................................................................................... 546 9.2.22 Rated capacity limiter (RCL)..................................................................... 547 CCS display......................................................................................... 547 RCL display......................................................................................... 556 RCL override – version A............................................................................ 557 RCL override – version B............................................................................ 558 9.2.23 Electrical system................................................................................ 559 9.2.24 Lighting, windscreen wiper/washing system........................................................ 560 Lighting............................................................................................ 560 Windscreen wiper/washing system.................................................................... 562 Horn................................................................................................ 563 9.2.25 Hand-held control................................................................................ 564 Sockets for hand- held control...................................................................... 564 Engine control panel................................................................................ 565 Horn................................................................................................ 565 9.2.26 Windows and doors................................................................................ 568 Window.............................................................................................. 568 Rear window......................................................................................... 568 Crane cab door...................................................................................... 569 9.2.27 Diagnostics...................................................................................... 570 9.2.28 Other............................................................................................ 570 9.3 Short description of the operating elements – driving from the crane cab................................ 571 9.3.1 Driving mode menu................................................................................. 571 9.3.2 Transmission...................................................................................... 572 9.3.3 Final drive....................................................................................... 573 9.3.4 Brakes............................................................................................ 575 CCS display......................................................................................... 575 Side panel from above............................................................................... 576 9.3.5 Steering.......................................................................................... 577 CCS display......................................................................................... 577 Separate steering................................................................................... 578 Control panels...................................................................................... 579 10 Starting/switching off the engine – for crane operation...................................................... 581 10.1 When starting the engine for the first time in the day................................................. 581 10.2 Starting the engine – from the crane cab............................................................... 583 10.2.1 Check the fuel level and AdBlue level............................................................ 583 Fuel................................................................................................ 583 AdBlue.............................................................................................. 583 10.2.2 Checks before starting the engine................................................................ 584 Checks on the carrier.............................................................................. 584 Checking the hand-held control...................................................................... 584 At the hydraulic tank............................................................................... 584 10.2.3 Switch the ignition on........................................................................... 585 10.2.4 Comparison of switching states................................................................... 586 10.2.5 Display – setting the brightness................................................................. 586 10.2.6 Starting the engine.............................................................................. 587 10.2.7 Checks after starting the engine................................................................. 588 10.2.8 Setting the idling speed......................................................................... 589 10.3 Starting the engine – with the hand-held control....................................................... 590 10.4 Switch off the engine.................................................................................. 591 10.4.1 At the ignition lock and with hand-held control.................................................. 591 After switching off................................................................................ 591 10.4.2 With the idling button........................................................................... 591 10.4.3 Using the emergency stop switches................................................................ 592 Resetting the emergency stop switch................................................................. 592 11 Crane operation.............................................................................................. 593 11.1 Before operating the crane............................................................................. 593 11.1.1 CHECKLIST: Checks before operating the crane..................................................... 593 11.1.2 Check the condition of the truck crane........................................................... 597 Fuel tank auxiliary heater.......................................................................... 597 Visual inspection................................................................................... 597 Checking the position of the hoist ropes............................................................ 598 Checking the electrical system...................................................................... 599 11.1.3 Adjusting the crane cab seat and front control panel............................................. 600 Crane cab seat...................................................................................... 600 Front control panel................................................................................. 601 11.1.4 Checking the safety equipment.................................................................... 602 Rated capacity limiter.............................................................................. 602 Lifting limit switch............................................................................... 602 Emergency stop switch............................................................................... 603 Seat contact switch................................................................................ 604 11.1.5 Earthing the load................................................................................ 605 11.1.6 Preheating hydraulic oil......................................................................... 606 Prerequisites....................................................................................... 606 Preheating.......................................................................................... 606 11.1.7 Locking/unlocking the superstructure............................................................. 607 Locking points...................................................................................... 607 Lock the superstructure............................................................................ 608 Unlocking the superstructure....................................................................... 608 11.1.8 Switching the houselock on/off................................................................... 609 Switching on the houselock......................................................................... 609 Switching off the houselock........................................................................ 611 11.2 Standard slewing range type............................................................................ 613 11.2.1 Permissible slewing ranges and working positions................................................. 613 360 slewing range.................................................................................. 613 Working position 0 to the rear..................................................................... 613 180 to the front rigging position.................................................................. 613 11.3 MAXbase slewing range type............................................................................. 615 11.3.1 Specifications in the lifting capacity tables.................................................... 616 11.3.2 Enabled slewing ranges........................................................................... 617 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit....... 620 11.4 Operation of the rated capacity limiter................................................................ 621 11.4.1 Switch on the RCL................................................................................ 622 Switching on........................................................................................ 622 11.4.2 Enter rigging mode............................................................................... 624 Notes on Input..................................................................................... 624 Enter the slewing range type........................................................................ 625 Entering individual components...................................................................... 626 Entering the RCLcode.............................................................................. 632 11.4.3 Pre-selecting telescoping........................................................................ 632 11.4.4 Confirm the rigging mode and lifting capacity table.............................................. 633 Slewing range type Standard......................................................................... 633 Slewing range type MAXbase.......................................................................... 635 11.4.5 Checks before operating the crane................................................................ 637 Monitoring menu..................................................................................... 637 Checking the rigging mode........................................................................... 637 Hoist checking...................................................................................... 639 11.4.6 Display during the crane operation............................................................... 641 On the RCL display.................................................................................. 641 On the CCS display.................................................................................. 645 11.4.7 RCL early warning................................................................................ 649 11.4.8 RCL shutdown..................................................................................... 649 Shutdown due to overload............................................................................ 649 11.4.9 Displaying the lifting capacity tables........................................................... 651 Slewing range type Standard......................................................................... 651 Slewing range type MAXbase.......................................................................... 653 11.4.10 RCL override – version A........................................................................ 655 Overview statusdisplay............................................................................. 655 When rigging........................................................................................ 656 To raise the boom................................................................................... 657 In emergencies...................................................................................... 658 11.4.11 RCL override – version B........................................................................ 659 11.4.12 Datalogger...................................................................................... 660 Export data......................................................................................... 660 Display the data.................................................................................... 661 11.5 Crane operation with main boom......................................................................... 665 11.5.1 Checks during crane operation.................................................................... 665 Horizontal alignment................................................................................ 665 Safe distances..................................................................................... 665 Checking the windspeed............................................................................. 666 11.5.2 Main hoist....................................................................................... 667 Switching on themain hoist......................................................................... 668 Lifting and lowering............................................................................... 668 Maximum permissible hoist rope speed................................................................ 669 Switching off the main hoist....................................................................... 670 11.5.3 Auxiliary hoist.................................................................................. 671 Switching on the auxiliary hoist................................................................... 671 Lifting and lowering............................................................................... 672 Maximum permissible hoist rope speed................................................................ 673 Switching off the auxiliary hoist.................................................................. 673 11.5.4 Lifting limit switch and lowering limit switch................................................... 674 Lifting limit switch................................................................................ 674 Lowering limit switch............................................................................... 676 11.5.5 Derricking gear.................................................................................. 677 Switching on the derricking gear................................................................... 677 Raising and lowering................................................................................ 678 Maximum derricking speed............................................................................ 679 Re-enable raising function.......................................................................... 679 Switching off the derricking gear................................................................... 680 Lowering the main boom to a horizontal position..................................................... 680 11.5.6 Telescoping mechanism............................................................................ 681 Overview............................................................................................ 683 Telescoping process................................................................................. 684 Assignment for display.............................................................................. 686 Fixed length, intermediate length, telescoping length.............................................. 687 Telescoping......................................................................................... 688 Telescoping sequence............................................................................... 688 Inspections prior to starting operations........................................................... 689 Switching on thetelescoping mechanism.............................................................. 690 Function of the control lever....................................................................... 690 Switching off thetelescoping mechanism............................................................. 692 Manual telescoping................................................................................. 693 Checking the initial position....................................................................... 693 Unlocking the telescoping cylinder.................................................................. 695 Extending/retracting the telescoping cylinder....................................................... 697 Lock telescoping cylinder........................................................................... 698 Unlocking the telescopic section................................................................... 699 Telescoping the telescopic section................................................................. 700 Locking the telescopic section..................................................................... 701 Locking the telescopic section for on-road driving................................................. 702 Telescoping with semi-automaton..................................................................... 702 Telescoping with pre-selection...................................................................... 704 11.5.7 High-speed mode.................................................................................. 705 Derricking gear telescoping mechanism.............................................................. 705 Hoists.............................................................................................. 705 11.5.8 Slewing gear..................................................................................... 707 Slewing gear brake.................................................................................. 707 Switching on the slewing gear...................................................................... 708 Releasing the slewing gear brake.................................................................... 708 Applying the slewing gear brake..................................................................... 708 Releasing locked slewing gear....................................................................... 709 Slewing............................................................................................. 709 Permissible slewing speed.......................................................................... 710 Braking the slewing movement........................................................................ 711 Slewing gear freewheel.............................................................................. 711 Switching off the slewing gear..................................................................... 712 11.5.9 Switching the reduction of slewing speed on and off.............................................. 713 Switching reduction off............................................................................. 713 11.5.10 Possible movement combinations.................................................................. 714 11.6 Settings and displays for crane operation.............................................................. 715 11.6.1 Inclining the crane cab.......................................................................... 715 11.6.2 Setting the idling speed......................................................................... 716 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper...................................... 716 11.6.4 Limiting the power unit speeds................................................................... 717 11.6.5 Economy mode..................................................................................... 718 Switching on........................................................................................ 718 Ending/ switchingoff............................................................................... 720 11.6.6 Switching units of measure....................................................................... 720 11.6.7 Setting the characteristic curves for the control levers......................................... 721 11.6.8 Using the slewable spotlights.................................................................... 722 Manually swinging................................................................................... 723 Automatic load tracking............................................................................. 723 11.6.9 Overriding torque reduction...................................................................... 724 11.6.10 Displaying the operating hours.................................................................. 725 11.7 Working range limiter.................................................................................. 727 11.7.1 Viewing current settings......................................................................... 728 On the RCL display.................................................................................. 728 In the CCS Start menu............................................................................... 729 11.7.2 Opening the working range limiter menu........................................................... 729 11.7.3 Entering limit values............................................................................ 732 Overall height...................................................................................... 732 Working radius...................................................................................... 733 Slewing angle....................................................................................... 733 Hoist rope limitation............................................................................... 734 11.7.4 Entering limit values manually................................................................... 736 Limit values........................................................................................ 736 11.7.5 Switching monitoring functions on/off............................................................ 738 11.7.6 Shutdown by working range limiter................................................................ 739 11.8 Work break............................................................................................. 741 11.8.1 In case of short work breaks..................................................................... 741 11.8.2 In case of work breaks of more than 8 hours...................................................... 742 To secure the truck crane........................................................................... 742 11.9 Heating and air-conditioning system.................................................................... 743 11.9.1 Standard heating system.......................................................................... 743 Switching on........................................................................................ 743 Heating............................................................................................. 743 Air distribution.................................................................................... 744 Switching off....................................................................................... 744 11.9.2 Air-conditioning system.......................................................................... 745 Information......................................................................................... 745 Switching on/off.................................................................................... 745 Cooling, automatic.................................................................................. 746 Cooling, maximum.................................................................................... 746 11.9.3 Auxiliary heater................................................................................. 747 Switching on........................................................................................ 747 Setting the temperature............................................................................. 748 Setting the heating start/ heating duration......................................................... 748 Switching heating start on/off...................................................................... 749 11.10 CraneSTAR system...................................................................................... 750 11.10.1 Overview........................................................................................ 750 11.10.2 Position of the components...................................................................... 750 12 Rigging work................................................................................................. 751 12.1 Rigging work checklists for crane operation with the main boom......................................... 751 12.1.1 CHECKLIST: Rigging............................................................................... 751 12.1.2 CHECKLIST: Unrigging............................................................................. 757 12.2 Choice of a suitable positioning site.................................................................. 761 12.2.1 Determining the required load-bearing area....................................................... 761 12.2.2 Safe distance from slopes and pits............................................................... 764 12.2.3 Earthing the truck crane......................................................................... 765 12.2.4 Safe distance from overhead power lines.......................................................... 766 12.3 Rigging work after driving with a dolly................................................................ 769 12.3.1 Switching off the boom floating position......................................................... 769 12.3.2 Switching off the slewing gear freewheel......................................................... 770 Before slewing...................................................................................... 770 12.3.3 Switching off boom pre-tensioning................................................................ 771 12.4 Connecting/disconnecting the hand-held control......................................................... 773 12.5 Starting the engine for rigging........................................................................ 777 Prerequisites........................................................................................... 777 Starting the engine..................................................................................... 777 Turning off theengine.................................................................................. 777 12.6 Slewing range – only with the Standard slewing range type.............................................. 779 12.6.1 Representation in the lifting capacity tables.................................................... 779 12.6.2 Enabled outrigger spans.......................................................................... 780 12.7 Outriggers – Overview – MAXbase slewing range type..................................................... 781 12.7.1 Definitions...................................................................................... 781 12.7.2 Representation in the lifting capacity tables.................................................... 783 12.7.3 Enabled outrigger spans.......................................................................... 784 12.8 Outrigger operation.................................................................................... 789 12.8.1 CHECKLIST: Extending the outriggers.............................................................. 789 12.8.2 CHECKLIST: Retracting the outriggers............................................................. 791 12.8.3 Preparing the truck crane........................................................................ 792 Driver's cab........................................................................................ 792 Crane cab........................................................................................... 792 12.8.4 Setting the outrigger spans...................................................................... 794 For on-road driving................................................................................. 797 12.8.5 Extending/retracting outrigger beams............................................................. 797 From the controlunits.............................................................................. 798 From the cranecab.................................................................................. 799 12.8.6 Moving the outrigger pads into operating/driving position........................................ 801 12.8.7 Enlarging the load-bearing area.................................................................. 803 12.8.8 Extending/retracting supporting cylinders........................................................ 804 From the control units.............................................................................. 805 From the cranecab.................................................................................. 806 12.8.9 Levelling the truck crane on outriggers horizontally............................................. 808 Inclination indicators.............................................................................. 808 Prerequisites....................................................................................... 809 Manual alignment................................................................................... 810 Automatic alignment................................................................................. 810 12.8.10 Levelling the free-standing truck crane......................................................... 812 12.8.11 Operating the axle raising system............................................................... 814 12.8.12 Outrigger pressure display...................................................................... 816 12.9 Rigging/unrigging the counterweight.................................................................... 819 Counterweight display rigged............................................................................ 819 12.9.1 Information on rigging........................................................................... 819 When rigging........................................................................................ 819 When unrigging...................................................................................... 820 12.9.2 Counterweight sections........................................................................... 821 12.9.3 Identification................................................................................... 823 12.9.4 Slinging points on the counterweight sections.................................................... 824 12.9.5 CHECKLIST: Rigging the counterweight............................................................. 826 12.9.6 CHECKLIST: Unrigging the counterweight........................................................... 828 12.9.7 Assembling counterweight combination............................................................. 830 12.9.8 Counterweight hoist unit......................................................................... 835 Counterweight menu................................................................................. 835 Extending/ retracting the lifting cylinders......................................................... 836 Automatic moderigging............................................................................. 838 Automatic mode unrigging........................................................................... 840 Cancel automatic mode.............................................................................. 841 12.9.9 Setting down counterweight for driving........................................................... 842 Rear counterweight platform......................................................................... 842 Front counterweight platform........................................................................ 844 12.9.10 Unlocking/locking the rear counterweight platform............................................... 845 Unlocking........................................................................................... 845 Locking............................................................................................. 846 12.9.11 Slewing with rigged counterweight............................................................... 847 12.10 Rigging work on the main boom......................................................................... 849 12.10.1 Hook block on the bumper........................................................................ 849 Picking up the hook block........................................................................... 849 Attaching the hook block............................................................................ 850 12.10.2 Hook block on a separate vehicle................................................................ 851 Picking up the hook block.......................................................................... 852 Setting down thehook block........................................................................ 852 12.10.3 Hook block, separable........................................................................... 854 Rigging for on-road driving......................................................................... 854 Rigging for crane operation......................................................................... 855 12.10.4 Hook block with ballast plates.................................................................. 856 Removing............................................................................................ 856 Installing.......................................................................................... 857 Information on crane operation...................................................................... 857 12.10.5 Reeving and unreeving the hoist rope............................................................ 858 Reeving the hoistrope.............................................................................. 859 Unreeving hoistrope............................................................................... 863 12.10.6 Possible reevings on the main boom.............................................................. 864 With 5 head sheaves................................................................................. 864 With 6 head sheaves................................................................................. 867 With 7 head sheaves................................................................................. 869 12.10.7 Installing/removing the lifting limit switch.................................................... 870 Installing the lifting limit switch................................................................. 870 Removing the lifting limit switch................................................................... 873 12.10.8 Locking/unlocking the lifting limit switch...................................................... 875 Locking............................................................................................. 875 Removing the lock.................................................................................. 875 12.10.9 Anemometer and air traffic control light........................................................ 876 Installing.......................................................................................... 876 Switching on/off.................................................................................... 877 Removing............................................................................................ 877 12.11 Other rigging work.................................................................................... 879 12.11.1 Railings on the turntable....................................................................... 879 12.11.2 Folding the mirrors in and out, and adjusting them.............................................. 880 12.11.3 Slinging points for personal protective equipment............................................... 881 12.11.4 Cameras for crane operation..................................................................... 882 Camera on mainboom................................................................................. 882 Camera on thehoists................................................................................ 885 Camera on the driver's cab.......................................................................... 885 Operating the camera................................................................................ 886 12.11.5 Step at the crane cab........................................................................... 887 13 Driving with a rigged truck crane............................................................................ 889 13.1 Route.................................................................................................. 889 13.2 Permissible rigging modes and axle loads............................................................... 890 Axle load table........................................................................................ 890 13.2.1 To drive without a load.......................................................................... 893 13.2.2 To drive with a load............................................................................. 893 13.2.3 Axle loads....................................................................................... 894 13.3 Before driving the rigged truck crane.................................................................. 895 13.3.1 Check the tyre pressures and wind speed.......................................................... 895 13.3.2 Secure the superstructure against slewing........................................................ 895 13.3.3 Putting the truck crane on the wheels – with Raise axle function................................. 896 13.3.4 Putting the truck crane on the wheels – with the outriggers...................................... 898 13.4 Driving from the driver's cab.......................................................................... 901 13.4.1 Preparing to drive............................................................................... 901 Transmission........................................................................................ 901 Switching on separate steering...................................................................... 901 Connections......................................................................................... 901 13.4.2 Whilst driving................................................................................... 902 13.4.3 After driving.................................................................................... 903 13.5 Driving from the crane cab............................................................................. 905 13.5.1 Preparing to drive............................................................................... 906 13.5.2 Opening/closing the Driving menu................................................................. 906 Opening............................................................................................. 906 Crane's hydraulic system on/off..................................................................... 907 Closing............................................................................................. 908 13.5.3 Steering......................................................................................... 909 Switching on........................................................................................ 909 Steering direction.................................................................................. 909 Displays when steering.............................................................................. 910 Separate steering................................................................................... 910 Normal steering mode................................................................................ 914 13.5.4 Operating the transmission....................................................................... 915 Selecting the transmission mode.................................................................... 915 13.5.5 Whilst driving................................................................................... 916 DM and RM transmission mode......................................................................... 916 Transmission mode D................................................................................. 916 Warning messages.................................................................................... 916 13.5.6 Possible connections............................................................................. 917 Longitudinal/ transverse differential locks......................................................... 917 13.5.7 After driving.................................................................................... 919 14 Malfunctions during crane operation.......................................................................... 921 14.1 Emergency stop switch.................................................................................. 921 14.2 What to do when malfunctions occur during crane operation.............................................. 922 The load can be set down................................................................................ 922 Load cannot besetdown................................................................................. 922 14.3 Warning and error messages............................................................................. 923 Program version......................................................................................... 923 14.3.1 Warning messages on the CCS display.............................................................. 923 Meaning of thesymbols.............................................................................. 924 14.3.2 Error messages on the CCS display................................................................ 927 14.3.3 Warning messages on the RCL display.............................................................. 929 14.4 Troubleshooting........................................................................................ 933 14.4.1 Malfunctions on the engine....................................................................... 933 14.4.2 Malfunctions on the main hoist/auxiliary hoist................................................... 933 14.4.3 Malfunctions in the hoist cameras................................................................ 935 14.4.4 Malfunctions in the main boom camera............................................................. 935 14.4.5 Malfunctions on the derricking gear.............................................................. 936 14.4.6 Malfunctions in the telescoping mechanism........................................................ 937 14.4.7 Malfunctions on the slewing gear................................................................. 938 14.4.8 Malfunctions on the counterweight hoist unit..................................................... 940 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 940 14.4.10 Malfunctions when inclining the crane cab....................................................... 940 14.4.11 Malfunctions when operating with the hand-held control.......................................... 941 14.4.12 Malfunctions when inclining the crane cab....................................................... 941 14.4.13 Malfunctions when raising the axles............................................................. 941 14.4.14 Malfunctions of the outriggers.................................................................. 942 14.4.15 Malfunctions on the turntable lock.............................................................. 942 14.4.16 Malfunctions on the CCS/RCL control units....................................................... 943 14.4.17 Malfunctions when driving from the crane cab.................................................... 943 14.4.18 Malfunctions on the CraneSTAR system............................................................ 944 14.5 Emergency operations and programs...................................................................... 947 14.5.1 Mechanical emergency activation for retracting................................................... 948 Prior to the emergency operation, check............................................................. 948 Procedure........................................................................................... 948 Mechanical emergency activation.................................................................... 949 14.5.2 Telescoping emergency program.................................................................... 951 Checks before using the emergency program........................................................... 951 Telescoping emergency program menu.................................................................. 952 Notes on the displays............................................................................... 953 Checks in theemergency program.................................................................... 954 Retracting withemergency program................................................................... 958 Tables for approaching the locking points........................................................... 960 14.5.3 Entering the current telescoping................................................................. 963 14.5.4 Emergency operation with the hand-held control................................................... 965 To pre-select a power unit.......................................................................... 966 Operating apowerunit.............................................................................. 966 Stopping movements................................................................................. 967 Stopping movements in emergencies................................................................... 968 Switch off theengine............................................................................... 968 14.5.5 Notes on slewing in emergency operation.......................................................... 968 For the Standard slewing range type................................................................. 968 For the MAXbase slewing range type.................................................................. 970 14.6 Hydraulic emergency operation with the hand pump....................................................... 971 14.6.1 Operating principle.............................................................................. 971 14.6.2 Switching over the crane's hydraulic system...................................................... 971 14.6.3 Establishing the hydraulic circuits required..................................................... 972 Releasing/ securing valves.......................................................................... 972 Switching over valves............................................................................... 973 For lowering........................................................................................ 974 14.6.4 Performing emergency activation.................................................................. 975 14.6.5 After emergency activation....................................................................... 975 14.7 Hydraulic emergency operation as per BGR 159........................................................... 977 14.7.1 Applications and function........................................................................ 977 14.7.2 CHECKLIST: Emergency operation................................................................... 979 14.7.3 CHECKLIST: After emergency operation............................................................. 980 14.7.4 Connecting/removing transformer – for self-sufficiency........................................... 981 Connecting.......................................................................................... 981 Removing............................................................................................ 982 14.7.5 Switching emergency operation on/off............................................................. 983 14.7.6 Connecting/removing transformer – for external energy source..................................... 984 14.7.7 Establishing the required hydraulic circuits..................................................... 985 Switching overvalves............................................................................... 985 For lifting/ lowering............................................................................... 987 For slewing......................................................................................... 988 14.7.8 Performing emergency operation................................................................... 989 Slewing............................................................................................. 989 Derricking.......................................................................................... 990 Lifting/lowering.................................................................................... 990 14.7.9 Emergency supply of another crane................................................................ 991 For emergency supply................................................................................ 991 After emergency supply.............................................................................. 991 14.8 Fuses in the crane cab................................................................................. 993 Information on changing fuses......................................................................... 993 Index............................................................................................................... 999 A...............................................................................................................1001 B...............................................................................................................1001 C...............................................................................................................1002 D...............................................................................................................1004 E...............................................................................................................1006 F...............................................................................................................1008 H...............................................................................................................1008 I...............................................................................................................1009 L...............................................................................................................1009 M...............................................................................................................1010 O...............................................................................................................1011 P...............................................................................................................1012 R...............................................................................................................1012 S...............................................................................................................1013 T...............................................................................................................1015 V...............................................................................................................1017 W...............................................................................................................1017
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