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Grove Crane GMK 4100L-1 Operating Manual 3302689en – PDF DOWNLOAD
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Description
Grove Crane GMK 4100L-1 Operating Manual 3302689en – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100L-1 Operating Manual 3302689en – PDF DOWNLOAD
Language : English
Pages : 1018
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 4100L-1 Operating Manual 3302689en – PDF DOWNLOAD
Documentation supplied:
The precise number of documents supplied depends on the rigging mode
of the truck crane. The following documents are included in delivery:
– Operating manual
Contains information on driving and crane operation.
– Lattice extension operating manual
Is only supplied when the truck crane is equipped with a lattice extension
or other parts for extending the main boom (e.g. auxiliary single-sheave
boom top and heavy load lattice extension).
– Operating manual for additional equipment
This is only supplied when the truck crane is supplied with additional
equipment which is not described in the operating manual for driving and
crane operation.
– Documents from other manufacturers
Original documentation for parts not manufactured by Manitowoc Crane
Group Germany GmbH, such as the engine and central lubrication system,
as well as the tachograph, auxiliary heaters, radio and, where appropriate,
other additional equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no
instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and
pneumatic systems are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes.
TABLE OF CONTENTS:
Grove Crane GMK 4100L-1 Operating Manual 3302689en – PDF DOWNLOAD
Operating manual........................................................................................................ 1 Table of contents................................................................................................... 39 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 programme................................................................................. 35 Return run of the telescoping cylinder...................................................................... 35 General............................................................................................................. 69 1 Overview...................................................................................................... 69 1.1 Accidents............................................................................................... 69 1.2 Branch offices.......................................................................................... 71 1.2.1 Manitowoc Crane Care.............................................................................. 71 1.2.2 Dealer list....................................................................................... 71 1.3 Warranty specifications................................................................................. 71 1.4 Terms used.............................................................................................. 72 1.5 Technical data.......................................................................................... 75 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................................. 75 1.5.2 Dimensions and weights of the truck crane, axle loads............................................. 76 Dimensions.......................................................................................... 77 Weight and axle loads............................................................................... 77 1.5.3 Dimensions and weights of removable parts......................................................... 78 Spare wheel......................................................................................... 78 Outrigger........................................................................................... 78 Hook blocks and hook tackle......................................................................... 0 Counterweight parts................................................................................ 82 Auxiliary hoist..................................................................................... 82 1.5.4 Carrier........................................................................................... 83 Motor............................................................................................... 83 Transmission........................................................................................ 83 Transfer case....................................................................................... 83 Axle lines.......................................................................................... 83 Steering............................................................................................ 84 Tyres............................................................................................... 84 Turning turning radii............................................................................... 84 Outrigger........................................................................................... 85 Electrical system................................................................................... 86 Tool................................................................................................ 86 Towing couplings................................................................................... 86 Driving speeds...................................................................................... 86 Climbing ability.................................................................................... 86 1.5.5 Superstructure.................................................................................... 87 Main hoist.......................................................................................... 87 Auxiliary hoist..................................................................................... 87 Slewing gears....................................................................................... 87 Derricking gear..................................................................................... 87 Main boom........................................................................................... 88 Lattice extension................................................................................... 88 Operating speeds.................................................................................... 88 1.6 Documentation supplied.................................................................................. 89 1.6.1 Questions on documentation........................................................................ 90 1.7 Notes on the operating manual........................................................................... 91 1.7.1 What do the symbols used mean?.................................................................... 91 1.7.2 How is the operating manual structured?........................................................... 93 Division............................................................................................ 93 Structure of thechapters........................................................................... 93 Structure of thepages.............................................................................. 94 1.7.3 How do I find the information I need?............................................................. 95 Cross-references example............................................................................ 96 1.7.4 What information is available for operations planning?............................................ 98 1.8 Conversion table for US measuring units................................................................. 99 1.9 Training – Information.................................................................................. 101 1.10 Identification......................................................................................... 102 1.11 EC Declaration of Conformity........................................................................... 104 2 Basic safety instructions..................................................................................... 105 2.1 Intended use............................................................................................ 105 2.1.1 Improper use...................................................................................... 106 2.2 Organisational measures................................................................................. 107 2.3 Personnel qualifications................................................................................ 109 2.4 Safety instructions for driving the truck crane......................................................... 110 2.5 Safety instructions for crane operation................................................................. 111 2.6 Instructions on transporting persons.................................................................... 114 Equipment for lifting persons........................................................................... 114 Personnel............................................................................................... 114 Operation............................................................................................... 115 Truck crane............................................................................................. 116 Driving............................................................................................................. 117 3 Operating elements for driving................................................................................ 117 3.1 Overview of the operating elements...................................................................... 117 3.1.1 On the outside of the truck crane................................................................. 118 3.1.2 Driver's cab...................................................................................... 122 Front overview...................................................................................... 122 Rear overview....................................................................................... 124 Behind the cover................................................................................... 125 3.1.3 Steering column/steering wheel.................................................................... 126 3.1.4 Instrument panel.................................................................................. 127 Left/right.......................................................................................... 127 Middle.............................................................................................. 128 3.1.5 Transmission operating elements................................................................... 130 3.1.6 On-board computer................................................................................. 131 3.1.7 Tachograph........................................................................................ 132 3.1.8 Heating and air-conditioning system............................................................... 133 Standard............................................................................................ 133 Auxiliary water heating system.................................................................... 134 Auxiliary air heater............................................................................... 135 3.1.9 CCS control unit.................................................................................. 137 3.1.10 CCS – menu-dependent displays.................................................................... 138 3.1.11 CCS – Start menu................................................................................. 139 3.1.12 CCS – Overview menu groups....................................................................... 140 3.1.13 Carrier menu group............................................................................... 142 Suspension/ level adjustment menu.................................................................. 143 Driving menu....................................................................................... 144 3.1.14 Settings menu group.............................................................................. 145 Set display brightness and date/time menu........................................................... 146 Switch units menu................................................................................... 147 3.1.15 Menu group Information........................................................................... 148 Operating hours menu............................................................................... 149 Engine/transmission error menu..................................................................... 150 Crane operation error menu......................................................................... 151 3.1.16 Various controls menu group...................................................................... 152 3.1.17 Emergency operations menu group.................................................................. 153 3.1.18 Outrigger control units.......................................................................... 154 3.2 Short description of the operating elements............................................................. 155 3.2.1 Definition of information relating to directions of movement...................................... 156 Basic rule.......................................................................................... 156 3.2.2 General rules for buttons and symbols on the display.............................................. 157 3.2.3 Motor............................................................................................. 158 Steering column..................................................................................... 158 On the steering wheel............................................................................... 158 Instrument panel.................................................................................... 159 3.2.4 AdBlue system..................................................................................... 160 Instrument panel.................................................................................... 160 CCS display......................................................................................... 161 3.2.5 Battery master switch............................................................................. 161 3.2.6 Electrical system................................................................................. 162 3.2.7 Crane control CCS................................................................................. 163 3.2.8 Transmission...................................................................................... 165 Transmission control unit........................................................................... 165 Display, driving mode,.............................................................................. 167 3.2.9 Reverse camera.................................................................................... 168 3.2.10 BirdView system 270 ............................................................................. 169 3.2.11 Transfer case.................................................................................... 171 3.2.12 Final drive...................................................................................... 172 3.2.13 Brakes........................................................................................... 174 Service brake....................................................................................... 174 Parking brake....................................................................................... 174 Additional brakes................................................................................... 175 3.2.14 Steering/separate steering....................................................................... 176 Instrument panel.................................................................................... 176 CCS display......................................................................................... 177 3.2.15 Suspension....................................................................................... 180 CCS display......................................................................................... 180 3.2.16 Lighting/windscreen wipers/horn.................................................................. 181 Steering column..................................................................................... 181 Steering wheel...................................................................................... 181 Instrument panel.................................................................................... 181 CCS display......................................................................................... 183 Roof................................................................................................ 183 3.2.17 Level adjustment system.......................................................................... 184 3.2.18 Tachograph/speedometer........................................................................... 186 Tachograph.......................................................................................... 186 Covers.............................................................................................. 186 Speedometer......................................................................................... 186 3.2.19 Diagnostics...................................................................................... 187 3.2.20 Push-up roof..................................................................................... 187 3.2.21 On-board computer................................................................................ 188 3.2.22 Front flap....................................................................................... 189 3.2.23 Windows and doors................................................................................ 190 Window winder....................................................................................... 190 Doors............................................................................................... 191 3.2.24 Access ladders and ladders....................................................................... 193 4 Starting the engine for driving / switching it off............................................................ 197 4.1 Starting the engine from the driver's cab............................................................... 197 4.1.1 CHECKLIST: Starting the engine.................................................................... 197 4.1.2 CHECKLIST: At low temperatures.................................................................... 200 4.1.3 Filling up........................................................................................ 201 Fuel tank........................................................................................... 201 AdBlue tank......................................................................................... 203 4.1.4 Checks before starting the engine................................................................. 204 At the hydraulic tank............................................................................... 204 Battery master switch............................................................................... 205 Checking the hand-held control...................................................................... 205 4.1.5 Switch the ignition on............................................................................ 205 4.1.6 Lamp test/equalisation of the switching states.................................................... 206 Lamp test........................................................................................... 206 Switching state alignment........................................................................... 206 4.1.7 Display – setting the brightness.................................................................. 207 4.1.8 Starting the engine............................................................................... 209 4.1.9 Checks after starting the engine.................................................................. 211 Start menu and on-board computer.................................................................... 211 Instrument panel.................................................................................... 212 4.1.10 Setting the idling speed......................................................................... 213 4.2 Switch off the engine................................................................................... 214 4.2.1 At the ignition lock and with the outrigger control units......................................... 214 After switching off................................................................................ 214 4.2.2 Using the emergency stop switches................................................................. 215 Resetting the emergency stop switch................................................................. 215 4.3 Air intake inhibitor.................................................................................... 216 Releasing the air intake inhibitor...................................................................... 216 5 Driving....................................................................................................... 217 5.1 Before driving.......................................................................................... 217 5.1.1 CHECKLIST: Checks before on-road driving.......................................................... 217 5.1.2 Check the condition of the truck crane............................................................ 223 Electrical system................................................................................... 223 Adjusting the mirrors............................................................................... 223 Warning plates for vehicle width.................................................................... 224 Checking the vehicle height......................................................................... 225 Supply pressure..................................................................................... 226 Parking brake....................................................................................... 227 5.1.3 Adjusting the seat and the steering column........................................................ 229 Adjusting the driver's seat........................................................................ 229 Adjusting the passenger seat....................................................................... 230 Adjusting the steering column...................................................................... 231 5.1.4 Switching the suspension on/off................................................................... 232 Open menu........................................................................................... 232 Switching the suspension on........................................................................ 233 Switching the suspension off....................................................................... 233 5.1.5 Setting the tachograph............................................................................ 234 Prerequisites....................................................................................... 234 In the event of malfunctions........................................................................ 234 Setting the tachograph............................................................................. 235 5.1.6 Setting the time.................................................................................. 239 5.1.7 Displaying and resetting operating hours.......................................................... 240 5.2 Operating the transmission.............................................................................. 241 5.2.1 Switching on...................................................................................... 241 5.2.2 Switching the transmission to the neutral position................................................ 242 5.2.3 Selecting the direction of travel and starting gear............................................... 243 Selecting the driving direction.................................................................... 243 Selecting the starting gear ...................................................................... 244 5.2.4 Changing the operating mode....................................................................... 245 Changing to automatic mode.......................................................................... 245 Change to manualmode............................................................................... 245 5.2.5 Starting.......................................................................................... 246 5.2.6 Driving and changing gears........................................................................ 247 In automatic operating mode......................................................................... 247 In manual operating mode............................................................................ 248 5.2.7 Changing the driving direction.................................................................... 249 5.2.8 Stopping.......................................................................................... 249 Stopping for longer periods........................................................................ 249 5.2.9 On the roller type dynamometer.................................................................... 250 5.2.10 Preheating transmission.......................................................................... 250 5.3 Driving the truck crane and switching it off............................................................ 251 5.3.1 Checks whilst driving............................................................................. 251 Brakes.............................................................................................. 251 ABS system.......................................................................................... 251 Steering............................................................................................ 252 Warning messages.................................................................................... 252 Monitoring elements................................................................................. 253 5.3.2 Cruise control.................................................................................... 254 Switching on........................................................................................ 254 Switching off....................................................................................... 255 5.3.3 Temposet.......................................................................................... 256 Switching on........................................................................................ 256 Switching off....................................................................................... 256 5.3.4 Driving downhill.................................................................................. 257 Starting............................................................................................ 257 Checks when driving downhill....................................................................... 258 Downshifting........................................................................................ 258 Additional brakes................................................................................... 259 5.3.5 Driving uphill.................................................................................... 260 Starting............................................................................................ 260 Driving............................................................................................. 260 5.3.6 Overriding torque reduction....................................................................... 261 5.3.7 Switching the truck crane off..................................................................... 262 Secure it against rolling away...................................................................... 262 When stationary for more than 8 hours............................................................... 263 5.3.8 Fold-up berth..................................................................................... 264 5.4 Off-road driving........................................................................................ 265 Adjustments to the transmission......................................................................... 265 Connections............................................................................................. 265 Changing the vehicle level.............................................................................. 265 Rocking the vehicle free and towing..................................................................... 265 5.4.1 Transfer case – switching the off-road gear on/off................................................ 266 Neutral position.................................................................................... 266 5.4.2 Longitudinal and transverse differential locks.................................................... 267 5.4.3 Operating the level adjustment system............................................................. 269 Open menu........................................................................................... 269 Setting the on-road level.......................................................................... 270 Pre-selecting suspension struts.................................................................... 270 Changing the vehicle level.......................................................................... 271 Viewing the current inclination..................................................................... 272 Exiting the menu................................................................................... 272 5.4.4 Freeing truck crane stuck in terrain.............................................................. 273 Rocking the truck crane free....................................................................... 273 Towing free forwards............................................................................... 274 Towing free totherear............................................................................ 274 5.5 Separate steering....................................................................................... 275 5.5.1 Switching to separate steering.................................................................... 276 5.5.2 Switching to normal steering mode................................................................. 279 5.5.3 Switching units of measure........................................................................ 280 5.6 Heating and air-conditioning system..................................................................... 281 5.6.1 Standard heating system........................................................................... 281 Switching on........................................................................................ 281 Heating............................................................................................. 281 Air distribution.................................................................................... 282 Examples............................................................................................ 283 Switching off....................................................................................... 283 5.6.2 Air-conditioning system........................................................................... 284 Information......................................................................................... 284 Switching on/off.................................................................................... 284 Cooling............................................................................................. 285 Drying.............................................................................................. 285 5.6.3 Auxiliary water heating system.................................................................... 286 Preheating theengine.............................................................................. 286 Preheating the driver's cab........................................................................ 287 Switching on........................................................................................ 287 Setting the date and time........................................................................... 289 Storing the heating start.......................................................................... 290 5.6.4 Auxiliary air heater.............................................................................. 292 Switching on........................................................................................ 292 Setting the heating level.......................................................................... 293 Setting the day and time........................................................................... 294 Setting the preselection time....................................................................... 294 Deleting preselection times......................................................................... 296 Switching off....................................................................................... 296 5.7 Radio................................................................................................... 296 5.8 Towing a trailer........................................................................................ 297 Effects on theaxleloads............................................................................... 297 Coupling the trailer................................................................................... 298 Connecting the supply lines............................................................................ 299 Removing supply lines................................................................................. 300 Uncoupling thetrailer................................................................................. 300 Checking the braking force.............................................................................. 302 6 Driving modes................................................................................................. 303 6.1 Driving modes........................................................................................... 303 Information about the axle loads........................................................................ 303 6.1.1 How to use the tables............................................................................ 304 6.1.2 Table for a maximum axle load of 12 t............................................................. 305 385/95 R25 tyres.................................................................................... 305 445/95 R25 tyres.................................................................................... 307 525/80 R25 tyres.................................................................................... 308 6.1.3 Maximum permitted speeds with an axle load of over 12 t........................................... 309 6.2 Weighing the truck crane................................................................................ 311 Axle groups............................................................................................. 312 Weighing procedure...................................................................................... 313 Evaluation.............................................................................................. 314 6.3 Rigging work for driving with a dolly................................................................... 315 6.3.1 Switching on the slewing gear freewheel........................................................... 316 6.3.2 Switching on the boom floating position........................................................... 317 6.3.3 Switching on boom pre-tensioning.................................................................. 318 6.4 Rigging the auxiliary hoist............................................................................. 319 6.4.1 Slinging the auxiliary hoist...................................................................... 319 6.4.2 CHECKLIST: Installing the auxiliary hoist......................................................... 320 6.4.3 CHECKLIST: Removing the auxiliary hoist........................................................... 321 6.4.4 Making/breaking the connection between the auxiliary hoist and the turntable...................... 322 6.4.5 Establishing/disconnecting the hydraulic connections.............................................. 323 6.4.6 Disconnecting/establishing the electrical connection.............................................. 324 6.4.7 Making/breaking the connection to the central lubrication......................................... 325 6.4.8 Transporting the auxiliary hoist.................................................................. 326 6.4.9 Check that the auxiliary hoist is functioning properly............................................ 327 Slewing direction................................................................................... 327 Slewing indicator................................................................................... 327 6.4.10 Rigging aid for the hoist rope................................................................... 328 6.5 Installing/removing the outrigger beams................................................................. 331 6.5.1 CHECKLIST: Removing the outrigger beams........................................................... 332 6.5.2 CHECKLIST: Installing the outrigger beams......................................................... 334 6.5.3 Centre of gravity data............................................................................ 336 6.5.4 Preparations – for removal........................................................................ 336 6.5.5 Preparations – on the truck crane................................................................. 337 Prerequisites....................................................................................... 337 6.5.6 Removing/attaching outrigger pads................................................................. 338 Removing the outrigger pads........................................................................ 338 Attaching the outrigger pads....................................................................... 339 6.5.7 Disconnecting/establishing hydraulic connection................................................... 340 6.5.8 Disconnecting/establishing the electrical connection.............................................. 341 6.5.9 Unscrewing/screwing in the spacers................................................................ 342 Unscrewing.......................................................................................... 342 Screwing in......................................................................................... 343 6.5.10 Disconnecting/establishing the connections to the supporting box................................. 344 6.5.11 Pulling out/Inserting the outrigger beam......................................................... 344 Extending the outrigger beam....................................................................... 344 Inserting the outrigger beam........................................................................ 346 6.5.12 Transporting the outrigger beams................................................................. 348 6.5.13 Note on error messages with removed outrigger beams.............................................. 349 7 Transport..................................................................................................... 351 7.1 Transport with transport vehicle........................................................................ 351 7.1.1 CHECKLIST: Checks before transport................................................................ 352 7.1.2 Drive the truck crane on to the transport vehicle................................................. 354 Driving on.......................................................................................... 355 Lashing............................................................................................. 355 7.2 Transport by ship....................................................................................... 356 8 Malfunctions in driving mode.................................................................................. 357 8.1 Emergency stop switch................................................................................... 357 8.2 Procedure during malfunctions........................................................................... 358 8.2.1 What to do when a malfunction occurs in road traffic.............................................. 358 8.2.2 Procedure during engine malfunctions.............................................................. 359 8.2.3 Procedure during transmission malfunctions........................................................ 360 8.3 Warning and error messages.............................................................................. 361 8.3.1 Warning or malfunction messages on the instrument panel........................................... 361 Meaning of thelamps................................................................................ 361 8.3.2 Warning and malfunction messages on the on-board computer display................................. 365 Messages............................................................................................ 365 Symbols............................................................................................. 366 8.3.3 Warning messages on the CCS display............................................................... 369 Symbols in the display area......................................................................... 369 8.3.4 Engine/transmission error messages................................................................ 373 Open menu........................................................................................... 373 Exiting the menu.................................................................................... 373 8.4 Troubleshooting......................................................................................... 375 8.4.1 Malfunctions on the engine........................................................................ 375 When operating with the dual tank................................................................... 377 8.4.2 Faults on the Adblue system....................................................................... 377 8.4.3 Differential lock malfunctions.................................................................... 378 8.4.4 Transfer case malfunctions........................................................................ 378 8.4.5 Malfunctions in the transmission.................................................................. 379 8.4.6 Malfunctions of the steering...................................................................... 380 8.4.7 Malfunctions of the service brake................................................................. 381 8.4.8 Malfunctions on the suspension.................................................................... 381 8.4.9 Malfunctions of the level adjustment system....................................................... 382 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 382 8.5 Emergency operation and breakdown assistance............................................................ 383 8.5.1 Starting the truck crane externally............................................................... 383 8.5.2 Battery charger................................................................................... 384 Prerequisites....................................................................................... 384 8.5.3 Towing the truck crane............................................................................ 385 In the case of engine/ transmission damage.......................................................... 385 Compressed-air supply............................................................................... 385 Longer towing distances............................................................................. 388 Tow starting........................................................................................ 388 8.5.4 Wheel change...................................................................................... 389 Removing a damaged wheel............................................................................ 390 On the spare wheel holder........................................................................... 390 Mounting a wheel.................................................................................... 391 8.5.5 Inflating the tyres yourself...................................................................... 393 Connecting thefilling hose......................................................................... 393 Inflating the tyres................................................................................. 394 Remove the fillinghose............................................................................ 394 8.5.6 Emergency operation, steering 3rd axle line....................................................... 395 Performing emergency operation..................................................................... 395 After emergency operation.......................................................................... 397 8.6 Tilting/lowering the driver's cab....................................................................... 399 8.6.1 Prerequisites and information on tilting.......................................................... 399 8.6.2 Tilting and lowering the driver's cab............................................................. 400 Operating the hand pump............................................................................. 400 Tilting the driver's cab............................................................................ 401 Lowering the driver's cab.......................................................................... 402 8.7 Fuses on the carrier.................................................................................... 405 Information on changing fuses......................................................................... 405 8.7.1 Fuses in the driver's cab......................................................................... 406 8.7.2 Fuses in the battery box.......................................................................... 412 Crane operation..................................................................................................... 413 9 Operating elements for crane operation........................................................................ 413 9.1 Overview of the operating elements...................................................................... 413 9.1.1 Exterior of the truck crane....................................................................... 414 9.1.2 Crane cab......................................................................................... 418 Side panel.......................................................................................... 420 Crane cab, rear..................................................................................... 422 9.1.3 Control panels.................................................................................... 424 Left................................................................................................ 424 Right............................................................................................... 425 9.1.4 Control lever assignment.......................................................................... 426 Version 1........................................................................................... 426 Version 2........................................................................................... 427 9.1.5 CCS control unit.................................................................................. 428 9.1.6 Menu-independent displays......................................................................... 430 9.1.7 CCS – Start menu.................................................................................. 431 RCL display......................................................................................... 432 Display Slewing ranges/working radii............................................................... 433 9.1.8 CCS – Overview menu groups........................................................................ 434 9.1.9 Superstructure menu group......................................................................... 438 Superstructure lock sub-menu...................................................................... 439 Counterweight menu.................................................................................. 440 9.1.10 Menu group outrigger/driving.................................................................... 441 Outrigger menu..................................................................................... 442 Outrigger cylinders menu........................................................................... 444 Driving mode menu.................................................................................. 446 9.1.11 RCL/Telescoping menu group....................................................................... 449 Menu enter rigging mode/ telescope................................................................. 450 Pre-selection telescoping menu..................................................................... 454 Lifting capacity tables menu........................................................................ 456 Telescoping semi- automation menu.................................................................. 457 Manual telescoping menu........................................................................... 458 9.1.12 Active working range limiter menu group.......................................................... 459 Overall height menu................................................................................ 460 Working radius menu................................................................................. 461 Slewing angle menu.................................................................................. 462 Hoist rope travel limitation menu................................................................... 463 9.1.13 Information menu group 1......................................................................... 464 Hydraulic pressure and fuel consumption menu........................................................ 465 9.1.14 Heating/Engine/Additional equipment menu group................................................... 466 Economy menu........................................................................................ 467 Remote control menu................................................................................. 468 Heating/ air-conditioning menu...................................................................... 469 Spotlights menu..................................................................................... 470 9.1.15 Telescoping emergency program menu group....................................................... 471 Telescoping emergency program menu................................................................ 472 Unknown telescoping menu........................................................................... 474 Swinging the swing-away lattice emergency operation menu............................................ 475 9.1.16 Settings menu group.............................................................................. 476 Crane cab menu...................................................................................... 477 Set display brightness and date/time menu........................................................... 478 Switch units menu................................................................................... 479 Set control lever characteristic curve menu......................................................... 480 Power unit speedsmenu............................................................................ 481 9.1.17 Information menu group 2......................................................................... 482 Operating hours menu................................................................................ 483 Engine/transmission errormenu...................................................................... 484 Crane operation error menu.......................................................................... 485 Program version menu................................................................................ 486 9.1.18 Various controls................................................................................. 487 9.1.19 RCL control unit................................................................................. 488 9.1.20 Menu-independent displays........................................................................ 489 9.1.21 RCL – menus...................................................................................... 490 Monitoring menu.................................................................................... 490 Lifting capacity tables menu........................................................................ 492 Datalogger menu..................................................................................... 493 9.1.22 Hand-held control................................................................................ 495 9.1.23 Outriggers control units......................................................................... 497 Menu- independent buttons.......................................................................... 497 Outrigger menu...................................................................................... 498 Raise axle menu.................................................................................... 500 9.2 Short description of the operating elements............................................................. 501 9.2.1 Definition of information relating to directions of movement...................................... 501 Basic rule.......................................................................................... 501 9.2.2 General rules for buttons and symbols on the display.............................................. 502 9.2.3 Engine............................................................................................ 503 Side panel......................................................................................... 503 Left control lever.................................................................................. 503 Economy mode menu................................................................................... 504 9.2.4 AdBlue system..................................................................................... 504 CCS display......................................................................................... 504 9.2.5 Seat contact switch and dead man's switch......................................................... 506 9.2.6 Crane control CCS................................................................................. 507 9.2.7 Outrigger – crane cab............................................................................. 512 Control panels...................................................................................... 512 CCS display......................................................................................... 513 9.2.8 Outrigger control units........................................................................... 515 General information................................................................................. 515 Outrigger menu...................................................................................... 516 9.2.9 Raise axle........................................................................................ 518 9.2.10 Inclination indicators........................................................................... 520 9.2.11 Outrigger pressure displays...................................................................... 521 Outrigger menu..................................................................................... 521 Outriggers control units........................................................................... 521 9.2.12 Anemometer displays.............................................................................. 521 9.2.13 Counterweight menu............................................................................... 522 9.2.14 Main hoist....................................................................................... 526 Control panels...................................................................................... 526 CCS display......................................................................................... 526 9.2.15 Auxiliary hoist.................................................................................. 528 Control panels...................................................................................... 528 CCS display......................................................................................... 528 9.2.16 Slewing gear..................................................................................... 530 Control panels...................................................................................... 530 CCS display......................................................................................... 531 9.2.17 Derricking gear.................................................................................. 532 Control panels...................................................................................... 532 CCS display......................................................................................... 533 Side panel.......................................................................................... 533 9.2.18 Telescoping mechanism............................................................................ 534 Control panels...................................................................................... 534 CCS display......................................................................................... 535 Telescoping semi- automation menu................................................................... 535 Manual telescoping menu............................................................................. 537 9.2.19 Hydraulic system................................................................................. 540 9.2.20 Superstructure lock/house lock menu.............................................................. 541 Superstructure lock................................................................................ 541 Houselock........................................................................................... 543 9.2.21 Remote control................................................................................... 544 9.2.22 Rated capacity limiter (RCL)..................................................................... 545 CCS display......................................................................................... 545 RCL display......................................................................................... 554 RCL override – version A............................................................................ 555 RCL override – version B............................................................................ 556 9.2.23 Electrical system................................................................................ 557 9.2.24 Lighting, windscreen wiper/washing system........................................................ 558 Lighting............................................................................................ 558 Windscreen wiper/washing system.................................................................... 560 Horn................................................................................................ 561 9.2.25 Hand-held control................................................................................ 562 Sockets for hand- held control...................................................................... 562 Engine control panel................................................................................ 563 Horn................................................................................................ 563 9.2.26 Windows and doors................................................................................ 566 Window.............................................................................................. 566 Rear window......................................................................................... 566 Crane cab door...................................................................................... 567 9.2.27 Diagnostics...................................................................................... 568 9.2.28 Other............................................................................................ 568 9.3 Short description of the operating elements – driving from the crane cab................................ 569 9.3.1 Driving mode menu................................................................................. 569 9.3.2 Transmission...................................................................................... 570 9.3.3 Final drive....................................................................................... 571 9.3.4 Brakes............................................................................................ 573 CCS display......................................................................................... 573 Side panel from above............................................................................... 574 9.3.5 Steering.......................................................................................... 575 CCS display......................................................................................... 575 Separate steering................................................................................... 576 Control panels...................................................................................... 577 10 Starting/switching off the engine – for crane operation...................................................... 579 10.1 When starting the engine for the first time in the day................................................. 579 10.2 Starting the engine – from the crane cab............................................................... 581 10.2.1 Check the fuel level and AdBlue level............................................................ 581 Fuel................................................................................................ 581 AdBlue.............................................................................................. 581 10.2.2 Checks before starting the engine................................................................ 582 Checks on the carrier.............................................................................. 582 Checking the hand-held control...................................................................... 582 At the hydraulic tank............................................................................... 582 10.2.3 Switch the ignition on........................................................................... 583 10.2.4 Comparison of switching states................................................................... 584 10.2.5 Display – setting the brightness................................................................. 584 10.2.6 Starting the engine.............................................................................. 585 10.2.7 Checks after starting the engine................................................................. 586 10.2.8 Setting the idling speed......................................................................... 587 10.3 Starting the engine – with the hand-held control....................................................... 588 10.4 Switch off the engine.................................................................................. 589 10.4.1 At the ignition lock and with hand-held control.................................................. 589 After switching off................................................................................ 589 10.4.2 With the idling button........................................................................... 589 10.4.3 Using the emergency stop switches................................................................ 590 Resetting the emergency stop switch................................................................. 590 11 Crane operation.............................................................................................. 591 11.1 Before operating the crane............................................................................. 591 11.1.1 CHECKLIST: Checks before operating the crane..................................................... 591 11.1.2 Check the condition of the truck crane........................................................... 595 Fuel tank auxiliary heater.......................................................................... 595 Visual inspection................................................................................... 595 Checking the position of the hoist ropes............................................................ 596 Checking the electrical system...................................................................... 597 11.1.3 Adjusting the crane cab seat and front control panel............................................. 598 Crane cab seat...................................................................................... 598 Front control panel................................................................................. 599 11.1.4 Checking the safety equipment.................................................................... 600 Rated capacity limiter.............................................................................. 600 Lifting limit switch............................................................................... 600 Emergency stop switch............................................................................... 601 Seat contact switch................................................................................ 602 11.1.5 Earthing the load................................................................................ 603 11.1.6 Preheating hydraulic oil......................................................................... 604 Prerequisites....................................................................................... 604 Preheating.......................................................................................... 604 11.1.7 Locking/unlocking the superstructure............................................................. 605 Locking points...................................................................................... 605 Lock the superstructure............................................................................ 606 Unlocking the superstructure....................................................................... 606 11.1.8 Switching the houselock on/off................................................................... 607 Switching on the houselock......................................................................... 607 Switching off the houselock........................................................................ 609 11.2 Standard slewing range type............................................................................ 611 11.2.1 Permissible slewing ranges and working positions................................................. 611 360 slewing range.................................................................................. 611 Working position 0 to the rear..................................................................... 611 180 to the front rigging position.................................................................. 611 11.3 MAXbase slewing range type............................................................................. 613 11.3.1 Specifications in the lifting capacity tables.................................................... 614 11.3.2 Enabled slewing ranges........................................................................... 615 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit....... 618 11.4 Operation of the rated capacity limiter................................................................ 619 11.4.1 Switch on the RCL................................................................................ 620 Switching on........................................................................................ 620 11.4.2 Enter rigging mode............................................................................... 622 Notes on Input..................................................................................... 622 Enter the slewing range type........................................................................ 623 Entering individual components...................................................................... 624 Entering the RCLcode.............................................................................. 630 11.4.3 Pre-selecting telescoping........................................................................ 630 11.4.4 Confirm the rigging mode and lifting capacity table.............................................. 631 Slewing range type Standard......................................................................... 631 Slewing range type MAXbase.......................................................................... 633 11.4.5 Checks before operating the crane................................................................ 635 Monitoring menu..................................................................................... 635 Checking the rigging mode........................................................................... 635 Hoist checking...................................................................................... 637 11.4.6 Display during the crane operation............................................................... 639 On the RCL display.................................................................................. 639 On the CCS display.................................................................................. 643 11.4.7 RCL early warning................................................................................ 647 11.4.8 RCL shutdown..................................................................................... 647 Shutdown due to overload............................................................................ 647 11.4.9 Displaying the lifting capacity tables........................................................... 649 Slewing range type Standard......................................................................... 649 Slewing range type MAXbase.......................................................................... 651 11.4.10 RCL override – version A........................................................................ 653 Overview statusdisplay............................................................................. 653 When rigging........................................................................................ 654 To raise the boom................................................................................... 655 In emergencies...................................................................................... 656 11.4.11 RCL override – version B........................................................................ 657 11.4.12 Datalogger...................................................................................... 658 Export data......................................................................................... 658 Display the data.................................................................................... 659 11.5 Crane operation with main boom......................................................................... 663 11.5.1 Checks during crane operation.................................................................... 663 Horizontal alignment................................................................................ 663 Safe distances..................................................................................... 663 Checking the windspeed............................................................................. 664 11.5.2 Main hoist....................................................................................... 665 Switching on themain hoist......................................................................... 666 Lifting and lowering............................................................................... 666 Maximum permissible hoist rope speed................................................................ 667 Switching off the main hoist....................................................................... 668 11.5.3 Auxiliary hoist.................................................................................. 669 Switching on the auxiliary hoist................................................................... 669 Lifting and lowering............................................................................... 670 Maximum permissible hoist rope speed................................................................ 671 Switching off the auxiliary hoist.................................................................. 671 11.5.4 Lifting limit switch and lowering limit switch................................................... 672 Lifting limit switch................................................................................ 672 Lowering limit switch............................................................................... 674 11.5.5 Derricking gear.................................................................................. 675 Switching on the derricking gear................................................................... 675 Raising and lowering................................................................................ 676 Maximum derricking speed............................................................................ 677 Re-enable raising function.......................................................................... 677 Switching off the derricking gear................................................................... 678 Lowering the main boom to a horizontal position..................................................... 678 11.5.6 Telescoping mechanism............................................................................ 679 Overview............................................................................................ 681 Telescoping process................................................................................. 682 Assignment for display.............................................................................. 684 Fixed length, intermediate length, telescoping length.............................................. 685 Telescoping......................................................................................... 686 Telescoping sequence............................................................................... 686 Inspections prior to starting operations........................................................... 687 Switching on thetelescoping mechanism.............................................................. 688 Function of the control lever....................................................................... 688 Switching off thetelescoping mechanism............................................................. 690 Manual telescoping................................................................................. 691 Checking the initial position....................................................................... 691 Unlocking the telescoping cylinder.................................................................. 693 Extending/retracting the telescoping cylinder....................................................... 695 Lock telescoping cylinder........................................................................... 696 Unlocking the telescopic section................................................................... 697 Telescoping the telescopic section................................................................. 698 Locking the telescopic section..................................................................... 699 Locking the telescopic section for on-road driving................................................. 700 Telescoping with semi-automaton..................................................................... 700 Telescoping with pre-selection...................................................................... 702 11.5.7 High-speed mode.................................................................................. 703 Derricking gear telescoping mechanism.............................................................. 703 Hoists.............................................................................................. 703 11.5.8 Slewing gear..................................................................................... 705 Slewing gear brake.................................................................................. 705 Switching on the slewing gear...................................................................... 706 Releasing the slewing gear brake.................................................................... 706 Applying the slewing gear brake..................................................................... 706 Releasing locked slewing gear....................................................................... 707 Slewing............................................................................................. 707 Permissible slewing speed.......................................................................... 708 Braking the slewing movement........................................................................ 709 Slewing gear freewheel.............................................................................. 709 Switching off the slewing gear..................................................................... 710 11.5.9 Switching the reduction of slewing speed on and off.............................................. 711 Switching reduction off............................................................................. 711 11.5.10 Possible movement combinations.................................................................. 712 11.6 Settings and displays for crane operation.............................................................. 713 11.6.1 Inclining the crane cab.......................................................................... 713 11.6.2 Setting the idling speed......................................................................... 714 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper...................................... 714 11.6.4 Limiting the power unit speeds................................................................... 715 11.6.5 Economy mode..................................................................................... 716 Switching on........................................................................................ 716 Ending/ switchingoff............................................................................... 718 11.6.6 Switching units of measure....................................................................... 718 11.6.7 Setting the characteristic curves for the control levers......................................... 719 11.6.8 Using the slewable spotlights.................................................................... 720 Manually swinging................................................................................... 721 Automatic load tracking............................................................................. 721 11.6.9 Overriding torque reduction...................................................................... 722 11.6.10 Displaying the operating hours.................................................................. 723 11.7 Working range limiter.................................................................................. 725 11.7.1 Viewing current settings......................................................................... 726 On the RCL display.................................................................................. 726 In the CCS Start menu............................................................................... 727 11.7.2 Opening the working range limiter menu........................................................... 727 11.7.3 Entering limit values............................................................................ 730 Overall height...................................................................................... 730 Working radius...................................................................................... 731 Slewing angle....................................................................................... 731 Hoist rope limitation............................................................................... 732 11.7.4 Entering limit values manually................................................................... 734 Limit values........................................................................................ 734 11.7.5 Switching monitoring functions on/off............................................................ 736 11.7.6 Shutdown by working range limiter................................................................ 737 11.8 Work break............................................................................................. 739 11.8.1 In case of short work breaks..................................................................... 739 11.8.2 In case of work breaks of more than 8 hours...................................................... 740 To secure the truck crane........................................................................... 740 11.9 Heating and air-conditioning system.................................................................... 741 11.9.1 Standard heating system.......................................................................... 741 Switching on........................................................................................ 741 Heating............................................................................................. 741 Air distribution.................................................................................... 742 Switching off....................................................................................... 742 11.9.2 Air-conditioning system.......................................................................... 743 Information......................................................................................... 743 Switching on/off.................................................................................... 743 Cooling, automatic.................................................................................. 744 Cooling, maximum.................................................................................... 744 11.9.3 Auxiliary heater................................................................................. 745 Switching on........................................................................................ 745 Setting the temperature............................................................................. 746 Setting the heating start/ heating duration......................................................... 746 Switching heating start on/off...................................................................... 747 11.10 CraneSTAR system...................................................................................... 748 11.10.1 Overview........................................................................................ 748 11.10.2 Position of the components...................................................................... 748 12 Rigging work................................................................................................. 749 12.1 Rigging work checklists for crane operation with the main boom......................................... 749 12.1.1 CHECKLIST: Rigging............................................................................... 749 12.1.2 CHECKLIST: Unrigging............................................................................. 755 12.2 Choice of a suitable positioning site.................................................................. 759 12.2.1 Determining the required load-bearing area....................................................... 759 12.2.2 Safe distance from slopes and pits............................................................... 762 12.2.3 Earthing the truck crane......................................................................... 763 12.2.4 Safe distance from overhead power lines.......................................................... 764 12.3 Rigging work after driving with a dolly................................................................ 767 12.3.1 Switching off the boom floating position......................................................... 767 12.3.2 Switching off the slewing gear freewheel......................................................... 768 Before slewing...................................................................................... 768 12.3.3 Switching off boom pre-tensioning................................................................ 769 12.4 Connecting/disconnecting the hand-held control......................................................... 771 12.5 Starting the engine for rigging........................................................................ 775 Prerequisites........................................................................................... 775 Starting the engine..................................................................................... 775 Turning off theengine.................................................................................. 775 12.6 Slewing range – only with the Standard slewing range type.............................................. 777 12.6.1 Representation in the lifting capacity tables.................................................... 777 12.6.2 Enabled outrigger spans.......................................................................... 778 12.7 Outriggers – Overview – MAXbase slewing range type..................................................... 779 12.7.1 Definitions...................................................................................... 779 12.7.2 Representation in the lifting capacity tables.................................................... 781 12.7.3 Enabled outrigger spans.......................................................................... 782 12.8 Outrigger operation.................................................................................... 787 12.8.1 CHECKLIST: Extending the outriggers.............................................................. 787 12.8.2 CHECKLIST: Retracting the outriggers............................................................. 789 12.8.3 Preparing the truck crane........................................................................ 790 Driver's cab........................................................................................ 790 Crane cab........................................................................................... 790 12.8.4 Setting the outrigger spans...................................................................... 792 For on-road driving................................................................................. 795 12.8.5 Extending/retracting outrigger beams............................................................. 795 From the controlunits.............................................................................. 796 From the cranecab.................................................................................. 797 12.8.6 Moving the outrigger pads into operating/driving position........................................ 799 12.8.7 Enlarging the load-bearing area.................................................................. 801 12.8.8 Extending/retracting supporting cylinders........................................................ 802 From the control units.............................................................................. 803 From the cranecab.................................................................................. 804 12.8.9 Levelling the truck crane on outriggers horizontally............................................. 806 Inclination indicators.............................................................................. 806 Prerequisites....................................................................................... 807 Manual alignment................................................................................... 808 Automatic alignment................................................................................. 808 12.8.10 Levelling the free-standing truck crane......................................................... 810 12.8.11 Operating the axle raising system............................................................... 812 12.8.12 Outrigger pressure display...................................................................... 814 12.9 Rigging/unrigging the counterweight.................................................................... 817 Counterweight display rigged............................................................................ 817 12.9.1 Information on rigging........................................................................... 817 When rigging........................................................................................ 817 When unrigging...................................................................................... 818 12.9.2 Counterweight sections........................................................................... 819 12.9.3 Identification................................................................................... 821 12.9.4 Slinging points on the counterweight sections.................................................... 822 12.9.5 CHECKLIST: Rigging the counterweight............................................................. 824 12.9.6 CHECKLIST: Unrigging the counterweight........................................................... 826 12.9.7 Assembling counterweight combination............................................................. 828 12.9.8 Counterweight hoist unit......................................................................... 833 Counterweight menu................................................................................. 833 Extending/ retracting the lifting cylinders......................................................... 834 Automatic moderigging............................................................................. 836 Automatic mode unrigging........................................................................... 838 Cancel automatic mode.............................................................................. 839 12.9.9 Setting down counterweight for driving........................................................... 840 Rear counterweight platform......................................................................... 840 Front counterweight platform........................................................................ 842 12.9.10 Unlocking/locking the rear counterweight platform............................................... 843 Unlocking........................................................................................... 843 Locking............................................................................................. 844 12.9.11 Slewing with rigged counterweight............................................................... 845 12.10 Rigging work on the main boom......................................................................... 847 12.10.1 Hook block on the bumper........................................................................ 847 Picking up the hook block........................................................................... 847 Attaching the hook block............................................................................ 848 12.10.2 Hook block on a separate vehicle................................................................ 849 Picking up the hook block.......................................................................... 850 Setting down thehook block........................................................................ 850 12.10.3 Hook block, separable........................................................................... 852 Rigging for on-road driving......................................................................... 852 Rigging for crane operation......................................................................... 853 12.10.4 Hook block with ballast plates.................................................................. 854 Removing............................................................................................ 854 Installing.......................................................................................... 855 Information on crane operation...................................................................... 855 12.10.5 Reeving and unreeving the hoist rope............................................................ 856 Reeving the hoistrope.............................................................................. 857 Unreeving hoistrope............................................................................... 861 12.10.6 Possible reevings on the main boom.............................................................. 862 With 5 head sheaves................................................................................. 862 With 6 head sheaves................................................................................. 865 With 7 head sheaves................................................................................. 867 12.10.7 Installing/removing the lifting limit switch.................................................... 868 Installing the lifting limit switch................................................................. 868 Removing the lifting limit switch................................................................... 871 12.10.8 Locking/unlocking the lifting limit switch...................................................... 873 Locking............................................................................................. 873 Removing the lock.................................................................................. 873 12.10.9 Anemometer and air traffic control light........................................................ 874 Installing.......................................................................................... 874 Switching on/off.................................................................................... 875 Removing............................................................................................ 875 12.11 Other rigging work.................................................................................... 877 12.11.1 Railings on the turntable....................................................................... 877 12.11.2 Folding the mirrors in and out, and adjusting them.............................................. 878 12.11.3 Slinging points for personal protective equipment............................................... 879 12.11.4 Cameras for crane operation..................................................................... 880 Camera on mainboom................................................................................. 880 Camera on thehoists................................................................................ 883 Camera on the driver's cab.......................................................................... 883 Operating the camera................................................................................ 884 12.11.5 Step at the crane cab........................................................................... 885 13 Driving with a rigged truck crane............................................................................ 887 13.1 Route.................................................................................................. 887 13.2 Permissible rigging modes and axle loads............................................................... 888 Axle load table........................................................................................ 888 13.2.1 To drive without a load.......................................................................... 891 13.2.2 To drive with a load............................................................................. 891 13.2.3 Axle loads....................................................................................... 892 13.3 Before driving the rigged truck crane.................................................................. 893 13.3.1 Check the tyre pressures and wind speed.......................................................... 893 13.3.2 Secure the superstructure against slewing........................................................ 893 13.3.3 Putting the truck crane on the wheels – with Raise axle function................................. 894 13.3.4 Putting the truck crane on the wheels – with the outriggers...................................... 896 13.4 Driving from the driver's cab.......................................................................... 899 13.4.1 Preparing to drive............................................................................... 899 Transmission........................................................................................ 899 Switching on separate steering...................................................................... 899 Connections......................................................................................... 899 13.4.2 Whilst driving................................................................................... 900 13.4.3 After driving.................................................................................... 901 13.5 Driving from the crane cab............................................................................. 903 13.5.1 Preparing to drive............................................................................... 904 13.5.2 Opening/closing the Driving menu................................................................. 904 Opening............................................................................................. 904 Crane's hydraulic system on/off..................................................................... 905 Closing............................................................................................. 906 13.5.3 Steering......................................................................................... 907 Switching on........................................................................................ 907 Steering direction.................................................................................. 907 Displays when steering.............................................................................. 908 Separate steering................................................................................... 908 Normal steering mode................................................................................ 912 13.5.4 Operating the transmission....................................................................... 913 Selecting the transmission mode.................................................................... 913 13.5.5 Whilst driving................................................................................... 914 DM and RM transmission mode......................................................................... 914 Transmission mode D................................................................................. 914 Warning messages.................................................................................... 914 13.5.6 Possible connections............................................................................. 915 Longitudinal/ transverse differential locks......................................................... 915 13.5.7 After driving.................................................................................... 917 14 Malfunctions during crane operation.......................................................................... 919 14.1 Emergency stop switch.................................................................................. 919 14.2 What to do when malfunctions occur during crane operation.............................................. 920 The load can be set down................................................................................ 920 Load cannot besetdown................................................................................. 920 14.3 Warning and error messages............................................................................. 921 Program version......................................................................................... 921 14.3.1 Warning messages on the CCS display.............................................................. 921 Meaning of thesymbols.............................................................................. 922 14.3.2 Error messages on the CCS display................................................................ 925 14.3.3 Warning messages on the RCL display.............................................................. 927 14.4 Troubleshooting........................................................................................ 931 14.4.1 Malfunctions on the engine....................................................................... 931 14.4.2 Malfunctions on the main hoist/auxiliary hoist................................................... 931 14.4.3 Malfunctions in the hoist cameras................................................................ 933 14.4.4 Malfunctions in the main boom camera............................................................. 933 14.4.5 Malfunctions on the derricking gear.............................................................. 934 14.4.6 Malfunctions in the telescoping mechanism........................................................ 935 14.4.7 Malfunctions on the slewing gear................................................................. 936 14.4.8 Malfunctions on the counterweight hoist unit..................................................... 938 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 938 14.4.10 Malfunctions when inclining the crane cab....................................................... 938 14.4.11 Malfunctions when operating with the hand-held control.......................................... 939 14.4.12 Malfunctions when inclining the crane cab....................................................... 939 14.4.13 Malfunctions when raising the axles............................................................. 939 14.4.14 Malfunctions of the outriggers.................................................................. 940 14.4.15 Malfunctions on the turntable lock.............................................................. 940 14.4.16 Malfunctions on the CCS/RCL control units....................................................... 941 14.4.17 Malfunctions when driving from the crane cab.................................................... 941 14.4.18 Malfunctions on the CraneSTAR system............................................................ 942 14.5 Emergency operations and programs...................................................................... 945 14.5.1 Mechanical emergency activation for retracting................................................... 946 Prior to the emergency operation, check............................................................. 946 Procedure........................................................................................... 946 Mechanical emergency activation.................................................................... 947 14.5.2 Telescoping emergency program.................................................................... 949 Checks before using the emergency program........................................................... 949 Telescoping emergency program menu.................................................................. 950 Notes on the displays............................................................................... 951 Checks in theemergency program.................................................................... 952 Retracting withemergency program................................................................... 956 Tables for approaching the locking points........................................................... 958 14.5.3 Entering the current telescoping................................................................. 961 14.5.4 Emergency operation with the hand-held control................................................... 963 To pre-select a power unit.......................................................................... 964 Operating apowerunit.............................................................................. 964 Stopping movements................................................................................. 965 Stopping movements in emergencies................................................................... 966 Switch off theengine............................................................................... 966 14.5.5 Notes on slewing in emergency operation.......................................................... 966 For the Standard slewing range type................................................................. 966 For the MAXbase slewing range type.................................................................. 968 14.6 Hydraulic emergency operation with the hand pump....................................................... 969 14.6.1 Operating principle.............................................................................. 969 14.6.2 Switching over the crane's hydraulic system...................................................... 969 14.6.3 Establishing the hydraulic circuits required..................................................... 970 Releasing/ securing valves.......................................................................... 970 Switching over valves............................................................................... 971 For lowering........................................................................................ 972 14.6.4 Performing emergency activation.................................................................. 973 14.6.5 After emergency activation....................................................................... 973 14.7 Hydraulic emergency operation as per BGR 159........................................................... 975 14.7.1 Applications and function........................................................................ 975 14.7.2 CHECKLIST: Emergency operation................................................................... 977 14.7.3 CHECKLIST: After emergency operation............................................................. 978 14.7.4 Connecting/removing transformer – for self-sufficiency........................................... 979 Connecting.......................................................................................... 979 Removing............................................................................................ 980 14.7.5 Switching emergency operation on/off............................................................. 981 14.7.6 Connecting/removing transformer – for external energy source..................................... 982 14.7.7 Establishing the required hydraulic circuits..................................................... 983 Switching overvalves............................................................................... 983 For lifting/ lowering............................................................................... 985 For slewing......................................................................................... 986 14.7.8 Performing emergency operation................................................................... 987 Slewing............................................................................................. 987 Derricking.......................................................................................... 988 Lifting/lowering.................................................................................... 988 14.7.9 Emergency supply of another crane................................................................ 989 For emergency supply................................................................................ 989 After emergency supply.............................................................................. 989 14.8 Fuses in the crane cab................................................................................. 991 Information on changing fuses......................................................................... 991 Index............................................................................................................... 997 A............................................................................................................... 999 B............................................................................................................... 999 C...............................................................................................................1000 D...............................................................................................................1002 E...............................................................................................................1004 F...............................................................................................................1006 H...............................................................................................................1006 I...............................................................................................................1007 L...............................................................................................................1007 M...............................................................................................................1008 O...............................................................................................................1009 P...............................................................................................................1010 R...............................................................................................................1010 S...............................................................................................................1011 T...............................................................................................................1013 V...............................................................................................................1015 W...............................................................................................................1015
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