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Grove Crane GMK 4100L-1 Operating Manual 3302690 – PDF DOWNLOAD
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Description
Grove Crane GMK 4100L-1 Operating Manual 3302690 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100L-1 Operating Manual 3302690 – PDF DOWNLOAD
Language : English
Pages : 1028
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 4100L-1 Operating Manual 3302690 – PDF DOWNLOAD
Intended use:
- The GMK4100L-1 truck crane is constructed in accordance with the latest
technology and the recognised safety regulations. Nevertheless, the operator
or third parties can still be endangered and the crane or other property
put at risk while using it. - The truck crane may be modified only with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK4100L-1 truck crane may be used only when it is in perfect technical
condition and for its intended purpose and with due attention paid to
safe operation and possible hazards. - Any malfunctions that could impair safety must be eliminated immediately.
- The GMK4100L-1 truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
data, p. 1 – 7. - The GMK4100L-1 truck crane is designed solely for lifting loads which are
within the permitted GMK4100L-1 lifting capacities. The load must be slung
as prescribed to a hook block which is positioned vertically over the load
prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
manual(s), the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
The GMK4100L-1 may only be operated with parts of equipment which have
been approved by Manitowoc Crane Group Germany GmbH and which are
labelled with the serial number of the GMK4100L-1.
The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK4100L-1 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 4100L-1 Operating Manual 3302690 – PDF DOWNLOAD
Operating manual........................................................................................................ 1 Correction sheets................................................................................................... 3 Hook blocks..................................................................................................... 3 Change / correction to the technical data................................................................... 3 Additional pages.................................................................................................... 5 MAXbase – Additional outrigger spans............................................................................ 5 Outrigger spans................................................................................................. 7 Driving from the crane cab...................................................................................... 9 Overview of Driving menu.................................................................................... 10 Brief description of the operating elements................................................................. 13 Driving menu............................................................................................ 13 Transmission............................................................................................ 15 Final drive............................................................................................. 17 Brakes.................................................................................................. 18 CCS display......................................................................................... 18 Side panel from above............................................................................... 18 Steering................................................................................................ 19 CCS display......................................................................................... 20 Control panels...................................................................................... 22 Driving from the crane cab.................................................................................. 23 Preparing to drive...................................................................................... 24 Opening/closing the Driving menu........................................................................ 25 Selecting the operating mode....................................................................... 25 Crane's hydraulic system Driving mode............................................................... 27 Closing menu........................................................................................ 27 Steering................................................................................................ 28 Switching on........................................................................................ 28 Display and steering direction...................................................................... 28 Switching the steering direction................................................................... 29 Displays when steering.............................................................................. 29 Separate steering................................................................................... 30 Normal steering..................................................................................... 33 Operating the transmission.............................................................................. 34 Selecting the transmission mode.................................................................... 34 While driving........................................................................................... 35 Warning messages.................................................................................... 35 Possible connections.................................................................................... 36 Longitudinal/transverse differential locks.......................................................... 36 After driving........................................................................................... 38 Telescoping emergency programe.................................................................................. 39 Crane cab heating and air-conditioning system................................................................... 41 Outrigger control units......................................................................................... 43 Switching over the display between metre/feet and percent................................................... 43 Steering system warning......................................................................................... 45 Additional functions........................................................................................ 45 Table of contents................................................................................................... 49 General............................................................................................................. 79 1 Overview...................................................................................................... 79 1.1 Accidents............................................................................................... 79 1.2 Branch offices.......................................................................................... 81 1.2.1 Manitowoc Crane Care.............................................................................. 81 1.2.2 Dealer list....................................................................................... 81 1.3 Warranty specifications................................................................................. 81 1.4 Terms used.............................................................................................. 82 1.5 Technical data.......................................................................................... 85 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................................. 85 1.5.2 Maximum lifting capacity (ASME B 30.5)............................................................ 85 1.5.3 Dimensions and weights of the truck crane, axle loads............................................. 86 Dimensions.......................................................................................... 87 Weight and axle loads............................................................................... 87 1.5.4 Dimensions and weights of removable parts......................................................... 88 Spare wheel......................................................................................... 88 Outrigger........................................................................................... 88 Hook blocks and hook tackle......................................................................... 89 Counterweight parts................................................................................ 92 Auxiliary hoist..................................................................................... 92 1.5.5 Carrier........................................................................................... 93 Motor............................................................................................... 93 Transmission........................................................................................ 93 Transfer case....................................................................................... 93 Axle lines.......................................................................................... 93 Steering............................................................................................ 94 Tyres............................................................................................... 94 Turning turning radii............................................................................... 94 Outrigger........................................................................................... 95 Electrical system................................................................................... 96 Tool................................................................................................ 96 Towing couplings................................................................................... 96 Driving speeds...................................................................................... 96 Climbing ability.................................................................................... 96 1.5.6 Superstructure.................................................................................... 97 Main hoist.......................................................................................... 97 Auxiliary hoist..................................................................................... 97 Slewing gears....................................................................................... 97 Derricking gear..................................................................................... 97 Main boom........................................................................................... 98 Lattice extension................................................................................... 98 Operating speeds.................................................................................... 98 1.6 Documentation supplied.................................................................................. 99 1.6.1 Questions on documentation........................................................................ 100 1.7 Notes on the operating manual........................................................................... 101 1.7.1 What do the symbols used mean?.................................................................... 101 1.7.2 How is the operating manual structured?........................................................... 103 Division............................................................................................ 103 Structure of thechapters........................................................................... 103 Structure of thepages.............................................................................. 104 1.7.3 How do I find the information I need?............................................................. 105 Cross-references example............................................................................ 106 1.7.4 What information is available for operations planning?............................................ 108 1.8 Conversion table for US measuring units................................................................. 109 1.9 Training – Information.................................................................................. 111 1.10 Identification......................................................................................... 112 1.11 EC Declaration of Conformity........................................................................... 114 2 Basic safety instructions..................................................................................... 115 2.1 Intended use............................................................................................ 115 2.1.1 Improper use...................................................................................... 116 2.2 Organisational measures................................................................................. 117 2.3 Personnel qualifications................................................................................ 119 2.4 Safety instructions for driving the truck crane......................................................... 120 2.5 Safety instructions for crane operation................................................................. 121 2.6 Instructions on transporting persons.................................................................... 124 Equipment for lifting persons........................................................................... 124 Personnel............................................................................................... 124 Operation............................................................................................... 125 Truck crane............................................................................................. 126 Driving............................................................................................................. 127 3 Operating elements for driving................................................................................ 127 3.1 Overview of the operating elements...................................................................... 127 3.1.1 On the outside of the truck crane................................................................. 128 3.1.2 Driver's cab...................................................................................... 132 Front overview...................................................................................... 132 Rear overview....................................................................................... 134 Behind the cover................................................................................... 135 3.1.3 Steering column/steering wheel.................................................................... 136 3.1.4 Instrument panel.................................................................................. 137 Left/right.......................................................................................... 137 Middle.............................................................................................. 138 3.1.5 Transmission operating elements................................................................... 140 3.1.6 On-board computer................................................................................. 141 3.1.7 Tachograph........................................................................................ 142 3.1.8 Heating and air-conditioning system............................................................... 143 Standard............................................................................................ 143 Auxiliary water heating system.................................................................... 144 Auxiliary air heater............................................................................... 145 3.1.9 CCS control unit.................................................................................. 147 3.1.10 CCS – menu-dependent displays.................................................................... 148 3.1.11 CCS – Start menu................................................................................. 149 3.1.12 CCS – Overview menu groups....................................................................... 150 3.1.13 Carrier menu group............................................................................... 152 Suspension/ level adjustment menu.................................................................. 153 Driving menu....................................................................................... 154 3.1.14 Settings menu group.............................................................................. 155 Set display brightness and date/time menu........................................................... 156 Switch units menu................................................................................... 157 3.1.15 Menu group Information........................................................................... 158 Operating hours menu............................................................................... 159 Engine/transmission error menu..................................................................... 160 Crane operation error menu......................................................................... 161 3.1.16 Various controls menu group...................................................................... 162 3.1.17 Emergency operations menu group.................................................................. 163 3.1.18 Outrigger control units.......................................................................... 164 3.2 Short description of the operating elements............................................................. 165 3.2.1 Definition of information relating to directions of movement...................................... 166 Basic rule.......................................................................................... 166 3.2.2 General rules for buttons and symbols on the display.............................................. 167 3.2.3 Motor............................................................................................. 168 Steering column..................................................................................... 168 On the steering wheel............................................................................... 168 Instrument panel.................................................................................... 169 3.2.4 AdBlue system..................................................................................... 170 Instrument panel.................................................................................... 170 CCS display......................................................................................... 171 3.2.5 Battery master switch............................................................................. 171 3.2.6 Electrical system................................................................................. 172 3.2.7 Crane control CCS................................................................................. 173 3.2.8 Transmission...................................................................................... 175 Transmission control unit........................................................................... 175 Display, driving mode,.............................................................................. 177 3.2.9 Reverse camera.................................................................................... 178 3.2.10 BirdView system 270 ............................................................................. 179 3.2.11 Transfer case.................................................................................... 181 3.2.12 Final drive...................................................................................... 182 3.2.13 Brakes........................................................................................... 184 Service brake....................................................................................... 184 Parking brake....................................................................................... 184 Additional brakes................................................................................... 185 3.2.14 Steering/separate steering....................................................................... 186 Instrument panel.................................................................................... 186 CCS display......................................................................................... 187 3.2.15 Suspension....................................................................................... 190 CCS display......................................................................................... 190 3.2.16 Lighting/windscreen wipers/horn.................................................................. 191 Steering column..................................................................................... 191 Steering wheel...................................................................................... 191 Instrument panel.................................................................................... 191 CCS display......................................................................................... 193 Roof................................................................................................ 193 3.2.17 Level adjustment system.......................................................................... 194 3.2.18 Tachograph/speedometer........................................................................... 196 Tachograph.......................................................................................... 196 Covers.............................................................................................. 196 Speedometer......................................................................................... 196 3.2.19 Diagnostics...................................................................................... 197 3.2.20 Push-up roof..................................................................................... 197 3.2.21 On-board computer................................................................................ 198 3.2.22 Front flap....................................................................................... 199 3.2.23 Windows and doors................................................................................ 200 Window winder....................................................................................... 200 Doors............................................................................................... 201 3.2.24 Access ladders and ladders....................................................................... 203 4 Starting the engine for driving / switching it off............................................................ 207 4.1 Starting the engine from the driver's cab............................................................... 207 4.1.1 CHECKLIST: Starting the engine.................................................................... 207 4.1.2 CHECKLIST: At low temperatures.................................................................... 210 4.1.3 Filling up........................................................................................ 211 Fuel tank........................................................................................... 211 AdBlue tank......................................................................................... 213 4.1.4 Checks before starting the engine................................................................. 214 At the hydraulic tank............................................................................... 214 Battery master switch............................................................................... 215 Checking the hand-held control...................................................................... 215 4.1.5 Switch the ignition on............................................................................ 215 4.1.6 Lamp test/equalisation of the switching states.................................................... 216 Lamp test........................................................................................... 216 Switching state alignment........................................................................... 216 4.1.7 Display – setting the brightness.................................................................. 217 4.1.8 Starting the engine............................................................................... 219 4.1.9 Checks after starting the engine.................................................................. 221 Start menu and on-board computer.................................................................... 221 Instrument panel.................................................................................... 222 4.1.10 Setting the idling speed......................................................................... 223 4.2 Switch off the engine................................................................................... 224 4.2.1 At the ignition lock and with the outrigger control units......................................... 224 After switching off................................................................................ 224 4.2.2 Using the emergency stop switches................................................................. 225 Resetting the emergency stop switch................................................................. 225 4.3 Air intake inhibitor.................................................................................... 226 Releasing the air intake inhibitor...................................................................... 226 5 Driving....................................................................................................... 227 5.1 Before driving.......................................................................................... 227 5.1.1 CHECKLIST: Checks before on-road driving.......................................................... 227 5.1.2 Check the condition of the truck crane............................................................ 233 Electrical system................................................................................... 233 Adjusting the mirrors............................................................................... 233 Warning plates for vehicle width.................................................................... 234 Checking the vehicle height......................................................................... 235 Supply pressure..................................................................................... 236 Parking brake....................................................................................... 237 5.1.3 Adjusting the seat and the steering column........................................................ 239 Adjusting the driver's seat........................................................................ 239 Adjusting the passenger seat....................................................................... 240 Adjusting the steering column...................................................................... 241 5.1.4 Switching the suspension on/off................................................................... 242 Open menu........................................................................................... 242 Switching the suspension on........................................................................ 243 Switching the suspension off....................................................................... 243 5.1.5 Setting the tachograph............................................................................ 244 Prerequisites....................................................................................... 244 In the event of malfunctions........................................................................ 244 Setting the tachograph............................................................................. 245 5.1.6 Setting the time.................................................................................. 249 5.1.7 Displaying and resetting operating hours.......................................................... 250 5.2 Operating the transmission.............................................................................. 251 5.2.1 Switching on...................................................................................... 251 5.2.2 Switching the transmission to the neutral position................................................ 252 5.2.3 Selecting the direction of travel and starting gear............................................... 253 Selecting the driving direction.................................................................... 253 Selecting the starting gear ...................................................................... 254 5.2.4 Changing the operating mode....................................................................... 255 Changing to automatic mode.......................................................................... 255 Change to manualmode............................................................................... 255 5.2.5 Starting.......................................................................................... 256 5.2.6 Driving and changing gears........................................................................ 257 In automatic operating mode......................................................................... 257 In manual operating mode............................................................................ 258 5.2.7 Changing the driving direction.................................................................... 259 5.2.8 Stopping.......................................................................................... 259 Stopping for longer periods........................................................................ 259 5.2.9 On the roller type dynamometer.................................................................... 260 5.2.10 Preheating transmission.......................................................................... 260 5.3 Driving the truck crane and switching it off............................................................ 261 5.3.1 Checks whilst driving............................................................................. 261 Brakes.............................................................................................. 261 ABS system.......................................................................................... 261 Steering............................................................................................ 262 Warning messages.................................................................................... 262 Monitoring elements................................................................................. 263 5.3.2 Cruise control.................................................................................... 264 Switching on........................................................................................ 264 Switching off....................................................................................... 265 5.3.3 Temposet.......................................................................................... 266 Switching on........................................................................................ 266 Switching off....................................................................................... 266 5.3.4 Driving downhill.................................................................................. 267 Starting............................................................................................ 267 Checks when driving downhill....................................................................... 268 Downshifting........................................................................................ 268 Additional brakes................................................................................... 269 5.3.5 Driving uphill.................................................................................... 270 Starting............................................................................................ 270 Driving............................................................................................. 270 5.3.6 Overriding torque reduction....................................................................... 271 5.3.7 Switching the truck crane off..................................................................... 272 Secure it against rolling away...................................................................... 272 When stationary for more than 8 hours............................................................... 273 5.3.8 Fold-up berth..................................................................................... 274 5.4 Off-road driving........................................................................................ 275 Adjustments to the transmission......................................................................... 275 Connections............................................................................................. 275 Changing the vehicle level.............................................................................. 275 Rocking the vehicle free and towing..................................................................... 275 5.4.1 Transfer case – switching the off-road gear on/off................................................ 276 Neutral position.................................................................................... 276 5.4.2 Longitudinal and transverse differential locks.................................................... 277 5.4.3 Operating the level adjustment system............................................................. 279 Open menu........................................................................................... 279 Setting the on-road level.......................................................................... 280 Pre-selecting suspension struts.................................................................... 280 Changing the vehicle level.......................................................................... 281 Viewing the current inclination..................................................................... 282 Exiting the menu................................................................................... 282 5.4.4 Freeing truck crane stuck in terrain.............................................................. 283 Rocking the truck crane free....................................................................... 283 Towing free forwards............................................................................... 284 Towing free totherear............................................................................ 284 5.5 Separate steering....................................................................................... 285 5.5.1 Switching to separate steering.................................................................... 286 5.5.2 Switching to normal steering mode................................................................. 289 5.5.3 Switching units of measure........................................................................ 290 5.6 Heating and air-conditioning system..................................................................... 291 5.6.1 Standard heating system........................................................................... 291 Switching on........................................................................................ 291 Heating............................................................................................. 291 Air distribution.................................................................................... 292 Examples............................................................................................ 293 Switching off....................................................................................... 293 5.6.2 Air-conditioning system........................................................................... 294 Information......................................................................................... 294 Switching on/off.................................................................................... 294 Cooling............................................................................................. 295 Drying.............................................................................................. 295 5.6.3 Auxiliary water heating system.................................................................... 296 Preheating theengine.............................................................................. 296 Preheating the driver's cab........................................................................ 297 Switching on........................................................................................ 297 Setting the date and time........................................................................... 299 Storing the heating start.......................................................................... 300 5.6.4 Auxiliary air heater.............................................................................. 302 Switching on........................................................................................ 302 Setting the heating level.......................................................................... 303 Setting the day and time........................................................................... 304 Setting the preselection time....................................................................... 304 Deleting preselection times......................................................................... 306 Switching off....................................................................................... 306 5.7 Radio................................................................................................... 306 5.8 Towing a trailer........................................................................................ 307 Effects on theaxleloads............................................................................... 307 Coupling the trailer................................................................................... 308 Connecting the supply lines............................................................................ 309 Removing supply lines................................................................................. 310 Uncoupling thetrailer................................................................................. 310 Checking the braking force.............................................................................. 312 6 Driving modes................................................................................................. 313 6.1 Driving modes........................................................................................... 313 Information about the axle loads........................................................................ 313 6.1.1 How to use the tables............................................................................ 314 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs)................................................ 315 385/95 R25 tyres.................................................................................... 315 445/95 R25 tyres.................................................................................... 317 525/80 R25 tyres.................................................................................... 318 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs).............................. 319 6.2 Weighing the truck crane................................................................................ 321 Axle groups............................................................................................. 322 Weighing procedure...................................................................................... 323 Evaluation.............................................................................................. 324 6.3 Rigging work for driving with a dolly................................................................... 325 6.3.1 Switching on the slewing gear freewheel........................................................... 326 6.3.2 Switching on the boom floating position........................................................... 327 6.3.3 Switching on boom pre-tensioning.................................................................. 328 6.4 Rigging the auxiliary hoist............................................................................. 329 6.4.1 Slinging the auxiliary hoist...................................................................... 329 6.4.2 CHECKLIST: Installing the auxiliary hoist......................................................... 330 6.4.3 CHECKLIST: Removing the auxiliary hoist........................................................... 331 6.4.4 Making/breaking the connection between the auxiliary hoist and the turntable...................... 332 6.4.5 Establishing/disconnecting the hydraulic connections.............................................. 333 6.4.6 Disconnecting/establishing the electrical connection.............................................. 334 6.4.7 Making/breaking the connection to the central lubrication......................................... 335 6.4.8 Transporting the auxiliary hoist.................................................................. 336 6.4.9 Check that the auxiliary hoist is functioning properly............................................ 337 Slewing direction................................................................................... 337 Slewing indicator................................................................................... 337 6.4.10 Rigging aid for the hoist rope................................................................... 338 6.5 Installing/removing the outrigger beams................................................................. 341 6.5.1 CHECKLIST: Removing the outrigger beams........................................................... 342 6.5.2 CHECKLIST: Installing the outrigger beams......................................................... 344 6.5.3 Centre of gravity data............................................................................ 346 6.5.4 Preparations – for removal........................................................................ 346 6.5.5 Preparations – on the truck crane................................................................. 347 Prerequisites....................................................................................... 347 6.5.6 Removing/attaching outrigger pads................................................................. 348 Removing the outrigger pads........................................................................ 348 Attaching the outrigger pads....................................................................... 349 6.5.7 Disconnecting/establishing hydraulic connection................................................... 350 6.5.8 Disconnecting/establishing the electrical connection.............................................. 351 6.5.9 Unscrewing/screwing in the spacers................................................................ 352 Unscrewing.......................................................................................... 352 Screwing in......................................................................................... 353 6.5.10 Disconnecting/establishing the connections to the supporting box................................. 354 6.5.11 Pulling out/Inserting the outrigger beam......................................................... 354 Extending the outrigger beam....................................................................... 354 Inserting the outrigger beam........................................................................ 356 6.5.12 Transporting the outrigger beams................................................................. 358 6.5.13 Note on error messages with removed outrigger beams.............................................. 359 7 Transport..................................................................................................... 361 7.1 Transport with transport vehicle........................................................................ 361 7.1.1 CHECKLIST: Checks before transport................................................................ 362 7.1.2 Drive the truck crane on to the transport vehicle................................................. 364 Driving on.......................................................................................... 365 Lashing............................................................................................. 365 7.2 Transport by ship....................................................................................... 366 8 Malfunctions in driving mode.................................................................................. 367 8.1 Emergency stop switch................................................................................... 367 8.2 Procedure during malfunctions........................................................................... 368 8.2.1 What to do when a malfunction occurs in road traffic.............................................. 368 8.2.2 Procedure during engine malfunctions.............................................................. 369 8.2.3 Procedure during transmission malfunctions........................................................ 370 8.3 Warning and error messages.............................................................................. 371 8.3.1 Warning or malfunction messages on the instrument panel........................................... 371 Meaning of thelamps................................................................................ 371 8.3.2 Warning and malfunction messages on the on-board computer display................................. 375 Messages............................................................................................ 375 Symbols............................................................................................. 376 8.3.3 Warning messages on the CCS display............................................................... 379 Symbols in the display area......................................................................... 379 8.3.4 Engine/transmission error messages................................................................ 383 Open menu........................................................................................... 383 Exiting the menu.................................................................................... 383 8.4 Troubleshooting......................................................................................... 385 8.4.1 Malfunctions on the engine........................................................................ 385 When operating with the dual tank................................................................... 387 8.4.2 Faults on the Adblue system....................................................................... 387 8.4.3 Differential lock malfunctions.................................................................... 388 8.4.4 Transfer case malfunctions........................................................................ 388 8.4.5 Malfunctions in the transmission.................................................................. 389 8.4.6 Malfunctions of the steering...................................................................... 390 8.4.7 Malfunctions of the service brake................................................................. 391 8.4.8 Malfunctions on the suspension.................................................................... 391 8.4.9 Malfunctions of the level adjustment system....................................................... 392 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 392 8.5 Emergency operation and breakdown assistance............................................................ 393 8.5.1 Starting the truck crane externally............................................................... 393 8.5.2 Battery charger................................................................................... 394 Prerequisites....................................................................................... 394 8.5.3 Towing the truck crane............................................................................ 395 In the case of engine/ transmission damage.......................................................... 395 Compressed-air supply............................................................................... 395 Longer towing distances............................................................................. 398 Tow starting........................................................................................ 398 8.5.4 Wheel change...................................................................................... 399 Removing a damaged wheel............................................................................ 400 On the spare wheel holder........................................................................... 400 Mounting a wheel.................................................................................... 401 8.5.5 Inflating the tyres yourself...................................................................... 403 Connecting thefilling hose......................................................................... 403 Inflating the tyres................................................................................. 404 Remove the fillinghose............................................................................ 404 8.5.6 Emergency operation, steering 3rd axle line....................................................... 405 Performing emergency operation..................................................................... 405 After emergency operation.......................................................................... 407 8.6 Tilting/lowering the driver's cab....................................................................... 409 8.6.1 Prerequisites and information on tilting.......................................................... 409 8.6.2 Tilting and lowering the driver's cab............................................................. 410 Operating the hand pump............................................................................. 410 Tilting the driver's cab............................................................................ 411 Lowering the driver's cab.......................................................................... 412 8.7 Fuses on the carrier.................................................................................... 415 Information on changing fuses......................................................................... 415 8.7.1 Fuses in the driver's cab......................................................................... 416 8.7.2 Fuses in the battery box.......................................................................... 422 9 Operating elements for crane operation............................................................................ 423 9.1 Overview of the operating elements.......................................................................... 423 9.1.1 Exterior of the truck crane........................................................................... 424 9.1.2 Crane cab............................................................................................. 428 Side panel.............................................................................................. 430 Crane cab, rear......................................................................................... 432 9.1.3 Control panels........................................................................................ 434 Left.................................................................................................... 434 Right................................................................................................... 435 9.1.4 Control lever assignment.............................................................................. 436 Version 1............................................................................................... 436 Version 2............................................................................................... 437 9.1.5 CCS control unit...................................................................................... 438 9.1.6 Menu-independent displays............................................................................. 440 9.1.7 CCS – Start menu...................................................................................... 441 RCL display............................................................................................. 442 Display Slewing ranges/working radii................................................................... 443 9.1.8 CCS – Overview menu groups............................................................................ 444 9.1.9 Superstructure menu group............................................................................. 448 Superstructure lock sub-menu.......................................................................... 449 Counterweight menu...................................................................................... 450 9.1.10 Menu group outrigger/driving........................................................................ 451 Outrigger menu......................................................................................... 452 Outrigger cylinders menu............................................................................... 454 Driving mode menu...................................................................................... 456 9.1.11 RCL/Telescoping menu group........................................................................... 459 Menu enter rigging mode/ telescope..................................................................... 460 Pre-selection telescoping menu......................................................................... 464 Lifting capacity tables menu............................................................................ 466 Telescoping semi- automation menu...................................................................... 467 Manual telescoping menu............................................................................... 468 9.1.12 Active working range limiter menu group.............................................................. 469 Overall height menu.................................................................................... 470 Working radius menu..................................................................................... 471 Slewing angle menu...................................................................................... 472 Hoist rope travel limitation menu....................................................................... 473 9.1.13 Information menu group 1............................................................................. 474 Hydraulic pressure and fuel consumption menu............................................................ 475 9.1.14 Heating/Engine/Additional equipment menu group....................................................... 476 Economy menu............................................................................................ 477 Remote control menu..................................................................................... 478 Heating/ air-conditioning menu.......................................................................... 479 Spotlights menu......................................................................................... 480 9.1.15 Telescoping emergency program menu group........................................................... 481 Telescoping emergency program menu.................................................................... 482 Unknown telescoping menu............................................................................... 484 Swinging the swing-away lattice emergency operation menu................................................ 485 9.1.16 Settings menu group.................................................................................. 486 Crane cab menu.......................................................................................... 487 Set display brightness and date/time menu............................................................... 488 Switch units menu....................................................................................... 489 Set control lever characteristic curve menu............................................................. 490 Power unit speedsmenu................................................................................ 491 9.1.17 Information menu group 2............................................................................. 492 Operating hours menu.................................................................................... 493 Engine/transmission errormenu.......................................................................... 494 Crane operation error menu.............................................................................. 495 Program version menu.................................................................................... 496 9.1.18 Various controls..................................................................................... 497 9.1.19 RCL control unit..................................................................................... 498 9.1.20 Menu-independent displays............................................................................ 499 9.1.21 RCL – menus.......................................................................................... 500 Monitoring menu........................................................................................ 500 Lifting capacity tables menu............................................................................ 502 Datalogger menu......................................................................................... 503 9.1.22 Hand-held control.................................................................................... 505 9.1.23 Outriggers control units............................................................................. 507 Menu- independent buttons.............................................................................. 507 Outrigger menu.......................................................................................... 508 Raise axle menu........................................................................................ 510 9.2 Short description of the operating elements................................................................. 511 9.2.1 Definition of information relating to directions of movement.......................................... 511 Basic rule.............................................................................................. 511 9.2.2 General rules for buttons and symbols on the display.................................................. 512 9.2.3 Engine................................................................................................ 513 Side panel............................................................................................. 513 Left control lever...................................................................................... 513 Economy mode menu....................................................................................... 514 9.2.4 AdBlue system......................................................................................... 514 CCS display............................................................................................. 514 9.2.5 Seat contact switch and dead man's switch............................................................. 516 9.2.6 Crane control CCS..................................................................................... 517 9.2.7 Outrigger – crane cab................................................................................. 522 Control panels.......................................................................................... 522 CCS display............................................................................................. 523 9.2.8 Outrigger control units............................................................................... 525 General information..................................................................................... 525 Outrigger menu.......................................................................................... 526 9.2.9 Raise axle............................................................................................ 528 9.2.10 Inclination indicators............................................................................... 530 9.2.11 Outrigger pressure displays.......................................................................... 531 Outrigger menu......................................................................................... 531 Outriggers control units............................................................................... 531 9.2.12 Anemometer displays.................................................................................. 531 9.2.13 Counterweight menu................................................................................... 532 9.2.14 Main hoist........................................................................................... 536 Control panels.......................................................................................... 536 CCS display............................................................................................. 536 9.2.15 Auxiliary hoist...................................................................................... 538 Control panels.......................................................................................... 538 CCS display............................................................................................. 538 9.2.16 Slewing gear......................................................................................... 540 Control panels.......................................................................................... 540 CCS display............................................................................................. 541 9.2.17 Derricking gear...................................................................................... 542 Control panels.......................................................................................... 542 CCS display............................................................................................. 543 Side panel.............................................................................................. 543 9.2.18 Telescoping mechanism................................................................................ 544 Control panels.......................................................................................... 544 CCS display............................................................................................. 545 Telescoping semi- automation menu....................................................................... 545 Manual telescoping menu................................................................................. 547 9.2.19 Hydraulic system..................................................................................... 550 9.2.20 Superstructure lock/house lock menu.................................................................. 551 Superstructure lock.................................................................................... 551 Houselock............................................................................................... 553 9.2.21 Remote control....................................................................................... 554 9.2.22 Rated capacity limiter (RCL)......................................................................... 555 CCS display............................................................................................. 555 RCL display............................................................................................. 564 RCL override – version A................................................................................ 565 RCL override – version B................................................................................ 566 9.2.23 Electrical system.................................................................................... 567 9.2.24 Lighting, windscreen wiper/washing system............................................................ 568 Lighting................................................................................................ 568 Windscreen wiper/washing system........................................................................ 570 Horn.................................................................................................... 571 9.2.25 Hand-held control.................................................................................... 572 Sockets for hand- held control.......................................................................... 572 Engine control panel.................................................................................... 573 Horn.................................................................................................... 573 9.2.26 Windows and doors.................................................................................... 576 Window.................................................................................................. 576 Rear window............................................................................................. 576 Crane cab door.......................................................................................... 577 9.2.27 Diagnostics.......................................................................................... 578 9.2.28 Other................................................................................................ 578 9.3 Short description of the operating elements – driving from the crane cab.................................... 579 9.3.1 Driving mode menu..................................................................................... 579 9.3.2 Transmission.......................................................................................... 580 9.3.3 Final drive........................................................................................... 581 9.3.4 Brakes................................................................................................ 583 CCS display............................................................................................. 583 Side panel from above................................................................................... 584 9.3.5 Steering.............................................................................................. 585 CCS display............................................................................................. 585 Separate steering....................................................................................... 586 Control panels.......................................................................................... 587 Crane operation..................................................................................................... 423 10 Starting/switching off the engine – for crane operation...................................................... 589 10.1 When starting the engine for the first time in the day................................................. 589 10.2 Starting the engine – from the crane cab............................................................... 591 10.2.1 Check the fuel level and AdBlue level............................................................ 591 Fuel................................................................................................ 591 AdBlue.............................................................................................. 591 10.2.2 Checks before starting the engine................................................................ 592 Checks on the carrier.............................................................................. 592 Checking the hand-held control...................................................................... 592 At the hydraulic tank............................................................................... 592 10.2.3 Switch the ignition on........................................................................... 593 10.2.4 Comparison of switching states................................................................... 594 10.2.5 Display – setting the brightness................................................................. 594 10.2.6 Starting the engine.............................................................................. 595 10.2.7 Checks after starting the engine................................................................. 596 10.2.8 Setting the idling speed......................................................................... 597 10.3 Starting the engine – with the hand-held control....................................................... 598 10.4 Switch off the engine.................................................................................. 599 10.4.1 At the ignition lock and with hand-held control.................................................. 599 After switching off................................................................................ 599 10.4.2 With the idling button........................................................................... 599 10.4.3 Using the emergency stop switches................................................................ 600 Resetting the emergency stop switch................................................................. 600 11 Crane operation.............................................................................................. 601 11.1 Before operating the crane............................................................................. 601 11.1.1 CHECKLIST: Checks before operating the crane..................................................... 601 11.1.2 Check the condition of the truck crane........................................................... 605 Fuel tank auxiliary heater.......................................................................... 605 Visual inspection................................................................................... 605 Checking the position of the hoist ropes............................................................ 606 Checking the electrical system...................................................................... 607 11.1.3 Adjusting the crane cab seat and front control panel............................................. 608 Crane cab seat...................................................................................... 608 Front control panel................................................................................. 609 11.1.4 Checking the safety equipment.................................................................... 610 Rated capacity limiter.............................................................................. 610 Lifting limit switch............................................................................... 610 Emergency stop switch............................................................................... 611 Seat contact switch................................................................................ 612 11.1.5 Earthing the load................................................................................ 613 11.1.6 Preheating hydraulic oil......................................................................... 614 Prerequisites....................................................................................... 614 Preheating.......................................................................................... 614 11.1.7 Locking/unlocking the superstructure............................................................. 615 Locking points...................................................................................... 615 Lock the superstructure............................................................................ 616 Unlocking the superstructure....................................................................... 616 11.1.8 Switching the houselock on/off................................................................... 617 Switching on the houselock......................................................................... 617 Switching off the houselock........................................................................ 619 11.2 Standard slewing range type............................................................................ 621 11.2.1 Permissible slewing ranges and working positions................................................. 621 360 slewing range.................................................................................. 621 Working position 0 to the rear..................................................................... 621 180 to the front rigging position.................................................................. 621 11.3 MAXbase slewing range type............................................................................. 623 11.3.1 Specifications in the lifting capacity tables.................................................... 624 11.3.2 Enabled slewing ranges........................................................................... 625 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit....... 628 11.4 Operation of the rated capacity limiter................................................................ 629 11.4.1 Switch on the RCL................................................................................ 630 Switching on........................................................................................ 630 11.4.2 Enter rigging mode............................................................................... 632 Notes on Input..................................................................................... 632 Enter the slewing range type........................................................................ 633 Entering individual components...................................................................... 634 Entering the RCLcode.............................................................................. 640 11.4.3 Pre-selecting telescoping........................................................................ 640 11.4.4 Confirm the rigging mode and lifting capacity table.............................................. 641 Slewing range type Standard......................................................................... 641 Slewing range type MAXbase.......................................................................... 643 11.4.5 Checks before operating the crane................................................................ 645 Monitoring menu..................................................................................... 645 Checking the rigging mode........................................................................... 645 Hoist checking...................................................................................... 647 11.4.6 Display during the crane operation............................................................... 649 On the RCL display.................................................................................. 649 On the CCS display.................................................................................. 653 11.4.7 RCL early warning................................................................................ 657 11.4.8 RCL shutdown..................................................................................... 657 Shutdown due to overload............................................................................ 657 11.4.9 Displaying the lifting capacity tables........................................................... 659 Slewing range type Standard......................................................................... 659 Slewing range type MAXbase.......................................................................... 661 11.4.10 RCL override – version A........................................................................ 663 Overview statusdisplay............................................................................. 663 When rigging........................................................................................ 664 To raise the boom................................................................................... 665 In emergencies...................................................................................... 666 11.4.11 RCL override – version B........................................................................ 667 11.4.12 Datalogger...................................................................................... 668 Export data......................................................................................... 668 Display the data.................................................................................... 669 11.5 Crane operation with main boom......................................................................... 673 11.5.1 Checks during crane operation.................................................................... 673 Horizontal alignment................................................................................ 673 Safe distances..................................................................................... 673 Checking the windspeed............................................................................. 674 11.5.2 Main hoist....................................................................................... 675 Switching on themain hoist......................................................................... 676 Lifting and lowering............................................................................... 676 Maximum permissible hoist rope speed................................................................ 677 Switching off the main hoist....................................................................... 678 11.5.3 Auxiliary hoist.................................................................................. 679 Switching on the auxiliary hoist................................................................... 679 Lifting and lowering............................................................................... 680 Maximum permissible hoist rope speed................................................................ 681 Switching off the auxiliary hoist.................................................................. 681 11.5.4 Lifting limit switch and lowering limit switch................................................... 682 Lifting limit switch................................................................................ 682 Lowering limit switch............................................................................... 684 11.5.5 Derricking gear.................................................................................. 685 Switching on the derricking gear................................................................... 685 Raising and lowering................................................................................ 686 Maximum derricking speed............................................................................ 687 Re-enable raising function.......................................................................... 687 Switching off the derricking gear................................................................... 688 Lowering the main boom to a horizontal position..................................................... 688 11.5.6 Telescoping mechanism............................................................................ 689 Overview............................................................................................ 691 Telescoping process................................................................................. 692 Assignment for display.............................................................................. 694 Fixed length, intermediate length, telescoping length.............................................. 695 Telescoping......................................................................................... 696 Telescoping sequence............................................................................... 696 Inspections prior to starting operations........................................................... 697 Switching on thetelescoping mechanism.............................................................. 698 Function of the control lever....................................................................... 698 Switching off thetelescoping mechanism............................................................. 700 Manual telescoping................................................................................. 701 Checking the initial position....................................................................... 701 Unlocking the telescoping cylinder.................................................................. 703 Extending/retracting the telescoping cylinder....................................................... 705 Lock telescoping cylinder........................................................................... 706 Unlocking the telescopic section................................................................... 707 Telescoping the telescopic section................................................................. 708 Locking the telescopic section..................................................................... 709 Locking the telescopic section for on-road driving................................................. 710 Telescoping with semi-automaton..................................................................... 710 Telescoping with pre-selection...................................................................... 712 11.5.7 High-speed mode.................................................................................. 713 Derricking gear telescoping mechanism.............................................................. 713 Hoists.............................................................................................. 713 11.5.8 Slewing gear..................................................................................... 715 Slewing gear brake.................................................................................. 715 Switching on the slewing gear...................................................................... 716 Releasing the slewing gear brake.................................................................... 716 Applying the slewing gear brake..................................................................... 716 Releasing locked slewing gear....................................................................... 717 Slewing............................................................................................. 717 Permissible slewing speed.......................................................................... 718 Braking the slewing movement........................................................................ 719 Slewing gear freewheel.............................................................................. 719 Switching off the slewing gear..................................................................... 720 11.5.9 Switching the reduction of slewing speed on and off.............................................. 721 Switching reduction off............................................................................. 721 11.5.10 Possible movement combinations.................................................................. 722 11.6 Settings and displays for crane operation.............................................................. 723 11.6.1 Inclining the crane cab.......................................................................... 723 11.6.2 Setting the idling speed......................................................................... 724 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper...................................... 724 11.6.4 Limiting the power unit speeds................................................................... 725 11.6.5 Economy mode..................................................................................... 726 Switching on........................................................................................ 726 Ending/ switchingoff............................................................................... 728 11.6.6 Switching units of measure....................................................................... 728 11.6.7 Setting the characteristic curves for the control levers......................................... 729 11.6.8 Using the slewable spotlights.................................................................... 730 Manually swinging................................................................................... 731 Automatic load tracking............................................................................. 731 11.6.9 Overriding torque reduction...................................................................... 732 11.6.10 Displaying the operating hours.................................................................. 733 11.7 Working range limiter.................................................................................. 735 11.7.1 Viewing current settings......................................................................... 736 On the RCL display.................................................................................. 736 In the CCS Start menu............................................................................... 737 11.7.2 Opening the working range limiter menu........................................................... 737 11.7.3 Entering limit values............................................................................ 740 Overall height...................................................................................... 740 Working radius...................................................................................... 741 Slewing angle....................................................................................... 741 Hoist rope limitation............................................................................... 742 11.7.4 Entering limit values manually................................................................... 744 Limit values........................................................................................ 744 11.7.5 Switching monitoring functions on/off............................................................ 746 11.7.6 Shutdown by working range limiter................................................................ 747 11.8 Work break............................................................................................. 749 11.8.1 In case of short work breaks..................................................................... 749 11.8.2 In case of work breaks of more than 8 hours...................................................... 750 To secure the truck crane........................................................................... 750 11.9 Heating and air-conditioning system.................................................................... 751 11.9.1 Standard heating system.......................................................................... 751 Switching on........................................................................................ 751 Heating............................................................................................. 751 Air distribution.................................................................................... 752 Switching off....................................................................................... 752 11.9.2 Air-conditioning system.......................................................................... 753 Information......................................................................................... 753 Switching on/off.................................................................................... 753 Cooling, automatic.................................................................................. 754 Cooling, maximum.................................................................................... 754 11.9.3 Auxiliary heater................................................................................. 755 Switching on........................................................................................ 755 Setting the temperature............................................................................. 756 Setting the heating start/ heating duration......................................................... 756 Switching heating start on/off...................................................................... 757 11.10 CraneSTAR system...................................................................................... 758 11.10.1 Overview........................................................................................ 758 11.10.2 Position of the components...................................................................... 758 12 Rigging work................................................................................................. 759 12.1 Rigging work checklists for crane operation with the main boom......................................... 759 12.1.1 CHECKLIST: Rigging............................................................................... 759 12.1.2 CHECKLIST: Unrigging............................................................................. 765 12.2 Choice of a suitable positioning site.................................................................. 769 12.2.1 Determining the required load-bearing area....................................................... 769 12.2.2 Safe distance from slopes and pits............................................................... 772 12.2.3 Earthing the truck crane......................................................................... 773 12.2.4 Safe distance from overhead power lines.......................................................... 774 12.3 Rigging work after driving with a dolly................................................................ 777 12.3.1 Switching off the boom floating position......................................................... 777 12.3.2 Switching off the slewing gear freewheel......................................................... 778 Before slewing...................................................................................... 778 12.3.3 Switching off boom pre-tensioning................................................................ 779 12.4 Connecting/disconnecting the hand-held control......................................................... 781 12.5 Starting the engine for rigging........................................................................ 785 Prerequisites........................................................................................... 785 Starting the engine..................................................................................... 785 Turning off theengine.................................................................................. 785 12.6 Slewing range – only with the Standard slewing range type.............................................. 787 12.6.1 Representation in the lifting capacity tables.................................................... 787 12.6.2 Enabled outrigger spans.......................................................................... 788 12.7 Outriggers – Overview – MAXbase slewing range type..................................................... 789 12.7.1 Definitions...................................................................................... 789 12.7.2 Representation in the lifting capacity tables.................................................... 791 12.7.3 Enabled outrigger spans.......................................................................... 792 12.8 Outrigger operation.................................................................................... 797 12.8.1 CHECKLIST: Extending the outriggers.............................................................. 797 12.8.2 CHECKLIST: Retracting the outriggers............................................................. 799 12.8.3 Preparing the truck crane........................................................................ 800 Driver's cab........................................................................................ 800 Crane cab........................................................................................... 800 12.8.4 Setting the outrigger spans...................................................................... 802 For on-road driving................................................................................. 805 12.8.5 Extending/retracting outrigger beams............................................................. 805 From the controlunits.............................................................................. 806 From the cranecab.................................................................................. 807 12.8.6 Moving the outrigger pads into operating/driving position........................................ 809 12.8.7 Enlarging the load-bearing area.................................................................. 811 12.8.8 Extending/retracting supporting cylinders........................................................ 812 From the control units.............................................................................. 813 From the cranecab.................................................................................. 814 12.8.9 Levelling the truck crane on outriggers horizontally............................................. 816 Inclination indicators.............................................................................. 816 Prerequisites....................................................................................... 817 Manual alignment................................................................................... 818 Automatic alignment................................................................................. 818 12.8.10 Levelling the free-standing truck crane......................................................... 820 12.8.11 Operating the axle raising system............................................................... 822 12.8.12 Outrigger pressure display...................................................................... 824 12.9 Rigging/unrigging the counterweight.................................................................... 827 Counterweight display rigged............................................................................ 827 12.9.1 Information on rigging........................................................................... 827 When rigging........................................................................................ 827 When unrigging...................................................................................... 828 12.9.2 Counterweight sections........................................................................... 829 12.9.3 Identification................................................................................... 831 12.9.4 Slinging points on the counterweight sections.................................................... 832 12.9.5 CHECKLIST: Rigging the counterweight............................................................. 834 12.9.6 CHECKLIST: Unrigging the counterweight........................................................... 836 12.9.7 Assembling counterweight combination............................................................. 838 12.9.8 Counterweight hoist unit......................................................................... 843 Counterweight menu................................................................................. 843 Extending/ retracting the lifting cylinders......................................................... 844 Automatic moderigging............................................................................. 846 Automatic mode unrigging........................................................................... 848 Cancel automatic mode.............................................................................. 849 12.9.9 Setting down counterweight for driving........................................................... 850 Rear counterweight platform......................................................................... 850 Front counterweight platform........................................................................ 852 12.9.10 Unlocking/locking the rear counterweight platform............................................... 853 Unlocking........................................................................................... 853 Locking............................................................................................. 854 12.9.11 Slewing with rigged counterweight............................................................... 855 12.10 Rigging work on the main boom......................................................................... 857 12.10.1 Hook block on the bumper........................................................................ 857 Picking up the hook block........................................................................... 857 Attaching the hook block............................................................................ 858 12.10.2 Hook block on a separate vehicle................................................................ 859 Picking up the hook block.......................................................................... 860 Setting down thehook block........................................................................ 860 12.10.3 Hook block, separable........................................................................... 862 Rigging for on-road driving......................................................................... 862 Rigging for crane operation......................................................................... 863 12.10.4 Hook block with ballast plates.................................................................. 864 Removing............................................................................................ 864 Installing.......................................................................................... 865 Information on crane operation...................................................................... 865 12.10.5 Reeving and unreeving the hoist rope............................................................ 866 Reeving the hoistrope.............................................................................. 867 Unreeving hoistrope............................................................................... 871 12.10.6 Possible reevings on the main boom.............................................................. 872 With 5 head sheaves................................................................................. 872 With 6 head sheaves................................................................................. 875 With 7 head sheaves................................................................................. 877 12.10.7 Installing/removing the lifting limit switch.................................................... 878 Installing the lifting limit switch................................................................. 878 Removing the lifting limit switch................................................................... 881 12.10.8 Locking/unlocking the lifting limit switch...................................................... 883 Locking............................................................................................. 883 Removing the lock.................................................................................. 883 12.10.9 Anemometer and air traffic control light........................................................ 884 Installing.......................................................................................... 884 Switching on/off.................................................................................... 885 Removing............................................................................................ 885 12.11 Other rigging work.................................................................................... 887 12.11.1 Railings on the turntable....................................................................... 887 12.11.2 Folding the mirrors in and out, and adjusting them.............................................. 888 12.11.3 Slinging points for personal protective equipment............................................... 889 12.11.4 Cameras for crane operation..................................................................... 890 Camera on mainboom................................................................................. 890 Camera on thehoists................................................................................ 893 Camera on the driver's cab.......................................................................... 893 Operating the camera................................................................................ 894 12.11.5 Step at the crane cab........................................................................... 895 13 Driving with a rigged truck crane............................................................................ 897 13.1 Route.................................................................................................. 897 13.2 Permissible rigging modes and axle loads............................................................... 898 Axle load table........................................................................................ 898 13.2.1 To drive without a load.......................................................................... 901 13.2.2 To drive with a load............................................................................. 901 13.2.3 Axle loads....................................................................................... 902 13.3 Before driving the rigged truck crane.................................................................. 903 13.3.1 Check the tyre pressures and wind speed.......................................................... 903 13.3.2 Secure the superstructure against slewing........................................................ 903 13.3.3 Putting the truck crane on the wheels – with Raise axle function................................. 904 13.3.4 Putting the truck crane on the wheels – with the outriggers...................................... 906 13.4 Driving from the driver's cab.......................................................................... 909 13.4.1 Preparing to drive............................................................................... 909 Transmission........................................................................................ 909 Switching on separate steering...................................................................... 909 Connections......................................................................................... 909 13.4.2 Whilst driving................................................................................... 910 13.4.3 After driving.................................................................................... 911 13.5 Driving from the crane cab............................................................................. 913 13.5.1 Preparing to drive............................................................................... 914 13.5.2 Opening/closing the Driving menu................................................................. 914 Opening............................................................................................. 914 Crane's hydraulic system on/off..................................................................... 915 Closing............................................................................................. 916 13.5.3 Steering......................................................................................... 917 Switching on........................................................................................ 917 Steering direction.................................................................................. 917 Displays when steering.............................................................................. 918 Separate steering................................................................................... 918 Normal steering mode................................................................................ 922 13.5.4 Operating the transmission....................................................................... 923 Selecting the transmission mode.................................................................... 923 13.5.5 Whilst driving................................................................................... 924 DM and RM transmission mode......................................................................... 924 Transmission mode D................................................................................. 924 Warning messages.................................................................................... 924 13.5.6 Possible connections............................................................................. 925 Longitudinal/ transverse differential locks......................................................... 925 13.5.7 After driving.................................................................................... 927 14 Malfunctions during crane operation.......................................................................... 929 14.1 Emergency stop switch.................................................................................. 929 14.2 What to do when malfunctions occur during crane operation.............................................. 930 The load can be set down................................................................................ 930 Load cannot besetdown................................................................................. 930 14.3 Warning and error messages............................................................................. 931 Program version......................................................................................... 931 14.3.1 Warning messages on the CCS display.............................................................. 931 Meaning of thesymbols.............................................................................. 932 14.3.2 Error messages on the CCS display................................................................ 935 14.3.3 Warning messages on the RCL display.............................................................. 937 14.4 Troubleshooting........................................................................................ 941 14.4.1 Malfunctions on the engine....................................................................... 941 14.4.2 Malfunctions on the main hoist/auxiliary hoist................................................... 941 14.4.3 Malfunctions in the hoist cameras................................................................ 943 14.4.4 Malfunctions in the main boom camera............................................................. 943 14.4.5 Malfunctions on the derricking gear.............................................................. 944 14.4.6 Malfunctions in the telescoping mechanism........................................................ 945 14.4.7 Malfunctions on the slewing gear................................................................. 946 14.4.8 Malfunctions on the counterweight hoist unit..................................................... 948 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 948 14.4.10 Malfunctions when inclining the crane cab....................................................... 948 14.4.11 Malfunctions when operating with the hand-held control.......................................... 949 14.4.12 Malfunctions when inclining the crane cab....................................................... 949 14.4.13 Malfunctions when raising the axles............................................................. 949 14.4.14 Malfunctions of the outriggers.................................................................. 950 14.4.15 Malfunctions on the turntable lock.............................................................. 950 14.4.16 Malfunctions on the CCS/RCL control units....................................................... 951 14.4.17 Malfunctions when driving from the crane cab.................................................... 951 14.4.18 Malfunctions on the CraneSTAR system............................................................ 952 14.5 Emergency operations and programs...................................................................... 955 14.5.1 Mechanical emergency activation for retracting................................................... 956 Prior to the emergency operation, check............................................................. 956 Procedure........................................................................................... 956 Mechanical emergency activation.................................................................... 957 14.5.2 Telescoping emergency program.................................................................... 959 Checks before using the emergency program........................................................... 959 Telescoping emergency program menu.................................................................. 960 Notes on the displays............................................................................... 961 Checks in theemergency program.................................................................... 962 Retracting withemergency program................................................................... 966 Tables for approaching the locking points........................................................... 968 14.5.3 Entering the current telescoping................................................................. 971 14.5.4 Emergency operation with the hand-held control................................................... 973 To pre-select a power unit.......................................................................... 974 Operating apowerunit.............................................................................. 974 Stopping movements................................................................................. 975 Stopping movements in emergencies................................................................... 976 Switch off theengine............................................................................... 976 14.5.5 Notes on slewing in emergency operation.......................................................... 976 For the Standard slewing range type................................................................. 976 For the MAXbase slewing range type.................................................................. 978 14.6 Hydraulic emergency operation with the hand pump....................................................... 979 14.6.1 Operating principle.............................................................................. 979 14.6.2 Switching over the crane's hydraulic system...................................................... 979 14.6.3 Establishing the hydraulic circuits required..................................................... 980 Releasing/ securing valves.......................................................................... 980 Switching over valves............................................................................... 981 For lowering........................................................................................ 982 14.6.4 Performing emergency activation.................................................................. 983 14.6.5 After emergency activation....................................................................... 983 14.7 Hydraulic emergency operation as per BGR 159........................................................... 985 14.7.1 Applications and function........................................................................ 985 14.7.2 CHECKLIST: Emergency operation................................................................... 987 14.7.3 CHECKLIST: After emergency operation............................................................. 988 14.7.4 Connecting/removing transformer – for self-sufficiency........................................... 989 Connecting.......................................................................................... 989 Removing............................................................................................ 990 14.7.5 Switching emergency operation on/off............................................................. 991 14.7.6 Connecting/removing transformer – for external energy source..................................... 992 14.7.7 Establishing the required hydraulic circuits..................................................... 993 Switching overvalves............................................................................... 993 For lifting/ lowering............................................................................... 995 For slewing......................................................................................... 996 14.7.8 Performing emergency operation................................................................... 997 Slewing............................................................................................. 997 Derricking.......................................................................................... 998 Lifting/lowering.................................................................................... 998 14.7.9 Emergency supply of another crane................................................................ 999 For emergency supply................................................................................ 999 After emergency supply.............................................................................. 999 14.8 Fuses in the crane cab.................................................................................1001 Information on changing fuses.........................................................................1001 15 Index............................................................................................................1007 A...............................................................................................................1009 B...............................................................................................................1009 C...............................................................................................................1010 D...............................................................................................................1012 E...............................................................................................................1014 F...............................................................................................................1016 H...............................................................................................................1016 I...............................................................................................................1017 L...............................................................................................................1017 M...............................................................................................................1018 O...............................................................................................................1019 P...............................................................................................................1020 R...............................................................................................................1020 S...............................................................................................................1021 T...............................................................................................................1023 V...............................................................................................................1025 W...............................................................................................................1025
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