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Grove Crane GMK 4100L-1 Operating Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 4100L-1 Operating Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100L-1 Operating Manual – PDF DOWNLOAD
Language : English
Pages : 1016
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 4100L-1 Operating Manual – PDF DOWNLOAD
Documentation supplied:
The precise number of documents supplied depends on the rigging mode of the truck crane. The
following documents are included in delivery:
– Operating manual
Contains information on driving and crane operation.
Contains information on driving and crane operation.
– Lattice extension operating manual
Is only supplied when the truck crane is equipped with a lattice extension or other parts for
extending the main boom (e.g. auxiliary single-sheave boom top and heavy load lattice extension).
Is only supplied when the truck crane is equipped with a lattice extension or other parts for
extending the main boom (e.g. auxiliary single-sheave boom top and heavy load lattice extension).
– Operating manual for additional equipment
This is only supplied when the truck crane is supplied with additional equipment which is not
described in the operating manual for driving and crane operation.
This is only supplied when the truck crane is supplied with additional equipment which is not
described in the operating manual for driving and crane operation.
– Documents from other manufacturers
Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH, such as
the engine and central lubrication system, as well as the tachograph, auxiliary heaters, radio and,
where appropri- ate, other additional equipment.
Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH, such as
the engine and central lubrication system, as well as the tachograph, auxiliary heaters, radio and,
where appropri- ate, other additional equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no instructions for repair work.
Contains solely information on maintenance work and contains no instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and pneumatic systems are supplied.
Circuit diagrams for the electrical systems, hydraulic systems and pneumatic systems are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes.
Information on the lifting capacity when the truck crane is in different
rigging modes.
TABLE OF CONTENTS:
Grove Crane GMK 4100L-1 Operating Manual – PDF DOWNLOAD
Operating manual........................................................................................................ 1 Table of contents................................................................................................... 37 Additional pages.................................................................................................... 5 Outrigger spans................................................................................................. 3 Driving from the crane cab...................................................................................... 5 Overview of Driving menu.................................................................................... 6 Brief description of the operating elements................................................................. 9 Driving menu............................................................................................ 9 Transmission............................................................................................ 11 Final drive............................................................................................. 13 Brakes.................................................................................................. 14 CCS display......................................................................................... 14 Side panel from above............................................................................... 14 Steering................................................................................................ 15 CCS display......................................................................................... 16 Control panels...................................................................................... 18 Driving from the crane cab.................................................................................. 19 Preparing to drive...................................................................................... 20 Opening/closing the Driving menu........................................................................ 21 Selecting the operating mode....................................................................... 21 Crane's hydraulic system Driving mode............................................................... 23 Closing menu........................................................................................ 23 Steering................................................................................................ 24 Switching on........................................................................................ 24 Display and steering direction...................................................................... 24 Switching the steering direction................................................................... 25 Displays when steering.............................................................................. 25 Separate steering................................................................................... 26 Normal steering..................................................................................... 29 Operating the transmission.............................................................................. 30 Selecting the transmission mode.................................................................... 30 While driving........................................................................................... 31 Warning messages.................................................................................... 31 Possible connections.................................................................................... 32 Longitudinal/transverse differential locks.......................................................... 32 After driving........................................................................................... 34 General............................................................................................................. 67 1 Overview...................................................................................................... 67 1.1 Accidents............................................................................................... 67 1.2 Branch offices.......................................................................................... 69 1.2.1 Manitowoc Crane Care.............................................................................. 69 1.2.2 Dealer list....................................................................................... 69 1.3 Warranty specifications................................................................................. 69 1.4 Terms used.............................................................................................. 70 1.5 Technical data.......................................................................................... 73 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................................. 73 1.5.2 Dimensions and weights of the truck crane, axle loads............................................. 74 Dimensions.......................................................................................... 75 Weight and axle loads............................................................................... 75 1.5.3 Dimensions and weights of removable parts......................................................... 76 Spare wheel......................................................................................... 76 Outrigger........................................................................................... 76 Hook blocks and hook tackle......................................................................... 0 Counterweight parts................................................................................ 80 Auxiliary hoist..................................................................................... 80 1.5.4 Carrier........................................................................................... 81 Motor............................................................................................... 81 Transmission........................................................................................ 81 Transfer case....................................................................................... 81 Axle lines.......................................................................................... 81 Steering............................................................................................ 82 Tyres............................................................................................... 82 Turning turning radii............................................................................... 82 Outrigger........................................................................................... 83 Electrical system................................................................................... 84 Tool................................................................................................ 84 Towing couplings................................................................................... 84 Driving speeds...................................................................................... 84 Climbing ability.................................................................................... 84 1.5.5 Superstructure.................................................................................... 85 Main hoist.......................................................................................... 85 Auxiliary hoist..................................................................................... 85 Slewing gears....................................................................................... 85 Derricking gear..................................................................................... 85 Main boom........................................................................................... 86 Lattice extension................................................................................... 86 Operating speeds.................................................................................... 86 1.6 Documentation supplied.................................................................................. 87 1.6.1 Questions on documentation........................................................................ 88 1.7 Notes on the operating manual........................................................................... 89 1.7.1 What do the symbols used mean?.................................................................... 89 1.7.2 How is the operating manual structured?........................................................... 91 Division............................................................................................ 91 Structure of thechapters........................................................................... 91 Structure of thepages.............................................................................. 92 1.7.3 How do I find the information I need?............................................................. 93 Cross-references example............................................................................ 94 1.7.4 What information is available for operations planning?............................................ 96 1.8 Conversion table for US measuring units................................................................. 97 1.9 Training – Information.................................................................................. 99 1.10 Identification......................................................................................... 100 1.11 EC Declaration of Conformity........................................................................... 102 2 Basic safety instructions..................................................................................... 103 2.1 Intended use............................................................................................ 103 2.1.1 Improper use...................................................................................... 104 2.2 Organisational measures................................................................................. 105 2.3 Personnel qualifications................................................................................ 107 2.4 Safety instructions for driving the truck crane......................................................... 108 2.5 Safety instructions for crane operation................................................................. 109 2.6 Instructions on transporting persons.................................................................... 112 Equipment for lifting persons........................................................................... 112 Personnel............................................................................................... 112 Operation............................................................................................... 113 Truck crane............................................................................................. 114 Driving............................................................................................................. 115 3 Operating elements for driving................................................................................ 115 3.1 Overview of the operating elements...................................................................... 115 3.1.1 On the outside of the truck crane................................................................. 116 3.1.2 Driver's cab...................................................................................... 120 Front overview...................................................................................... 120 Rear overview....................................................................................... 122 Behind the cover................................................................................... 123 3.1.3 Steering column/steering wheel.................................................................... 124 3.1.4 Instrument panel.................................................................................. 125 Left/right.......................................................................................... 125 Middle.............................................................................................. 126 3.1.5 Transmission operating elements................................................................... 128 3.1.6 On-board computer................................................................................. 129 3.1.7 Tachograph........................................................................................ 130 3.1.8 Heating and air-conditioning system............................................................... 131 Standard............................................................................................ 131 Auxiliary water heating system.................................................................... 132 Auxiliary air heater............................................................................... 133 3.1.9 CCS control unit.................................................................................. 135 3.1.10 CCS – menu-dependent displays.................................................................... 136 3.1.11 CCS – Start menu................................................................................. 137 3.1.12 CCS – Overview menu groups....................................................................... 138 3.1.13 Carrier menu group............................................................................... 140 Suspension/ level adjustment menu.................................................................. 141 Driving menu....................................................................................... 142 3.1.14 Settings menu group.............................................................................. 143 Set display brightness and date/time menu........................................................... 144 Switch units menu................................................................................... 145 3.1.15 Menu group Information........................................................................... 146 Operating hours menu............................................................................... 147 Engine/transmission error menu..................................................................... 148 Crane operation error menu......................................................................... 149 3.1.16 Various controls menu group...................................................................... 150 3.1.17 Emergency operations menu group.................................................................. 151 3.1.18 Outrigger control units.......................................................................... 152 3.2 Short description of the operating elements............................................................. 153 3.2.1 Definition of information relating to directions of movement...................................... 154 Basic rule.......................................................................................... 154 3.2.2 General rules for buttons and symbols on the display.............................................. 155 3.2.3 Motor............................................................................................. 156 Steering column..................................................................................... 156 On the steering wheel............................................................................... 156 Instrument panel.................................................................................... 157 3.2.4 AdBlue system..................................................................................... 158 Instrument panel.................................................................................... 158 CCS display......................................................................................... 159 3.2.5 Battery master switch............................................................................. 159 3.2.6 Electrical system................................................................................. 160 3.2.7 Crane control CCS................................................................................. 161 3.2.8 Transmission...................................................................................... 163 Transmission control unit........................................................................... 163 Display, driving mode,.............................................................................. 165 3.2.9 Reverse camera.................................................................................... 166 3.2.10 BirdView system 270 ............................................................................. 167 3.2.11 Transfer case.................................................................................... 169 3.2.12 Final drive...................................................................................... 170 3.2.13 Brakes........................................................................................... 172 Service brake....................................................................................... 172 Parking brake....................................................................................... 172 Additional brakes................................................................................... 173 3.2.14 Steering/separate steering....................................................................... 174 Instrument panel.................................................................................... 174 CCS display......................................................................................... 175 3.2.15 Suspension....................................................................................... 178 CCS display......................................................................................... 178 3.2.16 Lighting/windscreen wipers/horn.................................................................. 179 Steering column..................................................................................... 179 Steering wheel...................................................................................... 179 Instrument panel.................................................................................... 179 CCS display......................................................................................... 181 Roof................................................................................................ 181 3.2.17 Level adjustment system.......................................................................... 182 3.2.18 Tachograph/speedometer........................................................................... 184 Tachograph.......................................................................................... 184 Covers.............................................................................................. 184 Speedometer......................................................................................... 184 3.2.19 Diagnostics...................................................................................... 185 3.2.20 Push-up roof..................................................................................... 185 3.2.21 On-board computer................................................................................ 186 3.2.22 Front flap....................................................................................... 187 3.2.23 Windows and doors................................................................................ 188 Window winder....................................................................................... 188 Doors............................................................................................... 189 3.2.24 Access ladders and ladders....................................................................... 191 4 Starting the engine for driving / switching it off............................................................ 195 4.1 Starting the engine from the driver's cab............................................................... 195 4.1.1 CHECKLIST: Starting the engine.................................................................... 195 4.1.2 CHECKLIST: At low temperatures.................................................................... 198 4.1.3 Filling up........................................................................................ 199 Fuel tank........................................................................................... 199 AdBlue tank......................................................................................... 201 4.1.4 Checks before starting the engine................................................................. 202 At the hydraulic tank............................................................................... 202 Battery master switch............................................................................... 203 Checking the hand-held control...................................................................... 203 4.1.5 Switch the ignition on............................................................................ 203 4.1.6 Lamp test/equalisation of the switching states.................................................... 204 Lamp test........................................................................................... 204 Switching state alignment........................................................................... 204 4.1.7 Display – setting the brightness.................................................................. 205 4.1.8 Starting the engine............................................................................... 207 4.1.9 Checks after starting the engine.................................................................. 209 Start menu and on-board computer.................................................................... 209 Instrument panel.................................................................................... 210 4.1.10 Setting the idling speed......................................................................... 211 4.2 Switch off the engine................................................................................... 212 4.2.1 At the ignition lock and with the outrigger control units......................................... 212 After switching off................................................................................ 212 4.2.2 Using the emergency stop switches................................................................. 213 Resetting the emergency stop switch................................................................. 213 4.3 Air intake inhibitor.................................................................................... 214 Releasing the air intake inhibitor...................................................................... 214 5 Driving....................................................................................................... 215 5.1 Before driving.......................................................................................... 215 5.1.1 CHECKLIST: Checks before on-road driving.......................................................... 215 5.1.2 Check the condition of the truck crane............................................................ 221 Electrical system................................................................................... 221 Adjusting the mirrors............................................................................... 221 Warning plates for vehicle width.................................................................... 222 Checking the vehicle height......................................................................... 223 Supply pressure..................................................................................... 224 Parking brake....................................................................................... 225 5.1.3 Adjusting the seat and the steering column........................................................ 227 Adjusting the driver's seat........................................................................ 227 Adjusting the passenger seat....................................................................... 228 Adjusting the steering column...................................................................... 229 5.1.4 Switching the suspension on/off................................................................... 230 Open menu........................................................................................... 230 Switching the suspension on........................................................................ 231 Switching the suspension off....................................................................... 231 5.1.5 Setting the tachograph............................................................................ 232 Prerequisites....................................................................................... 232 In the event of malfunctions........................................................................ 232 Setting the tachograph............................................................................. 233 5.1.6 Setting the time.................................................................................. 237 5.1.7 Displaying and resetting operating hours.......................................................... 238 5.2 Operating the transmission.............................................................................. 239 5.2.1 Switching on...................................................................................... 239 5.2.2 Switching the transmission to the neutral position................................................ 240 5.2.3 Selecting the direction of travel and starting gear............................................... 241 Selecting the driving direction.................................................................... 241 Selecting the starting gear ...................................................................... 242 5.2.4 Changing the operating mode....................................................................... 243 Changing to automatic mode.......................................................................... 243 Change to manualmode............................................................................... 243 5.2.5 Starting.......................................................................................... 244 5.2.6 Driving and changing gears........................................................................ 245 In automatic operating mode......................................................................... 245 In manual operating mode............................................................................ 246 5.2.7 Changing the driving direction.................................................................... 247 5.2.8 Stopping.......................................................................................... 247 Stopping for longer periods........................................................................ 247 5.2.9 On the roller type dynamometer.................................................................... 248 5.2.10 Preheating transmission.......................................................................... 248 5.3 Driving the truck crane and switching it off............................................................ 249 5.3.1 Checks whilst driving............................................................................. 249 Brakes.............................................................................................. 249 ABS system.......................................................................................... 249 Steering............................................................................................ 250 Warning messages.................................................................................... 250 Monitoring elements................................................................................. 251 5.3.2 Cruise control.................................................................................... 252 Switching on........................................................................................ 252 Switching off....................................................................................... 253 5.3.3 Temposet.......................................................................................... 254 Switching on........................................................................................ 254 Switching off....................................................................................... 254 5.3.4 Driving downhill.................................................................................. 255 Starting............................................................................................ 255 Checks when driving downhill....................................................................... 256 Downshifting........................................................................................ 256 Additional brakes................................................................................... 257 5.3.5 Driving uphill.................................................................................... 258 Starting............................................................................................ 258 Driving............................................................................................. 258 5.3.6 Overriding torque reduction....................................................................... 259 5.3.7 Switching the truck crane off..................................................................... 260 Secure it against rolling away...................................................................... 260 When stationary for more than 8 hours............................................................... 261 5.3.8 Fold-up berth..................................................................................... 262 5.4 Off-road driving........................................................................................ 263 Adjustments to the transmission......................................................................... 263 Connections............................................................................................. 263 Changing the vehicle level.............................................................................. 263 Rocking the vehicle free and towing..................................................................... 263 5.4.1 Transfer case – switching the off-road gear on/off................................................ 264 Neutral position.................................................................................... 264 5.4.2 Longitudinal and transverse differential locks.................................................... 265 5.4.3 Operating the level adjustment system............................................................. 267 Open menu........................................................................................... 267 Setting the on-road level.......................................................................... 268 Pre-selecting suspension struts.................................................................... 268 Changing the vehicle level.......................................................................... 269 Viewing the current inclination..................................................................... 270 Exiting the menu................................................................................... 270 5.4.4 Freeing truck crane stuck in terrain.............................................................. 271 Rocking the truck crane free....................................................................... 271 Towing free forwards............................................................................... 272 Towing free totherear............................................................................ 272 5.5 Separate steering....................................................................................... 273 5.5.1 Switching to separate steering.................................................................... 274 5.5.2 Switching to normal steering mode................................................................. 277 5.5.3 Switching units of measure........................................................................ 278 5.6 Heating and air-conditioning system..................................................................... 279 5.6.1 Standard heating system........................................................................... 279 Switching on........................................................................................ 279 Heating............................................................................................. 279 Air distribution.................................................................................... 280 Examples............................................................................................ 281 Switching off....................................................................................... 281 5.6.2 Air-conditioning system........................................................................... 282 Information......................................................................................... 282 Switching on/off.................................................................................... 282 Cooling............................................................................................. 283 Drying.............................................................................................. 283 5.6.3 Auxiliary water heating system.................................................................... 284 Preheating theengine.............................................................................. 284 Preheating the driver's cab........................................................................ 285 Switching on........................................................................................ 285 Setting the date and time........................................................................... 287 Storing the heating start.......................................................................... 288 5.6.4 Auxiliary air heater.............................................................................. 290 Switching on........................................................................................ 290 Setting the heating level.......................................................................... 291 Setting the day and time........................................................................... 292 Setting the preselection time....................................................................... 292 Deleting preselection times......................................................................... 294 Switching off....................................................................................... 294 5.7 Radio................................................................................................... 294 5.8 Towing a trailer........................................................................................ 295 Effects on theaxleloads............................................................................... 295 Coupling the trailer................................................................................... 296 Connecting the supply lines............................................................................ 297 Removing supply lines................................................................................. 298 Uncoupling thetrailer................................................................................. 298 Checking the braking force.............................................................................. 300 6 Driving modes................................................................................................. 301 6.1 Driving modes........................................................................................... 301 Information about the axle loads........................................................................ 301 6.1.1 How to use the tables............................................................................ 302 6.1.2 Table for a maximum axle load of 12 t............................................................. 303 385/95 R25 tyres.................................................................................... 303 445/95 R25 tyres.................................................................................... 305 525/80 R25 tyres.................................................................................... 306 6.1.3 Maximum permitted speeds with an axle load of over 12 t........................................... 307 6.2 Weighing the truck crane................................................................................ 309 Axle groups............................................................................................. 310 Weighing procedure...................................................................................... 311 Evaluation.............................................................................................. 312 6.3 Rigging work for driving with a dolly................................................................... 313 6.3.1 Switching on the slewing gear freewheel........................................................... 314 6.3.2 Switching on the boom floating position........................................................... 315 6.3.3 Switching on boom pre-tensioning.................................................................. 316 6.4 Rigging the auxiliary hoist............................................................................. 317 6.4.1 Slinging the auxiliary hoist...................................................................... 317 6.4.2 CHECKLIST: Installing the auxiliary hoist......................................................... 318 6.4.3 CHECKLIST: Removing the auxiliary hoist........................................................... 319 6.4.4 Making/breaking the connection between the auxiliary hoist and the turntable...................... 320 6.4.5 Establishing/disconnecting the hydraulic connections.............................................. 321 6.4.6 Disconnecting/establishing the electrical connection.............................................. 322 6.4.7 Making/breaking the connection to the central lubrication......................................... 323 6.4.8 Transporting the auxiliary hoist.................................................................. 324 6.4.9 Check that the auxiliary hoist is functioning properly............................................ 325 Slewing direction................................................................................... 325 Slewing indicator................................................................................... 325 6.4.10 Rigging aid for the hoist rope................................................................... 326 6.5 Installing/removing the outrigger beams................................................................. 329 6.5.1 CHECKLIST: Removing the outrigger beams........................................................... 330 6.5.2 CHECKLIST: Installing the outrigger beams......................................................... 332 6.5.3 Centre of gravity data............................................................................ 334 6.5.4 Preparations – for removal........................................................................ 334 6.5.5 Preparations – on the truck crane................................................................. 335 Prerequisites....................................................................................... 335 6.5.6 Removing/attaching outrigger pads................................................................. 336 Removing the outrigger pads........................................................................ 336 Attaching the outrigger pads....................................................................... 337 6.5.7 Disconnecting/establishing hydraulic connection................................................... 338 6.5.8 Disconnecting/establishing the electrical connection.............................................. 339 6.5.9 Unscrewing/screwing in the spacers................................................................ 340 Unscrewing.......................................................................................... 340 Screwing in......................................................................................... 341 6.5.10 Disconnecting/establishing the connections to the supporting box................................. 342 6.5.11 Pulling out/Inserting the outrigger beam......................................................... 342 Extending the outrigger beam....................................................................... 342 Inserting the outrigger beam........................................................................ 344 6.5.12 Transporting the outrigger beams................................................................. 346 6.5.13 Note on error messages with removed outrigger beams.............................................. 347 7 Transport..................................................................................................... 349 7.1 Transport with transport vehicle........................................................................ 349 7.1.1 CHECKLIST: Checks before transport................................................................ 350 7.1.2 Drive the truck crane on to the transport vehicle................................................. 352 Driving on.......................................................................................... 353 Lashing............................................................................................. 353 7.2 Transport by ship....................................................................................... 354 8 Malfunctions in driving mode.................................................................................. 355 8.1 Emergency stop switch................................................................................... 355 8.2 Procedure during malfunctions........................................................................... 356 8.2.1 What to do when a malfunction occurs in road traffic.............................................. 356 8.2.2 Procedure during engine malfunctions.............................................................. 357 8.2.3 Procedure during transmission malfunctions........................................................ 358 8.3 Warning and error messages.............................................................................. 359 8.3.1 Warning or malfunction messages on the instrument panel........................................... 359 Meaning of thelamps................................................................................ 359 8.3.2 Warning and malfunction messages on the on-board computer display................................. 363 Messages............................................................................................ 363 Symbols............................................................................................. 364 8.3.3 Warning messages on the CCS display............................................................... 367 Symbols in the display area......................................................................... 367 8.3.4 Engine/transmission error messages................................................................ 371 Open menu........................................................................................... 371 Exiting the menu.................................................................................... 371 8.4 Troubleshooting......................................................................................... 373 8.4.1 Malfunctions on the engine........................................................................ 373 When operating with the dual tank................................................................... 375 8.4.2 Faults on the Adblue system....................................................................... 375 8.4.3 Differential lock malfunctions.................................................................... 376 8.4.4 Transfer case malfunctions........................................................................ 376 8.4.5 Malfunctions in the transmission.................................................................. 377 8.4.6 Malfunctions of the steering...................................................................... 378 8.4.7 Malfunctions of the service brake................................................................. 379 8.4.8 Malfunctions on the suspension.................................................................... 379 8.4.9 Malfunctions of the level adjustment system....................................................... 380 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 380 8.5 Emergency operation and breakdown assistance............................................................ 381 8.5.1 Starting the truck crane externally............................................................... 381 8.5.2 Battery charger................................................................................... 382 Prerequisites....................................................................................... 382 8.5.3 Towing the truck crane............................................................................ 383 In the case of engine/ transmission damage.......................................................... 383 Compressed-air supply............................................................................... 383 Longer towing distances............................................................................. 386 Tow starting........................................................................................ 386 8.5.4 Wheel change...................................................................................... 387 Removing a damaged wheel............................................................................ 388 On the spare wheel holder........................................................................... 388 Mounting a wheel.................................................................................... 389 8.5.5 Inflating the tyres yourself...................................................................... 391 Connecting thefilling hose......................................................................... 391 Inflating the tyres................................................................................. 392 Remove the fillinghose............................................................................ 392 8.5.6 Emergency operation, steering 3rd axle line....................................................... 393 Performing emergency operation..................................................................... 393 After emergency operation.......................................................................... 395 8.6 Tilting/lowering the driver's cab....................................................................... 397 8.6.1 Prerequisites and information on tilting.......................................................... 397 8.6.2 Tilting and lowering the driver's cab............................................................. 398 Operating the hand pump............................................................................. 398 Tilting the driver's cab............................................................................ 399 Lowering the driver's cab.......................................................................... 400 8.7 Fuses on the carrier.................................................................................... 403 Information on changing fuses......................................................................... 403 8.7.1 Fuses in the driver's cab......................................................................... 404 8.7.2 Fuses in the battery box.......................................................................... 410 Crane operation..................................................................................................... 411 9 Operating elements for crane operation........................................................................ 411 9.1 Overview of the operating elements...................................................................... 411 9.1.1 Exterior of the truck crane....................................................................... 412 9.1.2 Crane cab......................................................................................... 416 Side panel.......................................................................................... 418 Crane cab, rear..................................................................................... 420 9.1.3 Control panels.................................................................................... 422 Left................................................................................................ 422 Right............................................................................................... 423 9.1.4 Control lever assignment.......................................................................... 424 Version 1........................................................................................... 424 Version 2........................................................................................... 425 9.1.5 CCS control unit.................................................................................. 426 9.1.6 Menu-independent displays......................................................................... 428 9.1.7 CCS – Start menu.................................................................................. 429 RCL display......................................................................................... 430 Display Slewing ranges/working radii............................................................... 431 9.1.8 CCS – Overview menu groups........................................................................ 432 9.1.9 Superstructure menu group......................................................................... 436 Superstructure lock sub-menu...................................................................... 437 Counterweight menu.................................................................................. 438 9.1.10 Menu group outrigger/driving.................................................................... 439 Outrigger menu..................................................................................... 440 Outrigger cylinders menu........................................................................... 442 Driving mode menu.................................................................................. 444 9.1.11 RCL/Telescoping menu group....................................................................... 447 Menu enter rigging mode/ telescope................................................................. 448 Pre-selection telescoping menu..................................................................... 452 Lifting capacity tables menu........................................................................ 454 Telescoping semi- automation menu.................................................................. 455 Manual telescoping menu........................................................................... 456 9.1.12 Active working range limiter menu group.......................................................... 457 Overall height menu................................................................................ 458 Working radius menu................................................................................. 459 Slewing angle menu.................................................................................. 460 Hoist rope travel limitation menu................................................................... 461 9.1.13 Information menu group 1......................................................................... 462 Hydraulic pressure and fuel consumption menu........................................................ 463 9.1.14 Heating/Engine/Additional equipment menu group................................................... 464 Economy menu........................................................................................ 465 Remote control menu................................................................................. 466 Heating/ air-conditioning menu...................................................................... 467 Spotlights menu..................................................................................... 468 9.1.15 Telescoping emergency program menu group....................................................... 469 Telescoping emergency program menu................................................................ 470 Unknown telescoping menu........................................................................... 472 Swinging the swing-away lattice emergency operation menu............................................ 473 9.1.16 Settings menu group.............................................................................. 474 Crane cab menu...................................................................................... 475 Set display brightness and date/time menu........................................................... 476 Switch units menu................................................................................... 477 Set control lever characteristic curve menu......................................................... 478 Power unit speedsmenu............................................................................ 479 9.1.17 Information menu group 2......................................................................... 480 Operating hours menu................................................................................ 481 Engine/transmission errormenu...................................................................... 482 Crane operation error menu.......................................................................... 483 Program version menu................................................................................ 484 9.1.18 Various controls................................................................................. 485 9.1.19 RCL control unit................................................................................. 486 9.1.20 Menu-independent displays........................................................................ 487 9.1.21 RCL – menus...................................................................................... 488 Monitoring menu.................................................................................... 488 Lifting capacity tables menu........................................................................ 490 Datalogger menu..................................................................................... 491 9.1.22 Hand-held control................................................................................ 493 9.1.23 Outriggers control units......................................................................... 495 Menu- independent buttons.......................................................................... 495 Outrigger menu...................................................................................... 496 Raise axle menu.................................................................................... 498 9.2 Short description of the operating elements............................................................. 499 9.2.1 Definition of information relating to directions of movement...................................... 499 Basic rule.......................................................................................... 499 9.2.2 General rules for buttons and symbols on the display.............................................. 500 9.2.3 Engine............................................................................................ 501 Side panel......................................................................................... 501 Left control lever.................................................................................. 501 Economy mode menu................................................................................... 502 9.2.4 AdBlue system..................................................................................... 502 CCS display......................................................................................... 502 9.2.5 Seat contact switch and dead man's switch......................................................... 504 9.2.6 Crane control CCS................................................................................. 505 9.2.7 Outrigger – crane cab............................................................................. 510 Control panels...................................................................................... 510 CCS display......................................................................................... 511 9.2.8 Outrigger control units........................................................................... 513 General information................................................................................. 513 Outrigger menu...................................................................................... 514 9.2.9 Raise axle........................................................................................ 516 9.2.10 Inclination indicators........................................................................... 518 9.2.11 Outrigger pressure displays...................................................................... 519 Outrigger menu..................................................................................... 519 Outriggers control units........................................................................... 519 9.2.12 Anemometer displays.............................................................................. 519 9.2.13 Counterweight menu............................................................................... 520 9.2.14 Main hoist....................................................................................... 524 Control panels...................................................................................... 524 CCS display......................................................................................... 524 9.2.15 Auxiliary hoist.................................................................................. 526 Control panels...................................................................................... 526 CCS display......................................................................................... 526 9.2.16 Slewing gear..................................................................................... 528 Control panels...................................................................................... 528 CCS display......................................................................................... 529 9.2.17 Derricking gear.................................................................................. 530 Control panels...................................................................................... 530 CCS display......................................................................................... 531 Side panel.......................................................................................... 531 9.2.18 Telescoping mechanism............................................................................ 532 Control panels...................................................................................... 532 CCS display......................................................................................... 533 Telescoping semi- automation menu................................................................... 533 Manual telescoping menu............................................................................. 535 9.2.19 Hydraulic system................................................................................. 538 9.2.20 Superstructure lock/house lock menu.............................................................. 539 Superstructure lock................................................................................ 539 Houselock........................................................................................... 541 9.2.21 Remote control................................................................................... 542 9.2.22 Rated capacity limiter (RCL)..................................................................... 543 CCS display......................................................................................... 543 RCL display......................................................................................... 552 RCL override – version A............................................................................ 553 RCL override – version B............................................................................ 554 9.2.23 Electrical system................................................................................ 555 9.2.24 Lighting, windscreen wiper/washing system........................................................ 556 Lighting............................................................................................ 556 Windscreen wiper/washing system.................................................................... 558 Horn................................................................................................ 559 9.2.25 Hand-held control................................................................................ 560 Sockets for hand- held control...................................................................... 560 Engine control panel................................................................................ 561 Horn................................................................................................ 561 9.2.26 Windows and doors................................................................................ 564 Window.............................................................................................. 564 Rear window......................................................................................... 564 Crane cab door...................................................................................... 565 9.2.27 Diagnostics...................................................................................... 566 9.2.28 Other............................................................................................ 566 9.3 Short description of the operating elements – driving from the crane cab................................ 567 9.3.1 Driving mode menu................................................................................. 567 9.3.2 Transmission...................................................................................... 568 9.3.3 Final drive....................................................................................... 569 9.3.4 Brakes............................................................................................ 571 CCS display......................................................................................... 571 Side panel from above............................................................................... 572 9.3.5 Steering.......................................................................................... 573 CCS display......................................................................................... 573 Separate steering................................................................................... 574 Control panels...................................................................................... 575 10 Starting/switching off the engine – for crane operation...................................................... 577 10.1 When starting the engine for the first time in the day................................................. 577 10.2 Starting the engine – from the crane cab............................................................... 579 10.2.1 Check the fuel level and AdBlue level............................................................ 579 Fuel................................................................................................ 579 AdBlue.............................................................................................. 579 10.2.2 Checks before starting the engine................................................................ 580 Checks on the carrier.............................................................................. 580 Checking the hand-held control...................................................................... 580 At the hydraulic tank............................................................................... 580 10.2.3 Switch the ignition on........................................................................... 581 10.2.4 Comparison of switching states................................................................... 582 10.2.5 Display – setting the brightness................................................................. 582 10.2.6 Starting the engine.............................................................................. 583 10.2.7 Checks after starting the engine................................................................. 584 10.2.8 Setting the idling speed......................................................................... 585 10.3 Starting the engine – with the hand-held control....................................................... 586 10.4 Switch off the engine.................................................................................. 587 10.4.1 At the ignition lock and with hand-held control.................................................. 587 After switching off................................................................................ 587 10.4.2 With the idling button........................................................................... 587 10.4.3 Using the emergency stop switches................................................................ 588 Resetting the emergency stop switch................................................................. 588 11 Crane operation.............................................................................................. 589 11.1 Before operating the crane............................................................................. 589 11.1.1 CHECKLIST: Checks before operating the crane..................................................... 589 11.1.2 Check the condition of the truck crane........................................................... 593 Fuel tank auxiliary heater.......................................................................... 593 Visual inspection................................................................................... 593 Checking the position of the hoist ropes............................................................ 594 Checking the electrical system...................................................................... 595 11.1.3 Adjusting the crane cab seat and front control panel............................................. 596 Crane cab seat...................................................................................... 596 Front control panel................................................................................. 597 11.1.4 Checking the safety equipment.................................................................... 598 Rated capacity limiter.............................................................................. 598 Lifting limit switch............................................................................... 598 Emergency stop switch............................................................................... 599 Seat contact switch................................................................................ 600 11.1.5 Earthing the load................................................................................ 601 11.1.6 Preheating hydraulic oil......................................................................... 602 Prerequisites....................................................................................... 602 Preheating.......................................................................................... 602 11.1.7 Locking/unlocking the superstructure............................................................. 603 Locking points...................................................................................... 603 Lock the superstructure............................................................................ 604 Unlocking the superstructure....................................................................... 604 11.1.8 Switching the houselock on/off................................................................... 605 Switching on the houselock......................................................................... 605 Switching off the houselock........................................................................ 607 11.2 Standard slewing range type............................................................................ 609 11.2.1 Permissible slewing ranges and working positions................................................. 609 360 slewing range.................................................................................. 609 Working position 0 to the rear..................................................................... 609 180 to the front rigging position.................................................................. 609 11.3 MAXbase slewing range type............................................................................. 611 11.3.1 Specifications in the lifting capacity tables.................................................... 612 11.3.2 Enabled slewing ranges........................................................................... 613 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit....... 616 11.4 Operation of the rated capacity limiter................................................................ 617 11.4.1 Switch on the RCL................................................................................ 618 Switching on........................................................................................ 618 11.4.2 Enter rigging mode............................................................................... 620 Notes on Input..................................................................................... 620 Enter the slewing range type........................................................................ 621 Entering individual components...................................................................... 622 Entering the RCLcode.............................................................................. 628 11.4.3 Pre-selecting telescoping........................................................................ 628 11.4.4 Confirm the rigging mode and lifting capacity table.............................................. 629 Slewing range type Standard......................................................................... 629 Slewing range type MAXbase.......................................................................... 631 11.4.5 Checks before operating the crane................................................................ 633 Monitoring menu..................................................................................... 633 Checking the rigging mode........................................................................... 633 Hoist checking...................................................................................... 635 11.4.6 Display during the crane operation............................................................... 637 On the RCL display.................................................................................. 637 On the CCS display.................................................................................. 641 11.4.7 RCL early warning................................................................................ 645 11.4.8 RCL shutdown..................................................................................... 645 Shutdown due to overload............................................................................ 645 11.4.9 Displaying the lifting capacity tables........................................................... 647 Slewing range type Standard......................................................................... 647 Slewing range type MAXbase.......................................................................... 649 11.4.10 RCL override – version A........................................................................ 651 Overview statusdisplay............................................................................. 651 When rigging........................................................................................ 652 To raise the boom................................................................................... 653 In emergencies...................................................................................... 654 11.4.11 RCL override – version B........................................................................ 655 11.4.12 Datalogger...................................................................................... 656 Export data......................................................................................... 656 Display the data.................................................................................... 657 11.5 Crane operation with main boom......................................................................... 661 11.5.1 Checks during crane operation.................................................................... 661 Horizontal alignment................................................................................ 661 Safe distances..................................................................................... 661 Checking the windspeed............................................................................. 662 11.5.2 Main hoist....................................................................................... 663 Switching on themain hoist......................................................................... 664 Lifting and lowering............................................................................... 664 Maximum permissible hoist rope speed................................................................ 665 Switching off the main hoist....................................................................... 666 11.5.3 Auxiliary hoist.................................................................................. 667 Switching on the auxiliary hoist................................................................... 667 Lifting and lowering............................................................................... 668 Maximum permissible hoist rope speed................................................................ 669 Switching off the auxiliary hoist.................................................................. 669 11.5.4 Lifting limit switch and lowering limit switch................................................... 670 Lifting limit switch................................................................................ 670 Lowering limit switch............................................................................... 672 11.5.5 Derricking gear.................................................................................. 673 Switching on the derricking gear................................................................... 673 Raising and lowering................................................................................ 674 Maximum derricking speed............................................................................ 675 Re-enable raising function.......................................................................... 675 Switching off the derricking gear................................................................... 676 Lowering the main boom to a horizontal position..................................................... 676 11.5.6 Telescoping mechanism............................................................................ 677 Overview............................................................................................ 679 Telescoping process................................................................................. 680 Assignment for display.............................................................................. 682 Fixed length, intermediate length, telescoping length.............................................. 683 Telescoping......................................................................................... 684 Telescoping sequence............................................................................... 684 Inspections prior to starting operations........................................................... 685 Switching on thetelescoping mechanism.............................................................. 686 Function of the control lever....................................................................... 686 Switching off thetelescoping mechanism............................................................. 688 Manual telescoping................................................................................. 689 Checking the initial position....................................................................... 689 Unlocking the telescoping cylinder.................................................................. 691 Extending/retracting the telescoping cylinder....................................................... 693 Lock telescoping cylinder........................................................................... 694 Unlocking the telescopic section................................................................... 695 Telescoping the telescopic section................................................................. 696 Locking the telescopic section..................................................................... 697 Locking the telescopic section for on-road driving................................................. 698 Telescoping with semi-automaton..................................................................... 698 Telescoping with pre-selection...................................................................... 700 11.5.7 High-speed mode.................................................................................. 701 Derricking gear telescoping mechanism.............................................................. 701 Hoists.............................................................................................. 701 11.5.8 Slewing gear..................................................................................... 703 Slewing gear brake.................................................................................. 703 Switching on the slewing gear...................................................................... 704 Releasing the slewing gear brake.................................................................... 704 Applying the slewing gear brake..................................................................... 704 Releasing locked slewing gear....................................................................... 705 Slewing............................................................................................. 705 Permissible slewing speed.......................................................................... 706 Braking the slewing movement........................................................................ 707 Slewing gear freewheel.............................................................................. 707 Switching off the slewing gear..................................................................... 708 11.5.9 Switching the reduction of slewing speed on and off.............................................. 709 Switching reduction off............................................................................. 709 11.5.10 Possible movement combinations.................................................................. 710 11.6 Settings and displays for crane operation.............................................................. 711 11.6.1 Inclining the crane cab.......................................................................... 711 11.6.2 Setting the idling speed......................................................................... 712 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper...................................... 712 11.6.4 Limiting the power unit speeds................................................................... 713 11.6.5 Economy mode..................................................................................... 714 Switching on........................................................................................ 714 Ending/ switchingoff............................................................................... 716 11.6.6 Switching units of measure....................................................................... 716 11.6.7 Setting the characteristic curves for the control levers......................................... 717 11.6.8 Using the slewable spotlights.................................................................... 718 Manually swinging................................................................................... 719 Automatic load tracking............................................................................. 719 11.6.9 Overriding torque reduction...................................................................... 720 11.6.10 Displaying the operating hours.................................................................. 721 11.7 Working range limiter.................................................................................. 723 11.7.1 Viewing current settings......................................................................... 724 On the RCL display.................................................................................. 724 In the CCS Start menu............................................................................... 725 11.7.2 Opening the working range limiter menu........................................................... 725 11.7.3 Entering limit values............................................................................ 728 Overall height...................................................................................... 728 Working radius...................................................................................... 729 Slewing angle....................................................................................... 729 Hoist rope limitation............................................................................... 730 11.7.4 Entering limit values manually................................................................... 732 Limit values........................................................................................ 732 11.7.5 Switching monitoring functions on/off............................................................ 734 11.7.6 Shutdown by working range limiter................................................................ 735 11.8 Work break............................................................................................. 737 11.8.1 In case of short work breaks..................................................................... 737 11.8.2 In case of work breaks of more than 8 hours...................................................... 738 To secure the truck crane........................................................................... 738 11.9 Heating and air-conditioning system.................................................................... 739 11.9.1 Standard heating system.......................................................................... 739 Switching on........................................................................................ 739 Heating............................................................................................. 739 Air distribution.................................................................................... 740 Switching off....................................................................................... 740 11.9.2 Air-conditioning system.......................................................................... 741 Information......................................................................................... 741 Switching on/off.................................................................................... 741 Cooling, automatic.................................................................................. 742 Cooling, maximum.................................................................................... 742 11.9.3 Auxiliary heater................................................................................. 743 Switching on........................................................................................ 743 Setting the temperature............................................................................. 744 Setting the heating start/ heating duration......................................................... 744 Switching heating start on/off...................................................................... 745 11.10 CraneSTAR system...................................................................................... 746 11.10.1 Overview........................................................................................ 746 11.10.2 Position of the components...................................................................... 746 12 Rigging work................................................................................................. 747 12.1 Rigging work checklists for crane operation with the main boom......................................... 747 12.1.1 CHECKLIST: Rigging............................................................................... 747 12.1.2 CHECKLIST: Unrigging............................................................................. 753 12.2 Choice of a suitable positioning site.................................................................. 757 12.2.1 Determining the required load-bearing area....................................................... 757 12.2.2 Safe distance from slopes and pits............................................................... 760 12.2.3 Earthing the truck crane......................................................................... 761 12.2.4 Safe distance from overhead power lines.......................................................... 762 12.3 Rigging work after driving with a dolly................................................................ 765 12.3.1 Switching off the boom floating position......................................................... 765 12.3.2 Switching off the slewing gear freewheel......................................................... 766 Before slewing...................................................................................... 766 12.3.3 Switching off boom pre-tensioning................................................................ 767 12.4 Connecting/disconnecting the hand-held control......................................................... 769 12.5 Starting the engine for rigging........................................................................ 773 Prerequisites........................................................................................... 773 Starting the engine..................................................................................... 773 Turning off theengine.................................................................................. 773 12.6 Slewing range – only with the Standard slewing range type.............................................. 775 12.6.1 Representation in the lifting capacity tables.................................................... 775 12.6.2 Enabled outrigger spans.......................................................................... 776 12.7 Outriggers – Overview – MAXbase slewing range type..................................................... 777 12.7.1 Definitions...................................................................................... 777 12.7.2 Representation in the lifting capacity tables.................................................... 779 12.7.3 Enabled outrigger spans.......................................................................... 780 12.8 Outrigger operation.................................................................................... 785 12.8.1 CHECKLIST: Extending the outriggers.............................................................. 785 12.8.2 CHECKLIST: Retracting the outriggers............................................................. 787 12.8.3 Preparing the truck crane........................................................................ 788 Driver's cab........................................................................................ 788 Crane cab........................................................................................... 788 12.8.4 Setting the outrigger spans...................................................................... 790 For on-road driving................................................................................. 793 12.8.5 Extending/retracting outrigger beams............................................................. 793 From the controlunits.............................................................................. 794 From the cranecab.................................................................................. 795 12.8.6 Moving the outrigger pads into operating/driving position........................................ 797 12.8.7 Enlarging the load-bearing area.................................................................. 799 12.8.8 Extending/retracting supporting cylinders........................................................ 800 From the control units.............................................................................. 801 From the cranecab.................................................................................. 802 12.8.9 Levelling the truck crane on outriggers horizontally............................................. 804 Inclination indicators.............................................................................. 804 Prerequisites....................................................................................... 805 Manual alignment................................................................................... 806 Automatic alignment................................................................................. 806 12.8.10 Levelling the free-standing truck crane......................................................... 808 12.8.11 Operating the axle raising system............................................................... 810 12.8.12 Outrigger pressure display...................................................................... 812 12.9 Rigging/unrigging the counterweight.................................................................... 815 Counterweight display rigged............................................................................ 815 12.9.1 Information on rigging........................................................................... 815 When rigging........................................................................................ 815 When unrigging...................................................................................... 816 12.9.2 Counterweight sections........................................................................... 817 12.9.3 Identification................................................................................... 819 12.9.4 Slinging points on the counterweight sections.................................................... 820 12.9.5 CHECKLIST: Rigging the counterweight............................................................. 822 12.9.6 CHECKLIST: Unrigging the counterweight........................................................... 824 12.9.7 Assembling counterweight combination............................................................. 826 12.9.8 Counterweight hoist unit......................................................................... 831 Counterweight menu................................................................................. 831 Extending/ retracting the lifting cylinders......................................................... 832 Automatic moderigging............................................................................. 834 Automatic mode unrigging........................................................................... 836 Cancel automatic mode.............................................................................. 837 12.9.9 Setting down counterweight for driving........................................................... 838 Rear counterweight platform......................................................................... 838 Front counterweight platform........................................................................ 840 12.9.10 Unlocking/locking the rear counterweight platform............................................... 841 Unlocking........................................................................................... 841 Locking............................................................................................. 842 12.9.11 Slewing with rigged counterweight............................................................... 843 12.10 Rigging work on the main boom......................................................................... 845 12.10.1 Hook block on the bumper........................................................................ 845 Picking up the hook block........................................................................... 845 Attaching the hook block............................................................................ 846 12.10.2 Hook block on a separate vehicle................................................................ 847 Picking up the hook block.......................................................................... 848 Setting down thehook block........................................................................ 848 12.10.3 Hook block, separable........................................................................... 850 Rigging for on-road driving......................................................................... 850 Rigging for crane operation......................................................................... 851 12.10.4 Hook block with ballast plates.................................................................. 852 Removing............................................................................................ 852 Installing.......................................................................................... 853 Information on crane operation...................................................................... 853 12.10.5 Reeving and unreeving the hoist rope............................................................ 854 Reeving the hoistrope.............................................................................. 855 Unreeving hoistrope............................................................................... 859 12.10.6 Possible reevings on the main boom.............................................................. 860 With 5 head sheaves................................................................................. 860 With 6 head sheaves................................................................................. 863 With 7 head sheaves................................................................................. 865 12.10.7 Installing/removing the lifting limit switch.................................................... 866 Installing the lifting limit switch................................................................. 866 Removing the lifting limit switch................................................................... 869 12.10.8 Locking/unlocking the lifting limit switch...................................................... 871 Locking............................................................................................. 871 Removing the lock.................................................................................. 871 12.10.9 Anemometer and air traffic control light........................................................ 872 Installing.......................................................................................... 872 Switching on/off.................................................................................... 873 Removing............................................................................................ 873 12.11 Other rigging work.................................................................................... 875 12.11.1 Railings on the turntable....................................................................... 875 12.11.2 Folding the mirrors in and out, and adjusting them.............................................. 876 12.11.3 Slinging points for personal protective equipment............................................... 877 12.11.4 Cameras for crane operation..................................................................... 878 Camera on mainboom................................................................................. 878 Camera on thehoists................................................................................ 881 Camera on the driver's cab.......................................................................... 881 Operating the camera................................................................................ 882 12.11.5 Step at the crane cab........................................................................... 883 13 Driving with a rigged truck crane............................................................................ 885 13.1 Route.................................................................................................. 885 13.2 Permissible rigging modes and axle loads............................................................... 886 Axle load table........................................................................................ 886 13.2.1 To drive without a load.......................................................................... 889 13.2.2 To drive with a load............................................................................. 889 13.2.3 Axle loads....................................................................................... 890 13.3 Before driving the rigged truck crane.................................................................. 891 13.3.1 Check the tyre pressures and wind speed.......................................................... 891 13.3.2 Secure the superstructure against slewing........................................................ 891 13.3.3 Putting the truck crane on the wheels – with Raise axle function................................. 892 13.3.4 Putting the truck crane on the wheels – with the outriggers...................................... 894 13.4 Driving from the driver's cab.......................................................................... 897 13.4.1 Preparing to drive............................................................................... 897 Transmission........................................................................................ 897 Switching on separate steering...................................................................... 897 Connections......................................................................................... 897 13.4.2 Whilst driving................................................................................... 898 13.4.3 After driving.................................................................................... 899 13.5 Driving from the crane cab............................................................................. 901 13.5.1 Preparing to drive............................................................................... 902 13.5.2 Opening/closing the Driving menu................................................................. 902 Opening............................................................................................. 902 Crane's hydraulic system on/off..................................................................... 903 Closing............................................................................................. 904 13.5.3 Steering......................................................................................... 905 Switching on........................................................................................ 905 Steering direction.................................................................................. 905 Displays when steering.............................................................................. 906 Separate steering................................................................................... 906 Normal steering mode................................................................................ 910 13.5.4 Operating the transmission....................................................................... 911 Selecting the transmission mode.................................................................... 911 13.5.5 Whilst driving................................................................................... 912 DM and RM transmission mode......................................................................... 912 Transmission mode D................................................................................. 912 Warning messages.................................................................................... 912 13.5.6 Possible connections............................................................................. 913 Longitudinal/ transverse differential locks......................................................... 913 13.5.7 After driving.................................................................................... 915 14 Malfunctions during crane operation.......................................................................... 917 14.1 Emergency stop switch.................................................................................. 917 14.2 What to do when malfunctions occur during crane operation.............................................. 918 The load can be set down................................................................................ 918 Load cannot besetdown................................................................................. 918 14.3 Warning and error messages............................................................................. 919 Program version......................................................................................... 919 14.3.1 Warning messages on the CCS display.............................................................. 919 Meaning of thesymbols.............................................................................. 920 14.3.2 Error messages on the CCS display................................................................ 923 14.3.3 Warning messages on the RCL display.............................................................. 925 14.4 Troubleshooting........................................................................................ 929 14.4.1 Malfunctions on the engine....................................................................... 929 14.4.2 Malfunctions on the main hoist/auxiliary hoist................................................... 929 14.4.3 Malfunctions in the hoist cameras................................................................ 931 14.4.4 Malfunctions in the main boom camera............................................................. 931 14.4.5 Malfunctions on the derricking gear.............................................................. 932 14.4.6 Malfunctions in the telescoping mechanism........................................................ 933 14.4.7 Malfunctions on the slewing gear................................................................. 934 14.4.8 Malfunctions on the counterweight hoist unit..................................................... 936 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 936 14.4.10 Malfunctions when inclining the crane cab....................................................... 936 14.4.11 Malfunctions when operating with the hand-held control.......................................... 937 14.4.12 Malfunctions when inclining the crane cab....................................................... 937 14.4.13 Malfunctions when raising the axles............................................................. 937 14.4.14 Malfunctions of the outriggers.................................................................. 938 14.4.15 Malfunctions on the turntable lock.............................................................. 938 14.4.16 Malfunctions on the CCS/RCL control units....................................................... 939 14.4.17 Malfunctions when driving from the crane cab.................................................... 939 14.4.18 Malfunctions on the CraneSTAR system............................................................ 940 14.5 Emergency operations and programs...................................................................... 943 14.5.1 Mechanical emergency activation for retracting................................................... 944 Prior to the emergency operation, check............................................................. 944 Procedure........................................................................................... 944 Mechanical emergency activation.................................................................... 945 14.5.2 Telescoping emergency program.................................................................... 947 Checks before using the emergency program........................................................... 947 Telescoping emergency program menu.................................................................. 948 Notes on the displays............................................................................... 949 Checks in theemergency program.................................................................... 950 Retracting withemergency program................................................................... 954 Tables for approaching the locking points........................................................... 956 14.5.3 Entering the current telescoping................................................................. 959 14.5.4 Emergency operation with the hand-held control................................................... 961 To pre-select a power unit.......................................................................... 962 Operating apowerunit.............................................................................. 962 Stopping movements................................................................................. 963 Stopping movements in emergencies................................................................... 964 Switch off theengine............................................................................... 964 14.5.5 Notes on slewing in emergency operation.......................................................... 964 For the Standard slewing range type................................................................. 964 For the MAXbase slewing range type.................................................................. 966 14.6 Hydraulic emergency operation with the hand pump....................................................... 967 14.6.1 Operating principle.............................................................................. 967 14.6.2 Switching over the crane's hydraulic system...................................................... 967 14.6.3 Establishing the hydraulic circuits required..................................................... 968 Releasing/ securing valves.......................................................................... 968 Switching over valves............................................................................... 969 For lowering........................................................................................ 970 14.6.4 Performing emergency activation.................................................................. 971 14.6.5 After emergency activation....................................................................... 971 14.7 Hydraulic emergency operation as per BGR 159........................................................... 973 14.7.1 Applications and function........................................................................ 973 14.7.2 CHECKLIST: Emergency operation................................................................... 975 14.7.3 CHECKLIST: After emergency operation............................................................. 976 14.7.4 Connecting/removing transformer – for self-sufficiency........................................... 977 Connecting.......................................................................................... 977 Removing............................................................................................ 978 14.7.5 Switching emergency operation on/off............................................................. 979 14.7.6 Connecting/removing transformer – for external energy source..................................... 980 14.7.7 Establishing the required hydraulic circuits..................................................... 981 Switching overvalves............................................................................... 981 For lifting/ lowering............................................................................... 983 For slewing......................................................................................... 984 14.7.8 Performing emergency operation................................................................... 985 Slewing............................................................................................. 985 Derricking.......................................................................................... 986 Lifting/lowering.................................................................................... 986 14.7.9 Emergency supply of another crane................................................................ 987 For emergency supply................................................................................ 987 After emergency supply.............................................................................. 987 14.8 Fuses in the crane cab................................................................................. 989 Information on changing fuses......................................................................... 989 Index............................................................................................................... 995 A............................................................................................................... 997 B............................................................................................................... 997 C............................................................................................................... 998 D...............................................................................................................1000 E...............................................................................................................1002 F...............................................................................................................1004 H...............................................................................................................1004 I...............................................................................................................1005 L...............................................................................................................1005 M...............................................................................................................1006 O...............................................................................................................1007 P...............................................................................................................1008 R...............................................................................................................1008 S...............................................................................................................1009 T...............................................................................................................1011 V...............................................................................................................1013 W...............................................................................................................1013
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