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Grove Crane GMK 4100LB Operating Manual 3302799 – PDF DOWNLOAD
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Description
Grove Crane GMK 4100LB Operating Manual 3302799 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100LB Operating Manual 3302799 – PDF DOWNLOAD
Language : English
Pages : 1024
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 4100LB Operating Manual 3302799 – PDF DOWNLOAD
Intended use:
- The GMK4100LB truck crane is constructed in accordance with the latest
technology and the recognised safety regulations. Nevertheless, the operator
or third parties can still be endangered and the crane or other property
put at risk while using it. - The truck crane may be modified only with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK4100LB truck crane may be used only when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards. - Any malfunctions that could impair safety must be eliminated immediately.
The GMK4100LB truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
data, p. 1 – 7. - The GMK4100LB truck crane is designed solely for lifting loads which are
within the permitted GMK4100LB lifting capacities. The load must be slung
as prescribed to a hook block which is positioned vertically over the load
prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
manual(s), the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
- The GMK4100LB may only be operated with parts of equipment which have
been approved by Manitowoc Crane Group Germany GmbH and which are
labelled with the serial number of the GMK4100LB. - The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK4100LB truck crane. The user alone bears the risk.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 4100LB Operating Manual 3302799 – PDF DOWNLOAD
Operating manual........................................................................................................ 1 Correction sheets................................................................................................... 3 Hook blocks – Change / Correction .............................................................................. 3 Additional pages.................................................................................................... 5 MAXbase – Additional outrigger spans............................................................................ 5 Outrigger spans - Overview metres (feet) / per cent............................................................. 7 Driving from the crane cab...................................................................................... 9 Overview of Driving menu.................................................................................... 10 Brief description of the operating elements................................................................. 13 Driving menu............................................................................................ 13 Transmission............................................................................................ 15 Final drive............................................................................................. 17 Brakes.................................................................................................. 18 CCS display......................................................................................... 18 Side panel from above............................................................................... 18 Steering................................................................................................ 19 CCS display......................................................................................... 20 Control panels...................................................................................... 22 Driving from the crane cab.................................................................................. 23 Preparing to drive...................................................................................... 24 Opening/closing the Driving menu........................................................................ 25 Selecting the operating mode........................................................................ 25 Crane's hydraulic system Driving mode............................................................... 27 Closing menu........................................................................................ 27 Steering................................................................................................ 28 Switching on........................................................................................ 28 Display and steering direction...................................................................... 28 Switching the steering direction.................................................................... 29 Displays when steering.............................................................................. 29 Separate steering................................................................................... 30 Normal steering..................................................................................... 33 Operating the transmission.............................................................................. 34 Selecting the transmission mode..................................................................... 34 While driving........................................................................................... 35 Warning messages.................................................................................... 35 Possible connections.................................................................................... 36 Longitudinal/transverse differential locks.......................................................... 36 After driving........................................................................................... 38 Telescoping emergency programe.................................................................................. 39 Crane cab heating and air-conditioning system................................................................... 41 Operation from the driver's cab............................................................................. 41 Additional operating elements........................................................................... 41 Operation............................................................................................... 41 Table of contents................................................................................................... 45 General............................................................................................................. 75 1 Overview...................................................................................................... 75 1.1 Accidents............................................................................................... 75 1.2 Branch offices.......................................................................................... 77 1.2.1 Manitowoc Crane Care.............................................................................. 77 1.2.2 Dealer list....................................................................................... 77 1.3 Warranty specifications................................................................................. 77 1.4 Terms used.............................................................................................. 78 1.5 Technical data.......................................................................................... 81 1.5.1 Maximum lifting capacity (ASME B 30.5)............................................................ 81 1.5.2 Dimensions and weights of the truck crane, axle loads............................................. 82 Dimensions.......................................................................................... 83 Weight and axle loads............................................................................... 83 1.5.3 Dimensions and weights of removable parts......................................................... 84 Spare wheel......................................................................................... 84 Outrigger........................................................................................... 84 Hook blocks and hook tackle......................................................................... 85 Counterweight parts................................................................................ 88 Auxiliary hoist..................................................................................... 88 1.5.4 Carrier........................................................................................... 89 Motor............................................................................................... 89 Transmission........................................................................................ 89 Transfer case....................................................................................... 89 Axle lines.......................................................................................... 89 Steering............................................................................................ 90 Tyres............................................................................................... 90 Turning turning radii............................................................................... 90 Outrigger........................................................................................... 91 Electrical system................................................................................... 92 Tool................................................................................................ 92 Towing couplings................................................................................... 92 Driving speeds...................................................................................... 92 Climbing ability.................................................................................... 92 1.5.5 Superstructure.................................................................................... 93 Main hoist.......................................................................................... 93 Auxiliary hoist..................................................................................... 93 Slewing gears....................................................................................... 93 Derricking gear..................................................................................... 93 Main boom........................................................................................... 94 Lattice extension................................................................................... 94 Operating speeds.................................................................................... 94 1.6 Documentation supplied.................................................................................. 95 1.6.1 Questions on documentation........................................................................ 96 1.7 Notes on the operating manual........................................................................... 97 1.7.1 What do the symbols used mean?.................................................................... 97 1.7.2 How is the operating manual structured?........................................................... 99 Division............................................................................................ 99 Structure of thechapters........................................................................... 99 Structure of thepages.............................................................................. 100 1.7.3 How do I find the information I need?............................................................. 101 Cross-references example............................................................................ 102 1.7.4 What information is available for operations planning?............................................ 104 1.8 Conversion table for US measuring units................................................................. 105 1.9 Training – Information.................................................................................. 107 1.10 Identification......................................................................................... 108 1.11 EC Declaration of Conformity........................................................................... 110 2 Basic safety instructions..................................................................................... 111 2.1 Intended use............................................................................................ 111 2.1.1 Improper use...................................................................................... 112 2.2 Organisational measures................................................................................. 113 2.3 Personnel qualifications................................................................................ 115 2.4 Safety instructions for driving the truck crane......................................................... 116 2.5 Safety instructions for crane operation................................................................. 117 2.6 Instructions on transporting persons.................................................................... 120 Equipment for lifting persons........................................................................... 120 Personnel............................................................................................... 120 Operation............................................................................................... 121 Truck crane............................................................................................. 122 Driving............................................................................................................. 123 3 Operating elements for driving................................................................................ 123 3.1 Overview of the operating elements...................................................................... 123 3.1.1 On the outside of the truck crane................................................................. 124 3.1.2 Driver's cab...................................................................................... 128 Front overview...................................................................................... 128 Rear overview....................................................................................... 130 Behind the cover................................................................................... 131 3.1.3 Steering column/steering wheel.................................................................... 132 3.1.4 Instrument panel.................................................................................. 133 Left/right.......................................................................................... 133 Middle.............................................................................................. 134 3.1.5 Transmission operating elements................................................................... 136 3.1.6 On-board computer................................................................................. 137 3.1.7 Tachograph........................................................................................ 138 3.1.8 Heating and air-conditioning system............................................................... 139 Standard............................................................................................ 139 Auxiliary water heating system.................................................................... 140 Auxiliary air heater............................................................................... 141 3.1.9 CCS control unit.................................................................................. 143 3.1.10 CCS – menu-dependent displays.................................................................... 144 3.1.11 CCS – Start menu................................................................................. 145 3.1.12 CCS – Overview menu groups....................................................................... 146 3.1.13 Carrier menu group............................................................................... 148 Suspension/ level adjustment menu.................................................................. 149 Driving menu....................................................................................... 150 3.1.14 Settings menu group.............................................................................. 151 Set display brightness and date/time menu........................................................... 152 Switch units menu................................................................................... 153 3.1.15 Menu group Information........................................................................... 154 Operating hours menu............................................................................... 155 Engine/transmission error menu..................................................................... 156 Crane operation error menu......................................................................... 157 3.1.16 Various controls menu group...................................................................... 158 3.1.17 Emergency operations menu group.................................................................. 159 3.1.18 Outrigger control units.......................................................................... 160 3.2 Short description of the operating elements............................................................. 161 3.2.1 Definition of information relating to directions of movement...................................... 162 Basic rule.......................................................................................... 162 3.2.2 General rules for buttons and symbols on the display.............................................. 163 3.2.3 Motor............................................................................................. 164 Steering column..................................................................................... 164 On the steering wheel............................................................................... 164 Instrument panel.................................................................................... 165 3.2.4 AdBlue system..................................................................................... 166 Instrument panel.................................................................................... 166 CCS display......................................................................................... 167 3.2.5 Battery master switch............................................................................. 167 3.2.6 Electrical system................................................................................. 168 3.2.7 Crane control CCS................................................................................. 169 3.2.8 Transmission...................................................................................... 171 Transmission control unit........................................................................... 171 Display, driving mode,.............................................................................. 173 3.2.9 Reverse camera.................................................................................... 174 3.2.10 BirdView system 270 ............................................................................. 175 3.2.11 Transfer case.................................................................................... 177 3.2.12 Final drive...................................................................................... 178 3.2.13 Brakes........................................................................................... 180 Service brake....................................................................................... 180 Parking brake....................................................................................... 180 Additional brakes................................................................................... 181 3.2.14 Steering/separate steering....................................................................... 182 Instrument panel.................................................................................... 182 CCS display......................................................................................... 183 3.2.15 Suspension....................................................................................... 186 CCS display......................................................................................... 186 3.2.16 Lighting/windscreen wipers/horn.................................................................. 187 Steering column..................................................................................... 187 Steering wheel...................................................................................... 187 Instrument panel.................................................................................... 187 CCS display......................................................................................... 189 Roof................................................................................................ 189 3.2.17 Level adjustment system.......................................................................... 190 3.2.18 Tachograph/speedometer........................................................................... 192 Tachograph.......................................................................................... 192 Covers.............................................................................................. 192 Speedometer......................................................................................... 192 3.2.19 Diagnostics...................................................................................... 193 3.2.20 Push-up roof..................................................................................... 193 3.2.21 On-board computer................................................................................ 194 3.2.22 Front flap....................................................................................... 195 3.2.23 Windows and doors................................................................................ 196 Window winder....................................................................................... 196 Doors............................................................................................... 197 3.2.24 Access ladders and ladders....................................................................... 199 4 Starting the engine for driving / switching it off............................................................ 203 4.1 Starting the engine from the driver's cab............................................................... 203 4.1.1 CHECKLIST: Starting the engine.................................................................... 203 4.1.2 CHECKLIST: At low temperatures.................................................................... 206 4.1.3 Filling up........................................................................................ 207 Fuel tank........................................................................................... 207 AdBlue tank......................................................................................... 209 4.1.4 Checks before starting the engine................................................................. 210 At the hydraulic tank............................................................................... 210 Battery master switch............................................................................... 211 Checking the hand-held control...................................................................... 211 4.1.5 Switch the ignition on............................................................................ 211 4.1.6 Lamp test/equalisation of the switching states.................................................... 212 Lamp test........................................................................................... 212 Switching state alignment........................................................................... 212 4.1.7 Display – setting the brightness.................................................................. 213 4.1.8 Starting the engine............................................................................... 215 4.1.9 Checks after starting the engine.................................................................. 217 Start menu and on-board computer.................................................................... 217 Instrument panel.................................................................................... 218 4.1.10 Setting the idling speed......................................................................... 219 4.2 Switch off the engine................................................................................... 220 4.2.1 At the ignition lock and with the outrigger control units......................................... 220 After switching off................................................................................ 220 4.2.2 Using the emergency stop switches................................................................. 221 Resetting the emergency stop switch................................................................. 221 4.3 Air intake inhibitor.................................................................................... 222 Releasing the air intake inhibitor...................................................................... 222 5 Driving....................................................................................................... 223 5.1 Before driving.......................................................................................... 223 5.1.1 CHECKLIST: Checks before on-road driving.......................................................... 223 5.1.2 Check the condition of the truck crane............................................................ 229 Electrical system................................................................................... 229 Adjusting the mirrors............................................................................... 229 Warning plates for vehicle width.................................................................... 230 Checking the vehicle height......................................................................... 231 Supply pressure..................................................................................... 232 Parking brake....................................................................................... 233 5.1.3 Adjusting the seat and the steering column........................................................ 235 Adjusting the driver's seat........................................................................ 235 Adjusting the passenger seat....................................................................... 236 Adjusting the steering column...................................................................... 237 5.1.4 Switching the suspension on/off................................................................... 238 Open menu........................................................................................... 238 Switching the suspension on........................................................................ 239 Switching the suspension off....................................................................... 239 5.1.5 Setting the tachograph............................................................................ 240 Prerequisites....................................................................................... 240 In the event of malfunctions........................................................................ 240 Setting the tachograph............................................................................. 241 5.1.6 Setting the time.................................................................................. 245 5.1.7 Displaying and resetting operating hours.......................................................... 246 5.2 Operating the transmission.............................................................................. 247 5.2.1 Switching on...................................................................................... 247 5.2.2 Switching the transmission to the neutral position................................................ 248 5.2.3 Selecting the direction of travel and starting gear............................................... 249 Selecting the driving direction.................................................................... 249 Selecting the starting gear ...................................................................... 250 5.2.4 Changing the operating mode....................................................................... 251 Changing to automatic mode.......................................................................... 251 Change to manualmode............................................................................... 251 5.2.5 Starting.......................................................................................... 252 5.2.6 Driving and changing gears........................................................................ 253 In automatic operating mode......................................................................... 253 In manual operating mode............................................................................ 254 5.2.7 Changing the driving direction.................................................................... 255 5.2.8 Stopping.......................................................................................... 255 Stopping for longer periods........................................................................ 255 5.2.9 On the roller type dynamometer.................................................................... 256 5.2.10 Preheating transmission.......................................................................... 256 5.3 Driving the truck crane and switching it off............................................................ 257 5.3.1 Checks whilst driving............................................................................. 257 Brakes.............................................................................................. 257 ABS system.......................................................................................... 257 Steering............................................................................................ 258 Warning messages.................................................................................... 258 Monitoring elements................................................................................. 259 5.3.2 Cruise control.................................................................................... 260 Switching on........................................................................................ 260 Switching off....................................................................................... 261 5.3.3 Temposet.......................................................................................... 262 Switching on........................................................................................ 262 Switching off....................................................................................... 262 5.3.4 Driving downhill.................................................................................. 263 Starting............................................................................................ 263 Checks when driving downhill....................................................................... 264 Downshifting........................................................................................ 264 Additional brakes................................................................................... 265 5.3.5 Driving uphill.................................................................................... 266 Starting............................................................................................ 266 Driving............................................................................................. 266 5.3.6 Overriding torque reduction....................................................................... 267 5.3.7 Switching the truck crane off..................................................................... 268 Secure it against rolling away...................................................................... 268 When stationary for more than 8 hours............................................................... 269 5.3.8 Fold-up berth..................................................................................... 270 5.4 Off-road driving........................................................................................ 271 Adjustments to the transmission......................................................................... 271 Connections............................................................................................. 271 Changing the vehicle level.............................................................................. 271 Rocking the vehicle free and towing..................................................................... 271 5.4.1 Transfer case – switching the off-road gear on/off................................................ 272 Neutral position.................................................................................... 272 5.4.2 Longitudinal and transverse differential locks.................................................... 273 5.4.3 Operating the level adjustment system............................................................. 275 Open menu........................................................................................... 275 Setting the on-road level.......................................................................... 276 Pre-selecting suspension struts.................................................................... 276 Changing the vehicle level.......................................................................... 277 Viewing the current inclination..................................................................... 278 Exiting the menu................................................................................... 278 5.4.4 Freeing truck crane stuck in terrain.............................................................. 279 Rocking the truck crane free....................................................................... 279 Towing free forwards............................................................................... 280 Towing free totherear............................................................................ 280 5.5 Separate steering....................................................................................... 281 5.5.1 Switching to separate steering.................................................................... 282 5.5.2 Switching to normal steering mode................................................................. 285 5.5.3 Switching units of measure........................................................................ 286 5.6 Heating and air-conditioning system..................................................................... 287 5.6.1 Standard heating system........................................................................... 287 Switching on........................................................................................ 287 Heating............................................................................................. 287 Air distribution.................................................................................... 288 Examples............................................................................................ 289 Switching off....................................................................................... 289 5.6.2 Air-conditioning system........................................................................... 290 Information......................................................................................... 290 Switching on/off.................................................................................... 290 Cooling............................................................................................. 291 Drying.............................................................................................. 291 5.6.3 Auxiliary water heating system.................................................................... 292 Preheating theengine.............................................................................. 292 Preheating the driver's cab........................................................................ 293 Switching on........................................................................................ 293 Setting the date and time........................................................................... 295 Storing the heating start.......................................................................... 296 5.6.4 Auxiliary air heater.............................................................................. 298 Switching on........................................................................................ 298 Setting the heating level.......................................................................... 299 Setting the day and time........................................................................... 300 Setting the preselection time....................................................................... 300 Deleting preselection times......................................................................... 302 Switching off....................................................................................... 302 5.7 Radio................................................................................................... 302 5.8 Towing a trailer........................................................................................ 303 Effects on theaxleloads............................................................................... 303 Coupling the trailer................................................................................... 304 Connecting the supply lines............................................................................ 305 Removing supply lines................................................................................. 306 Uncoupling thetrailer................................................................................. 306 Checking the braking force.............................................................................. 308 6 Driving modes................................................................................................. 309 6.1 Driving modes........................................................................................... 309 Information about the axle loads........................................................................ 309 6.1.1 How to use the tables............................................................................ 310 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs)................................................ 311 385/95 R25 tyres.................................................................................... 311 445/95 R25 tyres.................................................................................... 313 525/80 R25 tyres.................................................................................... 314 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs).............................. 315 6.2 Weighing the truck crane................................................................................ 317 Axle groups............................................................................................. 318 Weighing procedure...................................................................................... 319 Evaluation.............................................................................................. 320 6.3 Rigging work for driving with a dolly................................................................... 321 6.3.1 Switching on the slewing gear freewheel........................................................... 322 6.3.2 Switching on the boom floating position........................................................... 323 6.3.3 Switching on boom pre-tensioning.................................................................. 324 6.4 Rigging the auxiliary hoist............................................................................. 325 6.4.1 Slinging the auxiliary hoist...................................................................... 325 6.4.2 CHECKLIST: Installing the auxiliary hoist......................................................... 326 6.4.3 CHECKLIST: Removing the auxiliary hoist........................................................... 327 6.4.4 Making/breaking the connection between the auxiliary hoist and the turntable...................... 328 6.4.5 Establishing/disconnecting the hydraulic connections.............................................. 329 6.4.6 Disconnecting/establishing the electrical connection.............................................. 330 6.4.7 Making/breaking the connection to the central lubrication......................................... 331 6.4.8 Transporting the auxiliary hoist.................................................................. 332 6.4.9 Check that the auxiliary hoist is functioning properly............................................ 333 Slewing direction................................................................................... 333 Slewing indicator................................................................................... 333 6.4.10 Rigging aid for the hoist rope................................................................... 334 6.5 Installing/removing the outrigger beams................................................................. 337 6.5.1 CHECKLIST: Removing the outrigger beams........................................................... 338 6.5.2 CHECKLIST: Installing the outrigger beams......................................................... 340 6.5.3 Centre of gravity data............................................................................ 342 6.5.4 Preparations – for removal........................................................................ 342 6.5.5 Preparations – on the truck crane................................................................. 343 Prerequisites....................................................................................... 343 6.5.6 Removing/attaching outrigger pads................................................................. 344 Removing the outrigger pads........................................................................ 344 Attaching the outrigger pads....................................................................... 345 6.5.7 Disconnecting/establishing hydraulic connection................................................... 346 6.5.8 Disconnecting/establishing the electrical connection.............................................. 347 6.5.9 Unscrewing/screwing in the spacers................................................................ 348 Unscrewing.......................................................................................... 348 Screwing in......................................................................................... 349 6.5.10 Disconnecting/establishing the connections to the supporting box................................. 350 6.5.11 Pulling out/Inserting the outrigger beam......................................................... 350 Extending the outrigger beam....................................................................... 350 Inserting the outrigger beam........................................................................ 352 6.5.12 Transporting the outrigger beams................................................................. 354 6.5.13 Note on error messages with removed outrigger beams.............................................. 355 7 Transport..................................................................................................... 357 7.1 Transport with transport vehicle........................................................................ 357 7.1.1 CHECKLIST: Checks before transport................................................................ 358 7.1.2 Drive the truck crane on to the transport vehicle................................................. 360 Driving on.......................................................................................... 361 Lashing............................................................................................. 361 7.2 Transport by ship....................................................................................... 362 8 Malfunctions in driving mode.................................................................................. 363 8.1 Emergency stop switch................................................................................... 363 8.2 Procedure during malfunctions........................................................................... 364 8.2.1 What to do when a malfunction occurs in road traffic.............................................. 364 8.2.2 Procedure during engine malfunctions.............................................................. 365 8.2.3 Procedure during transmission malfunctions........................................................ 366 8.3 Warning and error messages.............................................................................. 367 8.3.1 Warning or malfunction messages on the instrument panel........................................... 367 Meaning of thelamps................................................................................ 367 8.3.2 Warning and malfunction messages on the on-board computer display................................. 371 Messages............................................................................................ 371 Symbols............................................................................................. 372 8.3.3 Warning messages on the CCS display............................................................... 375 Symbols in the display area......................................................................... 375 8.3.4 Engine/transmission error messages................................................................ 379 Open menu........................................................................................... 379 Exiting the menu.................................................................................... 379 8.4 Troubleshooting......................................................................................... 381 8.4.1 Malfunctions on the engine........................................................................ 381 When operating with the dual tank................................................................... 383 8.4.2 Faults on the Adblue system....................................................................... 383 8.4.3 Differential lock malfunctions.................................................................... 384 8.4.4 Transfer case malfunctions........................................................................ 384 8.4.5 Malfunctions in the transmission.................................................................. 385 8.4.6 Malfunctions of the steering...................................................................... 386 8.4.7 Malfunctions of the service brake................................................................. 387 8.4.8 Malfunctions on the suspension.................................................................... 387 8.4.9 Malfunctions of the level adjustment system....................................................... 388 8.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 388 8.5 Emergency operation and breakdown assistance............................................................ 389 8.5.1 Starting the truck crane externally............................................................... 389 8.5.2 Battery charger................................................................................... 390 Prerequisites....................................................................................... 390 8.5.3 Towing the truck crane............................................................................ 391 In the case of engine/ transmission damage.......................................................... 391 Compressed-air supply............................................................................... 391 Longer towing distances............................................................................. 394 Tow starting........................................................................................ 394 8.5.4 Wheel change...................................................................................... 395 Removing a damaged wheel............................................................................ 396 On the spare wheel holder........................................................................... 396 Mounting a wheel.................................................................................... 397 8.5.5 Inflating the tyres yourself...................................................................... 399 Connecting thefilling hose......................................................................... 399 Inflating the tyres................................................................................. 400 Remove the fillinghose............................................................................ 400 8.5.6 Emergency operation, steering 3rd axle line....................................................... 401 Performing emergency operation..................................................................... 401 After emergency operation.......................................................................... 403 8.6 Tilting/lowering the driver's cab....................................................................... 405 8.6.1 Prerequisites and information on tilting.......................................................... 405 8.6.2 Tilting and lowering the driver's cab............................................................. 406 Operating the hand pump............................................................................. 406 Tilting the driver's cab............................................................................ 407 Lowering the driver's cab.......................................................................... 408 8.7 Fuses on the carrier.................................................................................... 411 Information on changing fuses......................................................................... 411 8.7.1 Fuses in the driver's cab......................................................................... 412 8.7.2 Fuses in the battery box.......................................................................... 418 Crane operation..................................................................................................... 419 9 Operating elements for crane operation........................................................................ 419 9.1 Overview of the operating elements...................................................................... 419 9.1.1 Exterior of the truck crane....................................................................... 420 9.1.2 Crane cab......................................................................................... 424 Side panel.......................................................................................... 426 Crane cab, rear..................................................................................... 428 9.1.3 Control panels.................................................................................... 430 Left................................................................................................ 430 Right............................................................................................... 431 9.1.4 Control lever assignment.......................................................................... 432 Version 1........................................................................................... 432 Version 2........................................................................................... 433 9.1.5 CCS control unit.................................................................................. 434 9.1.6 Menu-independent displays......................................................................... 436 9.1.7 CCS – Start menu.................................................................................. 437 RCL display......................................................................................... 438 Display Slewing ranges/working radii............................................................... 439 9.1.8 CCS – Overview menu groups........................................................................ 440 9.1.9 Superstructure menu group......................................................................... 444 Superstructure lock sub-menu...................................................................... 445 Counterweight menu.................................................................................. 446 9.1.10 Menu group outrigger/driving.................................................................... 447 Outrigger menu..................................................................................... 448 Outrigger cylinders menu........................................................................... 450 Driving mode menu.................................................................................. 452 9.1.11 RCL/Telescoping menu group....................................................................... 455 Menu enter rigging mode/ telescope................................................................. 456 Pre-selection telescoping menu..................................................................... 460 Lifting capacity tables menu........................................................................ 462 Telescoping semi- automation menu.................................................................. 463 Manual telescoping menu........................................................................... 464 9.1.12 Active working range limiter menu group.......................................................... 465 Overall height menu................................................................................ 466 Working radius menu................................................................................. 467 Slewing angle menu.................................................................................. 468 Hoist rope travel limitation menu................................................................... 469 9.1.13 Information menu group 1......................................................................... 470 Hydraulic pressure and fuel consumption menu........................................................ 471 9.1.14 Heating/Engine/Additional equipment menu group................................................... 472 Economy menu........................................................................................ 473 Remote control menu................................................................................. 474 Heating/ air-conditioning menu...................................................................... 475 Spotlights menu..................................................................................... 476 9.1.15 Telescoping emergency program menu group....................................................... 477 Telescoping emergency program menu................................................................ 478 Unknown telescoping menu........................................................................... 480 Swinging the swing-away lattice emergency operation menu............................................ 481 9.1.16 Settings menu group.............................................................................. 482 Crane cab menu...................................................................................... 483 Set display brightness and date/time menu........................................................... 484 Switch units menu................................................................................... 485 Set control lever characteristic curve menu......................................................... 486 Power unit speedsmenu............................................................................ 487 9.1.17 Information menu group 2......................................................................... 488 Operating hours menu................................................................................ 489 Engine/transmission errormenu...................................................................... 490 Crane operation error menu.......................................................................... 491 Program version menu................................................................................ 492 9.1.18 Various controls................................................................................. 493 9.1.19 RCL control unit................................................................................. 494 9.1.20 Menu-independent displays........................................................................ 495 9.1.21 RCL – menus...................................................................................... 496 Monitoring menu.................................................................................... 496 Lifting capacity tables menu........................................................................ 498 Datalogger menu..................................................................................... 499 9.1.22 Hand-held control................................................................................ 501 9.1.23 Outriggers control units......................................................................... 503 Menu- independent buttons.......................................................................... 503 Outrigger menu...................................................................................... 504 Raise axle menu.................................................................................... 506 9.2 Short description of the operating elements............................................................. 507 9.2.1 Definition of information relating to directions of movement...................................... 507 Basic rule.......................................................................................... 507 9.2.2 General rules for buttons and symbols on the display.............................................. 508 9.2.3 Engine............................................................................................ 509 Side panel......................................................................................... 509 Left control lever.................................................................................. 509 Economy mode menu................................................................................... 510 9.2.4 AdBlue system..................................................................................... 510 CCS display......................................................................................... 510 9.2.5 Seat contact switch and dead man's switch......................................................... 512 9.2.6 Crane control CCS................................................................................. 513 9.2.7 Outrigger – crane cab............................................................................. 518 Control panels...................................................................................... 518 CCS display......................................................................................... 519 9.2.8 Outrigger control units........................................................................... 521 General information................................................................................. 521 Outrigger menu...................................................................................... 522 9.2.9 Raise axle........................................................................................ 524 9.2.10 Inclination indicators........................................................................... 526 9.2.11 Outrigger pressure displays...................................................................... 527 Outrigger menu..................................................................................... 527 Outriggers control units........................................................................... 527 9.2.12 Anemometer displays.............................................................................. 527 9.2.13 Counterweight menu............................................................................... 528 9.2.14 Main hoist....................................................................................... 532 Control panels...................................................................................... 532 CCS display......................................................................................... 532 9.2.15 Auxiliary hoist.................................................................................. 534 Control panels...................................................................................... 534 CCS display......................................................................................... 534 9.2.16 Slewing gear..................................................................................... 536 Control panels...................................................................................... 536 CCS display......................................................................................... 537 9.2.17 Derricking gear.................................................................................. 538 Control panels...................................................................................... 538 CCS display......................................................................................... 539 Side panel.......................................................................................... 539 9.2.18 Telescoping mechanism............................................................................ 540 Control panels...................................................................................... 540 CCS display......................................................................................... 541 Telescoping semi- automation menu................................................................... 541 Manual telescoping menu............................................................................. 543 9.2.19 Hydraulic system................................................................................. 546 9.2.20 Superstructure lock/house lock menu.............................................................. 547 Superstructure lock................................................................................ 547 Houselock........................................................................................... 549 9.2.21 Remote control................................................................................... 550 9.2.22 Rated capacity limiter (RCL)..................................................................... 551 CCS display......................................................................................... 551 RCL display......................................................................................... 560 RCL override – version A............................................................................ 561 RCL override – version B............................................................................ 562 9.2.23 Electrical system................................................................................ 563 9.2.24 Lighting, windscreen wiper/washing system........................................................ 564 Lighting............................................................................................ 564 Windscreen wiper/washing system.................................................................... 566 Horn................................................................................................ 567 9.2.25 Hand-held control................................................................................ 568 Sockets for hand- held control...................................................................... 568 Engine control panel................................................................................ 569 Horn................................................................................................ 569 9.2.26 Windows and doors................................................................................ 572 Window.............................................................................................. 572 Rear window......................................................................................... 572 Crane cab door...................................................................................... 573 9.2.27 Diagnostics...................................................................................... 574 9.2.28 Other............................................................................................ 574 9.3 Short description of the operating elements – driving from the crane cab................................ 575 9.3.1 Driving mode menu................................................................................. 575 9.3.2 Transmission...................................................................................... 576 9.3.3 Final drive....................................................................................... 577 9.3.4 Brakes............................................................................................ 579 CCS display......................................................................................... 579 Side panel from above............................................................................... 580 9.3.5 Steering.......................................................................................... 581 CCS display......................................................................................... 581 Separate steering................................................................................... 582 Control panels...................................................................................... 583 10 Starting/switching off the engine – for crane operation...................................................... 585 10.1 When starting the engine for the first time in the day................................................. 585 10.2 Starting the engine – from the crane cab............................................................... 587 10.2.1 Check the fuel level and AdBlue level............................................................ 587 Fuel................................................................................................ 587 AdBlue.............................................................................................. 587 10.2.2 Checks before starting the engine................................................................ 588 Checks on the carrier.............................................................................. 588 Checking the hand-held control...................................................................... 588 At the hydraulic tank............................................................................... 588 10.2.3 Switch the ignition on........................................................................... 589 10.2.4 Comparison of switching states................................................................... 590 10.2.5 Display – setting the brightness................................................................. 590 10.2.6 Starting the engine.............................................................................. 591 10.2.7 Checks after starting the engine................................................................. 592 10.2.8 Setting the idling speed......................................................................... 593 10.3 Starting the engine – with the hand-held control....................................................... 594 10.4 Switch off the engine.................................................................................. 595 10.4.1 At the ignition lock and with hand-held control.................................................. 595 After switching off................................................................................ 595 10.4.2 With the idling button........................................................................... 595 10.4.3 Using the emergency stop switches................................................................ 596 Resetting the emergency stop switch................................................................. 596 11 Crane operation.............................................................................................. 597 11.1 Before operating the crane............................................................................. 597 11.1.1 CHECKLIST: Checks before operating the crane..................................................... 597 11.1.2 Check the condition of the truck crane........................................................... 601 Fuel tank auxiliary heater.......................................................................... 601 Visual inspection................................................................................... 601 Checking the position of the hoist ropes............................................................ 602 Checking the electrical system...................................................................... 603 11.1.3 Adjusting the crane cab seat and front control panel............................................. 604 Crane cab seat...................................................................................... 604 Front control panel................................................................................. 605 11.1.4 Checking the safety equipment.................................................................... 606 Rated capacity limiter.............................................................................. 606 Lifting limit switch............................................................................... 606 Emergency stop switch............................................................................... 607 Seat contact switch................................................................................ 608 11.1.5 Earthing the load................................................................................ 609 11.1.6 Preheating hydraulic oil......................................................................... 610 Prerequisites....................................................................................... 610 Preheating.......................................................................................... 610 11.1.7 Locking/unlocking the superstructure............................................................. 611 Locking points...................................................................................... 611 Lock the superstructure............................................................................ 612 Unlocking the superstructure....................................................................... 612 11.1.8 Switching the houselock on/off................................................................... 613 Switching on the houselock......................................................................... 613 Switching off the houselock........................................................................ 615 11.2 Standard slewing range type............................................................................ 617 11.2.1 Permissible slewing ranges and working positions................................................. 617 360 slewing range.................................................................................. 617 Working position 0 to the rear..................................................................... 617 180 to the front rigging position.................................................................. 617 11.3 MAXbase slewing range type............................................................................. 619 11.3.1 Specifications in the lifting capacity tables.................................................... 620 11.3.2 Enabled slewing ranges........................................................................... 621 11.3.3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacit....... 624 11.4 Operation of the rated capacity limiter................................................................ 625 11.4.1 Switch on the RCL................................................................................ 626 Switching on........................................................................................ 626 11.4.2 Enter rigging mode............................................................................... 628 Notes on Input..................................................................................... 628 Enter the slewing range type........................................................................ 629 Entering individual components...................................................................... 630 Entering the RCLcode.............................................................................. 636 11.4.3 Pre-selecting telescoping........................................................................ 636 11.4.4 Confirm the rigging mode and lifting capacity table.............................................. 637 Slewing range type Standard......................................................................... 637 Slewing range type MAXbase.......................................................................... 639 11.4.5 Checks before operating the crane................................................................ 641 Monitoring menu..................................................................................... 641 Checking the rigging mode........................................................................... 641 Hoist checking...................................................................................... 643 11.4.6 Display during the crane operation............................................................... 645 On the RCL display.................................................................................. 645 On the CCS display.................................................................................. 649 11.4.7 RCL early warning................................................................................ 653 11.4.8 RCL shutdown..................................................................................... 653 Shutdown due to overload............................................................................ 653 11.4.9 Displaying the lifting capacity tables........................................................... 655 Slewing range type Standard......................................................................... 655 Slewing range type MAXbase.......................................................................... 657 11.4.10 RCL override – version A........................................................................ 659 Overview statusdisplay............................................................................. 659 When rigging........................................................................................ 660 To raise the boom................................................................................... 661 In emergencies...................................................................................... 662 11.4.11 RCL override – version B........................................................................ 663 11.4.12 Datalogger...................................................................................... 664 Export data......................................................................................... 664 Display the data.................................................................................... 665 11.5 Crane operation with main boom......................................................................... 669 11.5.1 Checks during crane operation.................................................................... 669 Horizontal alignment................................................................................ 669 Safe distances..................................................................................... 669 Checking the windspeed............................................................................. 670 11.5.2 Main hoist....................................................................................... 671 Switching on themain hoist......................................................................... 672 Lifting and lowering............................................................................... 672 Maximum permissible hoist rope speed................................................................ 673 Switching off the main hoist....................................................................... 674 11.5.3 Auxiliary hoist.................................................................................. 675 Switching on the auxiliary hoist................................................................... 675 Lifting and lowering............................................................................... 676 Maximum permissible hoist rope speed................................................................ 677 Switching off the auxiliary hoist.................................................................. 677 11.5.4 Lifting limit switch and lowering limit switch................................................... 678 Lifting limit switch................................................................................ 678 Lowering limit switch............................................................................... 680 11.5.5 Derricking gear.................................................................................. 681 Switching on the derricking gear................................................................... 681 Raising and lowering................................................................................ 682 Maximum derricking speed............................................................................ 683 Re-enable raising function.......................................................................... 683 Switching off the derricking gear................................................................... 684 Lowering the main boom to a horizontal position..................................................... 684 11.5.6 Telescoping mechanism............................................................................ 685 Overview............................................................................................ 687 Telescoping process................................................................................. 688 Assignment for display.............................................................................. 690 Fixed length, intermediate length, telescoping length.............................................. 691 Telescoping......................................................................................... 692 Telescoping sequence............................................................................... 692 Inspections prior to starting operations........................................................... 693 Switching on thetelescoping mechanism.............................................................. 694 Function of the control lever....................................................................... 694 Switching off thetelescoping mechanism............................................................. 696 Manual telescoping................................................................................. 697 Checking the initial position....................................................................... 697 Unlocking the telescoping cylinder.................................................................. 699 Extending/retracting the telescoping cylinder....................................................... 701 Lock telescoping cylinder........................................................................... 702 Unlocking the telescopic section................................................................... 703 Telescoping the telescopic section................................................................. 704 Locking the telescopic section..................................................................... 705 Locking the telescopic section for on-road driving................................................. 706 Telescoping with semi-automaton..................................................................... 706 Telescoping with pre-selection...................................................................... 708 11.5.7 High-speed mode.................................................................................. 709 Derricking gear telescoping mechanism.............................................................. 709 Hoists.............................................................................................. 709 11.5.8 Slewing gear..................................................................................... 711 Slewing gear brake.................................................................................. 711 Switching on the slewing gear...................................................................... 712 Releasing the slewing gear brake.................................................................... 712 Applying the slewing gear brake..................................................................... 712 Releasing locked slewing gear....................................................................... 713 Slewing............................................................................................. 713 Permissible slewing speed.......................................................................... 714 Braking the slewing movement........................................................................ 715 Slewing gear freewheel.............................................................................. 715 Switching off the slewing gear..................................................................... 716 11.5.9 Switching the reduction of slewing speed on and off.............................................. 717 Switching reduction off............................................................................. 717 11.5.10 Possible movement combinations.................................................................. 718 11.6 Settings and displays for crane operation.............................................................. 719 11.6.1 Inclining the crane cab.......................................................................... 719 11.6.2 Setting the idling speed......................................................................... 720 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper...................................... 720 11.6.4 Limiting the power unit speeds................................................................... 721 11.6.5 Economy mode..................................................................................... 722 Switching on........................................................................................ 722 Ending/ switchingoff............................................................................... 724 11.6.6 Switching units of measure....................................................................... 724 11.6.7 Setting the characteristic curves for the control levers......................................... 725 11.6.8 Using the slewable spotlights.................................................................... 726 Manually swinging................................................................................... 727 Automatic load tracking............................................................................. 727 11.6.9 Overriding torque reduction...................................................................... 728 11.6.10 Displaying the operating hours.................................................................. 729 11.7 Working range limiter.................................................................................. 731 11.7.1 Viewing current settings......................................................................... 732 On the RCL display.................................................................................. 732 In the CCS Start menu............................................................................... 733 11.7.2 Opening the working range limiter menu........................................................... 733 11.7.3 Entering limit values............................................................................ 736 Overall height...................................................................................... 736 Working radius...................................................................................... 737 Slewing angle....................................................................................... 737 Hoist rope limitation............................................................................... 738 11.7.4 Entering limit values manually................................................................... 740 Limit values........................................................................................ 740 11.7.5 Switching monitoring functions on/off............................................................ 742 11.7.6 Shutdown by working range limiter................................................................ 743 11.8 Work break............................................................................................. 745 11.8.1 In case of short work breaks..................................................................... 745 11.8.2 In case of work breaks of more than 8 hours...................................................... 746 To secure the truck crane........................................................................... 746 11.9 Heating and air-conditioning system.................................................................... 747 11.9.1 Standard heating system.......................................................................... 747 Switching on........................................................................................ 747 Heating............................................................................................. 747 Air distribution.................................................................................... 748 Switching off....................................................................................... 748 11.9.2 Air-conditioning system.......................................................................... 749 Information......................................................................................... 749 Switching on/off.................................................................................... 749 Cooling, automatic.................................................................................. 750 Cooling, maximum.................................................................................... 750 11.9.3 Auxiliary heater................................................................................. 751 Switching on........................................................................................ 751 Setting the temperature............................................................................. 752 Setting the heating start/ heating duration......................................................... 752 Switching heating start on/off...................................................................... 753 11.10 CraneSTAR system...................................................................................... 754 11.10.1 Overview........................................................................................ 754 11.10.2 Position of the components...................................................................... 754 12 Rigging work................................................................................................. 755 12.1 Rigging work checklists for crane operation with the main boom......................................... 755 12.1.1 CHECKLIST: Rigging............................................................................... 755 12.1.2 CHECKLIST: Unrigging............................................................................. 761 12.2 Choice of a suitable positioning site.................................................................. 765 12.2.1 Determining the required load-bearing area....................................................... 765 12.2.2 Safe distance from slopes and pits............................................................... 768 12.2.3 Earthing the truck crane......................................................................... 769 12.2.4 Safe distance from overhead power lines.......................................................... 770 12.3 Rigging work after driving with a dolly................................................................ 773 12.3.1 Switching off the boom floating position......................................................... 773 12.3.2 Switching off the slewing gear freewheel......................................................... 774 Before slewing...................................................................................... 774 12.3.3 Switching off boom pre-tensioning................................................................ 775 12.4 Connecting/disconnecting the hand-held control......................................................... 777 12.5 Starting the engine for rigging........................................................................ 781 Prerequisites........................................................................................... 781 Starting the engine..................................................................................... 781 Turning off theengine.................................................................................. 781 12.6 Slewing range – only with the Standard slewing range type.............................................. 783 12.6.1 Representation in the lifting capacity tables.................................................... 783 12.6.2 Enabled outrigger spans.......................................................................... 784 12.7 Outriggers – Overview – MAXbase slewing range type..................................................... 785 12.7.1 Definitions...................................................................................... 785 12.7.2 Representation in the lifting capacity tables.................................................... 787 12.7.3 Enabled outrigger spans.......................................................................... 788 12.8 Outrigger operation.................................................................................... 793 12.8.1 CHECKLIST: Extending the outriggers.............................................................. 793 12.8.2 CHECKLIST: Retracting the outriggers............................................................. 795 12.8.3 Preparing the truck crane........................................................................ 796 Driver's cab........................................................................................ 796 Crane cab........................................................................................... 796 12.8.4 Setting the outrigger spans...................................................................... 798 For on-road driving................................................................................. 801 12.8.5 Extending/retracting outrigger beams............................................................. 801 From the controlunits.............................................................................. 802 From the cranecab.................................................................................. 803 12.8.6 Moving the outrigger pads into operating/driving position........................................ 805 12.8.7 Enlarging the load-bearing area.................................................................. 807 12.8.8 Extending/retracting supporting cylinders........................................................ 808 From the control units.............................................................................. 809 From the cranecab.................................................................................. 810 12.8.9 Levelling the truck crane on outriggers horizontally............................................. 812 Inclination indicators.............................................................................. 812 Prerequisites....................................................................................... 813 Manual alignment................................................................................... 814 Automatic alignment................................................................................. 814 12.8.10 Levelling the free-standing truck crane......................................................... 816 12.8.11 Operating the axle raising system............................................................... 818 12.8.12 Outrigger pressure display...................................................................... 820 12.9 Rigging/unrigging the counterweight.................................................................... 823 Counterweight display rigged............................................................................ 823 12.9.1 Information on rigging........................................................................... 823 When rigging........................................................................................ 823 When unrigging...................................................................................... 824 12.9.2 Counterweight sections........................................................................... 825 12.9.3 Identification................................................................................... 827 12.9.4 Slinging points on the counterweight sections.................................................... 828 12.9.5 CHECKLIST: Rigging the counterweight............................................................. 830 12.9.6 CHECKLIST: Unrigging the counterweight........................................................... 832 12.9.7 Assembling counterweight combination............................................................. 834 12.9.8 Counterweight hoist unit......................................................................... 839 Counterweight menu................................................................................. 839 Extending/ retracting the lifting cylinders......................................................... 840 Automatic moderigging............................................................................. 842 Automatic mode unrigging........................................................................... 844 Cancel automatic mode.............................................................................. 845 12.9.9 Setting down counterweight for driving........................................................... 846 Rear counterweight platform......................................................................... 846 Front counterweight platform........................................................................ 848 12.9.10 Unlocking/locking the rear counterweight platform............................................... 849 Unlocking........................................................................................... 849 Locking............................................................................................. 850 12.9.11 Slewing with rigged counterweight............................................................... 851 12.10 Rigging work on the main boom......................................................................... 853 12.10.1 Hook block on the bumper........................................................................ 853 Picking up the hook block........................................................................... 853 Attaching the hook block............................................................................ 854 12.10.2 Hook block on a separate vehicle................................................................ 855 Picking up the hook block.......................................................................... 856 Setting down thehook block........................................................................ 856 12.10.3 Hook block, separable........................................................................... 858 Rigging for on-road driving......................................................................... 858 Rigging for crane operation......................................................................... 859 12.10.4 Hook block with ballast plates.................................................................. 860 Removing............................................................................................ 860 Installing.......................................................................................... 861 Information on crane operation...................................................................... 861 12.10.5 Reeving and unreeving the hoist rope............................................................ 862 Reeving the hoistrope.............................................................................. 863 Unreeving hoistrope............................................................................... 867 12.10.6 Possible reevings on the main boom.............................................................. 868 With 5 head sheaves................................................................................. 868 With 6 head sheaves................................................................................. 871 With 7 head sheaves................................................................................. 873 12.10.7 Installing/removing the lifting limit switch.................................................... 874 Installing the lifting limit switch................................................................. 874 Removing the lifting limit switch................................................................... 877 12.10.8 Locking/unlocking the lifting limit switch...................................................... 879 Locking............................................................................................. 879 Removing the lock.................................................................................. 879 12.10.9 Anemometer and air traffic control light........................................................ 880 Installing.......................................................................................... 880 Switching on/off.................................................................................... 881 Removing............................................................................................ 881 12.11 Other rigging work.................................................................................... 883 12.11.1 Railings on the turntable....................................................................... 883 12.11.2 Folding the mirrors in and out, and adjusting them.............................................. 884 12.11.3 Slinging points for personal protective equipment............................................... 885 12.11.4 Cameras for crane operation..................................................................... 886 Camera on mainboom................................................................................. 886 Camera on thehoists................................................................................ 889 Camera on the driver's cab.......................................................................... 889 Operating the camera................................................................................ 890 12.11.5 Step at the crane cab........................................................................... 891 13 Driving with a rigged truck crane............................................................................ 893 13.1 Route.................................................................................................. 893 13.2 Permissible rigging modes and axle loads............................................................... 894 Axle load table........................................................................................ 894 13.2.1 To drive without a load.......................................................................... 897 13.2.2 To drive with a load............................................................................. 897 13.2.3 Axle loads....................................................................................... 898 13.3 Before driving the rigged truck crane.................................................................. 899 13.3.1 Check the tyre pressures and wind speed.......................................................... 899 13.3.2 Secure the superstructure against slewing........................................................ 899 13.3.3 Putting the truck crane on the wheels – with Raise axle function................................. 900 13.3.4 Putting the truck crane on the wheels – with the outriggers...................................... 902 13.4 Driving from the driver's cab.......................................................................... 905 13.4.1 Preparing to drive............................................................................... 905 Transmission........................................................................................ 905 Switching on separate steering...................................................................... 905 Connections......................................................................................... 905 13.4.2 Whilst driving................................................................................... 906 13.4.3 After driving.................................................................................... 907 13.5 Driving from the crane cab............................................................................. 909 13.5.1 Preparing to drive............................................................................... 910 13.5.2 Opening/closing the Driving menu................................................................. 910 Opening............................................................................................. 910 Crane's hydraulic system on/off..................................................................... 911 Closing............................................................................................. 912 13.5.3 Steering......................................................................................... 913 Switching on........................................................................................ 913 Steering direction.................................................................................. 913 Displays when steering.............................................................................. 914 Separate steering................................................................................... 914 Normal steering mode................................................................................ 918 13.5.4 Operating the transmission....................................................................... 919 Selecting the transmission mode.................................................................... 919 13.5.5 Whilst driving................................................................................... 920 DM and RM transmission mode......................................................................... 920 Transmission mode D................................................................................. 920 Warning messages.................................................................................... 920 13.5.6 Possible connections............................................................................. 921 Longitudinal/ transverse differential locks......................................................... 921 13.5.7 After driving.................................................................................... 923 14 Malfunctions during crane operation.......................................................................... 925 14.1 Emergency stop switch.................................................................................. 925 14.2 What to do when malfunctions occur during crane operation.............................................. 926 The load can be set down................................................................................ 926 Load cannot besetdown................................................................................. 926 14.3 Warning and error messages............................................................................. 927 Program version......................................................................................... 927 14.3.1 Warning messages on the CCS display.............................................................. 927 Meaning of thesymbols.............................................................................. 928 14.3.2 Error messages on the CCS display................................................................ 931 14.3.3 Warning messages on the RCL display.............................................................. 933 14.4 Troubleshooting........................................................................................ 937 14.4.1 Malfunctions on the engine....................................................................... 937 14.4.2 Malfunctions on the main hoist/auxiliary hoist................................................... 937 14.4.3 Malfunctions in the hoist cameras................................................................ 939 14.4.4 Malfunctions in the main boom camera............................................................. 939 14.4.5 Malfunctions on the derricking gear.............................................................. 940 14.4.6 Malfunctions in the telescoping mechanism........................................................ 941 14.4.7 Malfunctions on the slewing gear................................................................. 942 14.4.8 Malfunctions on the counterweight hoist unit..................................................... 944 14.4.9 Malfunctions in the hydraulic system/hydraulic oil cooler........................................ 944 14.4.10 Malfunctions when inclining the crane cab....................................................... 944 14.4.11 Malfunctions when operating with the hand-held control.......................................... 945 14.4.12 Malfunctions when inclining the crane cab....................................................... 945 14.4.13 Malfunctions when raising the axles............................................................. 945 14.4.14 Malfunctions of the outriggers.................................................................. 946 14.4.15 Malfunctions on the turntable lock.............................................................. 946 14.4.16 Malfunctions on the CCS/RCL control units....................................................... 947 14.4.17 Malfunctions when driving from the crane cab.................................................... 947 14.4.18 Malfunctions on the CraneSTAR system............................................................ 948 14.5 Emergency operations and programs...................................................................... 951 14.5.1 Mechanical emergency activation for retracting................................................... 952 Prior to the emergency operation, check............................................................. 952 Procedure........................................................................................... 952 Mechanical emergency activation.................................................................... 953 14.5.2 Telescoping emergency program.................................................................... 955 Checks before using the emergency program........................................................... 955 Telescoping emergency program menu.................................................................. 956 Notes on the displays............................................................................... 957 Checks in theemergency program.................................................................... 958 Retracting withemergency program................................................................... 962 Tables for approaching the locking points........................................................... 964 14.5.3 Entering the current telescoping................................................................. 967 14.5.4 Emergency operation with the hand-held control................................................... 969 To pre-select a power unit.......................................................................... 970 Operating apowerunit.............................................................................. 970 Stopping movements................................................................................. 971 Stopping movements in emergencies................................................................... 972 Switch off theengine............................................................................... 972 14.5.5 Notes on slewing in emergency operation.......................................................... 972 For the Standard slewing range type................................................................. 972 For the MAXbase slewing range type.................................................................. 974 14.6 Hydraulic emergency operation with the hand pump....................................................... 975 14.6.1 Operating principle.............................................................................. 975 14.6.2 Switching over the crane's hydraulic system...................................................... 975 14.6.3 Establishing the hydraulic circuits required..................................................... 976 Releasing/ securing valves.......................................................................... 976 Switching over valves............................................................................... 977 For lowering........................................................................................ 978 14.6.4 Performing emergency activation.................................................................. 979 14.6.5 After emergency activation....................................................................... 979 14.7 Hydraulic emergency operation as per BGR 159........................................................... 981 14.7.1 Applications and function........................................................................ 981 14.7.2 CHECKLIST: Emergency operation................................................................... 983 14.7.3 CHECKLIST: After emergency operation............................................................. 984 14.7.4 Connecting/removing transformer – for self-sufficiency........................................... 985 Connecting.......................................................................................... 985 Removing............................................................................................ 986 14.7.5 Switching emergency operation on/off............................................................. 987 14.7.6 Connecting/removing transformer – for external energy source..................................... 988 14.7.7 Establishing the required hydraulic circuits..................................................... 989 Switching overvalves............................................................................... 989 For lifting/ lowering............................................................................... 991 For slewing......................................................................................... 992 14.7.8 Performing emergency operation................................................................... 993 Slewing............................................................................................. 993 Derricking.......................................................................................... 994 Lifting/lowering.................................................................................... 994 14.7.9 Emergency supply of another crane................................................................ 995 For emergency supply................................................................................ 995 After emergency supply.............................................................................. 995 14.8 Fuses in the crane cab................................................................................. 997 Information on changing fuses......................................................................... 997 Index...............................................................................................................1003 A...............................................................................................................1005 B...............................................................................................................1005 C...............................................................................................................1006 D...............................................................................................................1008 E...............................................................................................................1010 F...............................................................................................................1012 H...............................................................................................................1012 I...............................................................................................................1013 L...............................................................................................................1013 M...............................................................................................................1014 O...............................................................................................................1015 P...............................................................................................................1016 R...............................................................................................................1016 S...............................................................................................................1017 T...............................................................................................................1019 V...............................................................................................................1021 W...............................................................................................................1021
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