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Grove Crane GMK 6300L-1 Driving & Crane Operation Operating Manual – PDF DOWNLOAD
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Grove Crane GMK 6300L-1 Driving & Crane Operation Operating Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 6300L-1 Driving & Crane Operation Operating Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L-1 Driving & Crane Operation Operating Manual – PDF DOWNLOAD
Language : English
Pages : 1002
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L-1 Driving & Crane Operation Operating Manual – PDF DOWNLOAD
Documentation supplied:
The precise number of documents supplied depends on the rigging mode of the truck crane. The
following documents are included in delivery:
– Operating Manual
Contains information on driving and crane operation.
Contains information on driving and crane operation.
– Lattice extension operating manual
Is only supplied when the truck crane is equipped with a lattice extension or other parts for
extending the main boom (e.g. auxiliary single-sheave boom top and heavy load lattice extension).
Is only supplied when the truck crane is equipped with a lattice extension or other parts for
extending the main boom (e.g. auxiliary single-sheave boom top and heavy load lattice extension).
– Operating manual for additional equipment
This is only supplied when the truck crane is supplied with additional equipment which is not
described in the operating manual for driving and crane operation.
This is only supplied when the truck crane is supplied with additional equipment which is not
described in the operating manual for driving and crane operation.
– Documents from other manufacturers
Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH, such as
the engine and central lubrication system, as well as the tachograph, auxiliary heaters, radio and,
where appropriate, other additional equipment.
Original documentation for parts not manufactured by Manitowoc Crane Group Germany GmbH, such as
the engine and central lubrication system, as well as the tachograph, auxiliary heaters, radio and,
where appropriate, other additional equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no instructions for repair work.
Contains solely information on maintenance work and contains no instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and pneumatic systems are supplied.
Circuit diagrams for the electrical systems, hydraulic systems and pneumatic systems are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes.
Information on the lifting capacity when the truck crane is in different
rigging modes.
TABLE OF CONTENTS:
Grove Crane GMK 6300L-1 Driving & Crane Operation Operating Manual – PDF DOWNLOAD
Operating Manual..................................................................................... 1 Driving ......................................................................................... 1 Additional pages ............................................................................ 3 Possible reeving methods on the main boom................................................ 3 Counterweight version B.................................................................. 13 Information on weight specifications................................................. 13 Hydraulic emergency operation............................................................ 15 Additional switches required......................................................... 15 1 Overview................................................................................... 21 1.1 Accidents............................................................................ 21 1.2 Branch offices....................................................................... 23 1.2.1 Manitowoc Crane Care........................................................... 23 1.2.2 Dealer list.................................................................... 23 1.3 Warranty specifications.............................................................. 23 1.4 Terms used........................................................................... 24 1.5 Technical data....................................................................... 27 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 27 1.5.2 Maximum lifting capacity (ASME B 30.5)......................................... 27 1.5.3 Dimensions and weights of the truck crane, axle loads.......................... 28 Dimensions....................................................................... 29 Weight and axleloads............................................................ 29 1.5.4 Dimensions and weights of removable parts...................................... 30 Spare wheel...................................................................... 30 Outriggers....................................................................... 30 Driver's safety guard............................................................ 31 Hose drum........................................................................ 31 Hook blocks and hook tackle...................................................... 31 Auxiliary hoist.................................................................. 32 Main boom........................................................................ 32 Counterweight parts............................................................. 32 1.5.5 Carrier........................................................................ 33 Engine........................................................................... 33 Transmission..................................................................... 33 Transfer case.................................................................... 33 Axle lines....................................................................... 33 Steering......................................................................... 34 Tyres............................................................................ 34 Outriggers....................................................................... 34 Auxiliary supports............................................................... 35 Electrical system................................................................ 35 Tool............................................................................. 35 Towing coupling................................................................. 35 Driving speeds................................................................... 35 Climbing ability................................................................. 35 Turning radii.................................................................... 36 1.5.6 Superstructure................................................................. 37 Engine........................................................................... 37 Main hoist....................................................................... 37 Auxiliary hoist.................................................................. 37 Slewing gears.................................................................... 38 Derricking gear.................................................................. 38 Main boom........................................................................ 38 Lattice extension................................................................ 38 Operating speeds................................................................. 39 1.6 Documentation supplied............................................................... 41 1.6.1 Questions on documentation..................................................... 42 1.7 Notes on the operating manual........................................................ 43 1.7.1 What do the symbols used mean?................................................. 43 1.7.2 How is the operating manual structured?........................................ 45 Division......................................................................... 45 Structure of thechapters........................................................ 45 Structure of thepages........................................................... 46 1.7.3 How do I find the information I need?.......................................... 47 Cross-references example......................................................... 48 1.7.4 What information is available for operations planning?......................... 50 1.8 Conversion table for US measuring units.............................................. 51 1.9 Training – Information............................................................... 53 1.10 Identification...................................................................... 54 1.11 EC Declaration of Conformity........................................................ 56 2 Basic safety instructions.................................................................. 59 2.1 Intended use......................................................................... 59 2.1.1 Improper use................................................................... 60 2.2 Organisational measures.............................................................. 61 2.3 Personnel qualifications............................................................. 63 2.4 Safety instructions for driving the truck crane...................................... 65 2.5 Safety instructions for crane operation.............................................. 67 2.6 Instructions on transporting persons................................................. 71 Equipment for lifting persons........................................................ 71 Personnel............................................................................ 72 Operation............................................................................ 72 Truck crane.......................................................................... 73 3 Operating elements for driving............................................................. 77 3.1 Overview of the operating elements................................................... 77 3.1.1 On the outside of the truck crane.............................................. 78 3.1.2 Driver's cab................................................................... 82 Front overview................................................................... 82 Behind the cover................................................................ 86 Rear overview.................................................................... 87 3.1.3 Instrument panel............................................................... 88 Left/right....................................................................... 88 Middle........................................................................... 89 3.1.4 Display, driving mode.......................................................... 92 3.1.5 Steering column/steering wheel................................................. 93 3.1.6 Transmission operating elements................................................ 94 3.1.7 Tachograph, time correction.................................................... 95 3.1.8 ECOS control unit.............................................................. 96 3.1.9 ECOS display – main menu....................................................... 98 3.1.10 ECOS display – submenus.......................................................100 Level adjustment system submenu.................................................100 Settings submenu.................................................................102 Monitoring submenu...............................................................103 Operating hours submenu.........................................................104 Warning submenu..................................................................104 Error submenu....................................................................105 3.1.11 Heating/Air-conditioning system...............................................106 Standard heating system..........................................................106 Auxiliary water heating system..................................................107 3.1.12 Outrigger control units.......................................................108 3.1.13 Rear supporting box control unit..............................................109 3.2 Short description of the operating elements..........................................111 3.2.1 Definition of direction information............................................111 Basic rule.......................................................................111 Switches and buttons............................................................112 3.2.2 General notes on the operating elements........................................112 3.2.3 General rules for buttons and symbols on the display...........................113 3.2.4 Engine.........................................................................114 Steering column..................................................................114 Multipurpose switch..............................................................114 Instrument panel.................................................................115 Main menu........................................................................116 3.2.5 Carbamide system...............................................................117 Instrument panel.................................................................117 Display, driving mode............................................................118 ECOS display.....................................................................118 3.2.6 Electrical system..............................................................119 3.2.7 ECOS crane control.............................................................120 Control unit.....................................................................120 3.2.8 Transmission...................................................................123 Instrument panel, middle.........................................................123 Display, driving mode............................................................123 Transmission control unit........................................................123 3.2.9 Reverse camera.................................................................127 Reverse camera on/off............................................................127 3.2.10 Transfer case.................................................................128 3.2.11 Final drive...................................................................129 3.2.12 Brakes........................................................................130 Service brake....................................................................130 Additional brakes................................................................130 Parking brake....................................................................131 3.2.13 Steering/separate steering....................................................132 Instrument panel.................................................................132 ECOS display.....................................................................133 Driver's door....................................................................134 3.2.14 Suspension....................................................................135 3.2.15 Lighting/windscreen wipers/horn...............................................136 Steering column..................................................................136 Instrument panel.................................................................136 Roof.............................................................................139 3.2.16 Level adjustment system.......................................................140 3.2.17 Tachograph/speedometer........................................................143 Tachograph.......................................................................143 Speedometer......................................................................143 3.2.18 Rear supporting box control unit..............................................144 3.2.19 Diagnostics...................................................................145 Displays/ submenu................................................................145 3.2.20 Windows, doors, keys..........................................................146 Window winder....................................................................146 Doors............................................................................147 Keys.............................................................................147 3.2.21 Front flap....................................................................148 4 Starting the engine for driving / switching it off.........................................151 4.1 Starting the engine from the driver's cab............................................151 4.1.1 CHECKLIST: Starting the engine.................................................151 4.1.2 CHECKLIST: At low temperatures.................................................154 4.1.3 Ladders and access ladders.....................................................154 Fixed ladders....................................................................154 Ladders..........................................................................155 4.1.4 Refuel.........................................................................157 Fuel.............................................................................157 Carbamide........................................................................158 4.1.5 Checks before starting the engine..............................................160 At the hydraulic tank............................................................160 Battery master switch............................................................160 Checking the hand-held control...................................................161 4.1.6 Switch on the ignition.........................................................161 4.1.7 Lamp test/equalisation of the switching states.................................162 Lamp test........................................................................162 Switching state alignment........................................................163 4.1.8 Display – setting the brightness...............................................164 4.1.9 Starting the engine............................................................165 Without flame start system.......................................................166 With flame start system.........................................................166 4.1.10 Checks after starting the engine..............................................168 Checking in the main menu........................................................168 Indicator lamps on the instrument panel..........................................168 4.1.11 Monitoring elements...........................................................170 Instrument panel.................................................................170 4.1.12 Monitoring submenu............................................................171 4.1.13 Setting idling speed..........................................................172 4.2 Switch the engine off................................................................173 4.2.1 At the ignition lock and with the outrigger control units......................173 After switching off.............................................................173 4.2.2 Using the emergency stop switches..............................................174 Resetting the emergency stop switch..............................................174 4.3 Air intake inhibitor.................................................................175 Releasing the air intake inhibitor...................................................175 5 Driving....................................................................................179 5.1 Before driving.......................................................................179 5.1.1 CHECKLIST: Checks before on-road driving.......................................179 5.1.2 Checking the condition of the truck crane......................................185 Windscreen washing system........................................................185 Electrical system................................................................185 Adjusting themirrors............................................................186 Warning plates for vehicle width.................................................187 Displaying vehicle height........................................................187 Supply pressure..................................................................188 Parking brake....................................................................189 5.1.3 Adjusting the seats and steering column........................................191 Driver's seat....................................................................191 Passenger's seat.................................................................193 Adjusting the steering column...................................................194 5.1.4 Switching the suspension on/off................................................195 Opening the submenu..............................................................195 Switching the suspension on.....................................................196 Switching the suspension off....................................................196 5.1.5 Setting the tachograph.........................................................197 Prerequisites....................................................................197 In the event of malfunctions.....................................................197 Setting the tachograph..........................................................198 5.1.6 Displaying the operating hours.................................................203 5.1.7 Settings/indications on the driving display....................................204 5.2 Operating the transmission...........................................................205 5.2.1 Switching on...................................................................205 5.2.2 Switching the transmission to the neutral position.............................206 While driving....................................................................206 5.2.3 Changing the driving mode......................................................207 5.2.4 Selecting the driving direction................................................208 5.2.5 Changing highest gear/starting gear............................................210 5.2.6 Starting.......................................................................210 5.2.7 Driving and changing gears.....................................................211 5.2.8 Changing the driving direction.................................................212 5.2.9 Stopping.......................................................................213 Stopping for longer periods.....................................................213 5.2.10 On the roller type dynamometer................................................213 5.2.11 Oil level gauge...............................................................214 5.3 Driving the truck crane and switching it off.........................................217 5.3.1 Checks whilst driving..........................................................217 Immediately after you start to move..............................................217 While driving....................................................................219 5.3.2 Cruise control.................................................................220 Switching on.....................................................................220 Switching off....................................................................221 5.3.3 Temposet.......................................................................221 Switching on.....................................................................221 Switching off....................................................................221 5.3.4 Driving downhill...............................................................222 Starting.........................................................................222 Checks when driving downhill....................................................222 Shifting down from the highest gear..............................................223 Additional brakes................................................................224 5.3.5 Driving uphill.................................................................225 Starting.........................................................................225 Driving..........................................................................225 5.3.6 Warning submenu................................................................226 Meaning of thesymbols...........................................................226 Exiting the submenu.............................................................228 5.3.7 Warning or malfunction messages on the instrument panel........................229 Meaning of the lamps.............................................................229 5.3.8 Override torque reduction......................................................231 5.3.9 Error submenu..................................................................232 5.3.10 Switching the truck crane off.................................................232 Secure it against rolling away...................................................232 When stationary for more than 8hours............................................233 5.3.11 Folding berth.................................................................235 5.4 Off-road driving.....................................................................237 Adjustments to the transmission......................................................237 Connections..........................................................................237 Changing the vehicle level...........................................................237 Rocking the vehicle free andtowing..................................................237 5.4.1 Transfer case – switching the off-road gear on/off.............................238 Prerequisites....................................................................238 Switching on.....................................................................239 Switching off....................................................................239 Neutral position.................................................................239 5.4.2 Longitudinal and transverse differential locks.................................240 5.4.3 Operating the level adjustment system..........................................242 Opening the submenu..............................................................242 Setting the on-road level.......................................................243 Pre-selecting suspension struts.................................................243 Changing the vehicle level.......................................................244 Viewing the current inclination..................................................244 Exiting the submenu.............................................................245 5.4.4 Freeing truck crane stuck in terrain...........................................246 Rocking the truck crane free....................................................246 Towing free to thefront........................................................247 Towing free to therear.........................................................247 5.5 Separate steering....................................................................249 5.5.1 Switching to separate steering.................................................249 Manual...........................................................................250 Automatic........................................................................251 switching to normal steering mode................................................252 5.6 Heating and air-conditioning system..................................................253 5.6.1 Standard heating system........................................................253 Switching on.....................................................................253 Heating..........................................................................253 Air distribution.................................................................254 Examples.........................................................................255 Switching off....................................................................255 5.6.2 Air-conditioning system........................................................256 Information......................................................................256 Switching on/off.................................................................256 Cooling..........................................................................257 Drying...........................................................................257 5.6.3 Auxiliary water heater.........................................................258 Preheating theengine............................................................258 Preheating the driver's cab.....................................................259 Switching on the auxiliary heater................................................259 Switching off the auxiliary heater...............................................260 Setting time andweekday.........................................................260 Saving automatic heating start..................................................261 Setting the heating period......................................................262 Switching the automatic heating start on and off.................................263 Setting the remaining run time..................................................263 5.7 Towing a trailer.....................................................................265 Effects on the axleloads............................................................265 Coupling the trailer................................................................266 Connecting the supply lines.........................................................267 Removing supply lines..............................................................268 Uncoupling thetrailer..............................................................268 Checking the braking force...........................................................270 6 Driving modes..............................................................................273 6.1 Driving modes........................................................................273 Information about the axle loads.....................................................273 6.1.1 Information on how to use the tables...........................................274 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs)............................275 For tyres 385/95 R25.............................................................275 For tyres 445/95 R25.............................................................276 For tyres 525/80 R25.............................................................277 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)...........278 6.2 Weighing the truck crane.............................................................279 Determining..........................................................................279 Axle groups..........................................................................280 Weighing procedure...................................................................281 Evaluation...........................................................................282 6.3 Rigging work for driving with a trailer..............................................283 6.3.1 Switching on the slewing gear freewheel........................................284 6.3.2 Switching on the boom floating position........................................285 6.3.3 Switching on boom pre-tensioning...............................................286 6.3.4 Adjusting axle pressure........................................................287 Preselecting the axle pair.......................................................287 Adjusting axle pressure..........................................................288 Driving with changed axle pressures..............................................288 Adjusting axle pressure for on-road driving......................................288 6.3.5 Switching the superstructure driving lights on/off.............................289 Switching off....................................................................289 Switching on.....................................................................289 6.4 Main boom, removing/installing.......................................................291 Additional equipment required........................................................291 6.4.1 CHECKLIST: Removing the main boom..............................................292 Prerequisites....................................................................292 Checklist........................................................................292 6.4.2 CHECKLIST: Mounting the main boom..............................................295 Prerequisites....................................................................295 Checklist........................................................................295 6.4.3 Slinging the main boom.........................................................298 Marking..........................................................................298 Installing the lifting gear......................................................298 Removing the lifting gear........................................................299 6.4.4 Removing/attaching the clamps..................................................300 6.4.5 Switching the pressure relief on/off...........................................301 6.4.6 Connecting/disconnecting the derricking cylinder from the boom.................302 Retracting the derricking cylinder head axle.....................................303 Fitting the derricking cylinder head axle........................................304 6.4.7 Extending/retracting the boom pivot pin........................................305 Before pulling itout............................................................305 After pushing it in..............................................................305 Pulling out the pivot pin........................................................306 Pushing the pivot pin in.........................................................307 6.4.8 Disconnecting/connecting hydraulics/electrical.................................308 Disconnecting....................................................................308 Connecting.......................................................................309 6.4.9 Lifting the main boom off/on the turntable.....................................310 Lifting from the turntable.......................................................310 Lifting on to the turntable......................................................311 6.4.10 Aligning the connecting points................................................312 6.4.11 Securing/releasing the derricking cylinder....................................312 6.4.12 Transporting the main boom....................................................313 6.4.13 Inspections after main boom mounting..........................................314 6.4.14 Installing/removing the hose drum.............................................315 Installing.......................................................................315 Removing.........................................................................316 6.5 Installing/removing outrigger beams..................................................319 6.5.1 CHECKLIST: Removing the outrigger beams........................................320 6.5.2 CHECKLIST: Installing the outrigger beams......................................322 6.5.3 Preparing the truck crane......................................................324 Prerequisites....................................................................324 For removal......................................................................324 6.5.4 Removing/attaching outrigger pads..............................................325 Removing outrigger pads.........................................................325 Attaching outrigger pads........................................................326 6.5.5 Disconnecting/establishing the hydraulic connection............................327 6.5.6 Disconnecting/establishing the electrical connection...........................328 6.5.7 Unscrewing/screwing in the spacers.............................................329 Unscrewing.......................................................................329 Screwing in......................................................................330 6.5.8 Disconnecting/establishing the connections to the supporting box...............331 6.5.9 Extending/retracting the outrigger beam........................................331 Extending the outrigger beam....................................................331 Inserting the outrigger beam.....................................................333 6.5.10 Transporting the outrigger beams..............................................335 6.6 Installing/removing the supporting box...............................................337 6.6.1 CHECKLIST: Removing the supporting box.........................................338 6.6.2 CHECKLIST: Installing the supporting box.......................................341 6.6.3 Rig the outrigger span 7.98x8.50/1.00m (26.1x27.9/3.3ft).................343 Front outrigger..................................................................344 Auxiliary supports...............................................................344 6.6.4 Establishing/disconnecting the pneumatic connection............................346 6.6.5 Disconnecting/establishing the electrical connection...........................347 6.6.6 Disconnecting/establishing the hydraulic connection............................348 6.6.7 Attaching/raising the supporting box with the truck crane......................349 Prerequisites:...................................................................349 Lifting..........................................................................350 Hanging..........................................................................351 6.6.8 Installing the reverse camera..................................................352 6.6.9 Crane movements during installation and removal................................353 Prerequisites....................................................................353 Before installation..............................................................353 After the removal...............................................................353 6.6.10 Slinging points on the supporting box.........................................354 6.6.11 Locking/unlocking the supporting box..........................................355 Locking..........................................................................355 Unlocking........................................................................356 6.6.12 Transporting the supporting box on the separate vehicle.......................357 Lashing eyelets..................................................................357 6.6.13 Installing / removing the rear bumper.........................................358 Prerequisites:...................................................................358 Installing.......................................................................359 Removing.........................................................................359 6.7 Rigging the auxiliary hoist..........................................................361 6.7.1 CHECKLIST: Auxiliary hoist, installing.........................................361 Prerequisites....................................................................361 6.7.2 CHECKLIST: Auxiliary hoist, removing...........................................363 Prerequisites....................................................................363 6.7.3 Slinging the auxiliary hoist...................................................365 6.7.4 Installing/removing the rigging frame..........................................366 Prerequisite.....................................................................366 6.7.5 Setting down the auxiliary hoist...............................................367 6.7.6 Making/breaking the hydraulic connection.......................................368 6.7.7 Establishing/disconnecting the electrical connection...........................369 6.7.8 Creating the connection to the turntable.......................................370 Establishing the connection......................................................370 Separating the connection........................................................372 6.7.9 Securing the hoist rope........................................................373 6.7.10 Transporting the auxiliary hoist..............................................374 6.7.11 Check that the auxiliary hoist is functioning properly........................375 Slewing direction................................................................375 Slewing indicator................................................................375 7 Malfunctions in driving mode...............................................................379 7.1 Emergency stop switch................................................................379 7.2 What to do when a malfunction occurs in road traffic.................................381 7.3 Towing the truck crane...............................................................383 7.3.1 Towing after engine/transmission damage........................................384 Compressed-air supply............................................................384 Electric power supply............................................................385 On the transmission..............................................................385 Axle drives......................................................................385 Transfer case....................................................................386 Parking brake....................................................................386 Towing the truck crane out of the danger area....................................387 7.3.2 Tow starting...................................................................387 7.3.3 External starting socket.......................................................388 Performing a jump start..........................................................388 7.3.4 Battery charger................................................................389 Prerequisites....................................................................389 7.4 Wheels and tyres.....................................................................391 7.4.1 Wheel change...................................................................391 Removing adamaged wheel.........................................................392 On the spare wheel holder........................................................392 Mounting a wheel.................................................................393 7.4.2 Inflating the tyres yourself...................................................395 Connecting the filling hose......................................................395 Inflating the tyres..............................................................396 Removing the filling hose........................................................396 7.5 Fuses................................................................................397 Information on replacing fuses.....................................................397 7.5.1 Fuses in the driver's cab......................................................398 Group F1.........................................................................398 Group F2.........................................................................399 Group F3.........................................................................399 Group F4.........................................................................400 Group F5.........................................................................400 Group F6.........................................................................401 Group F7.........................................................................401 Group F8.........................................................................401 Group F9.........................................................................402 Group F10........................................................................402 7.5.2 Fuses in the battery box.......................................................403 7.6 Troubleshooting......................................................................405 7.6.1 Malfunctions on the engine.....................................................405 7.6.2 Malfunctions in the exhaust system.............................................407 7.6.3 Malfunctions in the transmission...............................................408 7.6.4 Transfer case malfunctions.....................................................409 7.6.5 Malfunctions of the service brake..............................................409 7.6.6 Malfunctions of the steering...................................................410 7.6.7 Differential lock malfunctions.................................................411 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................411 7.6.9 Malfunctions on the suspension.................................................412 7.6.10 Malfunctions of the level adjustment system...................................412 7.6.11 Malfunctions on the ECOS carrier..............................................413 ECOS programme version...........................................................413 General malfunctions............................................................413 Error messages...................................................................414 Exiting the submenu.............................................................415 7.7 Procedure in the event of malfunctions...............................................416 7.7.1 Switching on emergency operation in coolant circuit............................416 7.7.2 Procedure during engine malfunctions...........................................417 7.7.3 Malfunctions in the transmission...............................................418 General malfunctions.............................................................418 Transmission malfunction.........................................................418 Reading out error codes.........................................................420 8 Index......................................................................................423 A........................................................................................425 B........................................................................................425 C........................................................................................426 D........................................................................................427 E........................................................................................429 F........................................................................................431 H........................................................................................431 I........................................................................................432 K........................................................................................432 L........................................................................................433 M........................................................................................433 O........................................................................................434 P........................................................................................436 R........................................................................................436 S........................................................................................437 T........................................................................................439 V........................................................................................441 W........................................................................................441 Crane operation .................................................................................445 Additional pages ............................................................................447 Possible reeving methods on the main boom................................................447 Counterweight version B..................................................................457 Information on weight specifications.................................................457 9 Operating elements for crane operation.....................................................463 9.1 Overview of the operating elements...................................................463 9.1.1 Exterior of the truck crane....................................................464 9.1.2 Crane cab......................................................................468 9.1.3 Front panel....................................................................470 9.1.4 Side panel.....................................................................471 Bottom...........................................................................471 Top..............................................................................472 Console, rear....................................................................474 Standard heating system..........................................................475 Auxiliary water heating system..................................................476 Auxiliary air heater............................................................477 9.1.5 Control panels.................................................................478 Left.............................................................................478 Right............................................................................479 9.1.6 Control lever configuration....................................................480 Version 1........................................................................480 Version 2........................................................................481 9.1.7 ECOS control unit..............................................................482 9.1.8 ECOS display – main menu.......................................................484 9.1.9 ECOS display – submenus........................................................486 Counterweight submenu...........................................................486 Slewing gear/ houselock submenu..................................................487 Outriggers submenu..............................................................488 Telescoping submenu.............................................................490 Power unit speeds submenu.....................................................492 Monitoring submenu..............................................................493 Settings submenu................................................................494 Operating hours submenu.........................................................495 Submenu Warning.................................................................496 Error submenu....................................................................499 Working range limiter submenu..................................................500 9.1.10 RCL control unit..............................................................502 9.1.11 RCL display – main menu.......................................................503 9.1.12 Display RCL – submenus........................................................505 Enter rigging mode submenu....................................................505 Monitoring submenu..............................................................506 Rigging mode monitoring submenu................................................508 Lifting capacity table submenu.................................................509 Working range submenu...........................................................510 Error submenu....................................................................511 Settings submenu.................................................................512 9.1.13 Hand-held control.............................................................513 9.1.14 Outrigger control units.......................................................514 Button...........................................................................514 Outrigger button.................................................................515 Inclination and outrigger pressure display.......................................516 Raise axle display...............................................................517 9.2 Short description of the operating elements..........................................519 9.2.1 Definition of direction information............................................519 Basic rule.......................................................................519 Switches.........................................................................520 9.2.2 General rules for buttons and symbols on the display...........................520 9.2.3 Engine for crane operation.....................................................521 Side panel......................................................................521 Console, rear....................................................................522 ECOS display.....................................................................522 9.2.4 Engine for driving.............................................................522 Side panel.......................................................................522 Main menu........................................................................522 Outriggers submenu..............................................................523 9.2.5 Seat contact switch and dead man's switch......................................524 9.2.6 ECOS crane control.............................................................525 Control unit.....................................................................525 9.2.7 Outriggers.....................................................................528 In the Outriggers submenu.......................................................528 In the Settings submenu..........................................................529 On the outrigger control units...................................................530 9.2.8 Inclination indicators.........................................................532 9.2.9 Raise axle.....................................................................533 Outrigger control units..........................................................533 9.2.10 Outrigger pressure displays...................................................535 Outriggers submenu..............................................................535 Outriggers controlunits........................................................535 9.2.11 Anemometer display............................................................535 9.2.12 Counterweight submenu.........................................................536 Counterweight submenu...........................................................536 9.2.13 Main hoist....................................................................540 9.2.14 Auxiliary hoist...............................................................542 9.2.15 Slewing gear..................................................................543 Submenu..........................................................................544 9.2.16 Derricking gear...............................................................546 9.2.17 Telescoping mechanism.........................................................548 Control panels...................................................................548 Submenu..........................................................................549 In the Settings submenu..........................................................554 9.2.18 Hydraulic system..............................................................555 9.2.19 House lock....................................................................556 9.2.20 Rated capacity limiter (RCL)..................................................557 Control unit.....................................................................557 Main menu........................................................................559 Submenu Rigging mode entry.......................................................560 Monitoring submenu...............................................................564 Submenu Lifting capacity table...................................................568 Working range submenu...........................................................569 RCL override.....................................................................570 External displays................................................................571 9.2.21 Electrical system.............................................................572 9.2.22 Lighting, windscreen wiper/washing system.....................................573 Lighting.........................................................................573 Windscreen wiper/washing system.................................................575 9.2.23 Hand-held control.............................................................576 Sockets for hand-held control....................................................576 Engine control panel.............................................................577 Horn.............................................................................577 9.2.24 Windows, doors, keys..........................................................580 Windscreen.......................................................................580 Rear window......................................................................580 Crane cab door...................................................................581 Keys.............................................................................582 9.2.25 Diagnostics...................................................................582 10 Starting/switching off the engine – for crane operation...................................585 10.1 Starting the engine – from the crane cab............................................585 10.1.1 CHECKLIST: Starting the engine................................................585 10.1.2 CHECKLIST: At low temperatures................................................588 10.1.3 Refuel........................................................................588 Fuel.............................................................................588 Carbamide........................................................................590 10.1.4 Checks before starting the engine.............................................591 At the hydraulic tank............................................................591 Battery master switch............................................................591 Checking the hand-held control...................................................592 10.1.5 Switch on the ignition........................................................592 10.1.6 Lamp test / switching state alignment.........................................593 Lamp test........................................................................593 10.1.7 Adjusting display brightness..................................................595 10.1.8 Starting the engine...........................................................596 Without flame start system.......................................................596 With flame start system..........................................................597 10.1.9 Checks after starting the engine..............................................598 10.1.10 Monitoring submenu...........................................................599 10.1.11 Setting idling speed.........................................................600 10.1.12 Override torque reduction....................................................601 10.2 Starting the engine – with the hand-held control....................................603 Prerequisites........................................................................603 Starting the engine..................................................................603 10.3 Switching off the engine............................................................605 10.3.1 During normal operation, with the ignition lock/with the hand-held control....605 After switching off.............................................................605 10.3.2 In emergencies, with the emergency stop switches..............................606 Resetting the emergency stop switch..............................................606 10.4 Air intake inhibitor................................................................607 Releasing the air intake inhibitor...................................................607 11 Crane operation...........................................................................611 11.1 Before operating the crane..........................................................611 11.1.1 CHECKLIST: Checks before operating the crane..................................611 11.1.2 Checking the condition of the truck crane.....................................615 Windscreen washing system – Tank.................................................615 Visual inspection................................................................615 Checking the position of the hoist ropes.........................................616 Checking the electrical system...................................................616 11.1.3 Adjusting the crane cab seat and front control panel..........................617 Crane cab seat...................................................................617 Front control panel..............................................................618 11.1.4 Checking the safety equipment.................................................619 Rated capacity limiter...........................................................619 Lifting limit switch............................................................619 Emergency stop switch............................................................620 Seat contact switch..............................................................621 11.1.5 Earthing the load.............................................................622 11.1.6 Preheating the hydraulic oil..................................................623 11.1.7 Locking/unlocking the turntable...............................................624 Locking points...................................................................624 11.1.8 Switching the houselock on/off................................................625 Switching on the houselock......................................................625 Switching off the houselock.....................................................627 11.2 Operation of the rated capacity limiter.............................................629 11.2.1 Switch on the RCL.............................................................630 Switching on.....................................................................630 Brightness of the displays.......................................................632 11.2.2 Enter rigging mode............................................................633 Entering individual components...................................................634 Entering the RCL code...........................................................638 Entering the reeving............................................................639 Accepting the rigging mode.......................................................639 11.2.3 Checks before operating the crane.............................................641 Opening the submenu..............................................................641 Checks...........................................................................642 11.2.4 Displays during crane operation...............................................644 11.2.5 RCL early warning.............................................................647 11.2.6 RCL shutdown..................................................................647 Shutdown due to overload.........................................................647 11.2.7 Display in the event of errors................................................649 11.2.8 RCL override..................................................................650 Table – error/ information codes.................................................656 11.2.9 Displaying the lifting capacity tables........................................657 11.2.10 Entering the time/date.......................................................659 11.3 Crane operation with main boom......................................................661 11.3.1 Checks during crane operation.................................................661 Horizontal alignment.............................................................661 Safe distances..................................................................661 Checking the windspeed..........................................................662 11.3.2 Permissible slewing ranges and working positions..............................663 360 slewing range...............................................................663 Working position 0 to the rear..................................................663 180 to the front rigging position...............................................663 11.3.3 Main hoist....................................................................664 Maximum permissible hoistrope speed.............................................664 Switching on the main hoist......................................................665 Lifting and lowering............................................................665 Switching off the main hoist....................................................666 11.3.4 Auxiliary hoist...............................................................667 Maximum permissible hoist rope speed.............................................667 Switching on the auxiliary hoist................................................668 Lifting and lowering............................................................669 Switching off the auxiliary hoist...............................................669 11.3.5 Lifting limit switch and lowering limit switch................................670 Lifting limit switch.............................................................670 Lowering limit switch............................................................671 11.3.6 Derricking gear...............................................................672 Switching on the derricking gear................................................672 Maximum permissible derricking speed.............................................672 raising and lowering.............................................................673 Re-enable raising function.......................................................674 Switching off the derricking gear................................................674 Lowering the main boom to ahorizontal position..................................675 11.3.7 Telescoping mechanism.........................................................676 Overview.........................................................................677 Telescoping process..............................................................677 Assignment for display...........................................................679 Fixed length, intermediate length, telescoping length...........................681 Telescoping......................................................................682 Telescoping sequence............................................................682 Checks before starting work.....................................................683 Switching on the telescoping mechanism...........................................684 Function of the control lever....................................................684 Telescoping with lattice extension folded at the side............................686 Switching off the telescoping mechanism..........................................686 Manual telescoping..............................................................687 Checking the initial position....................................................687 Unlocking the telescoping cylinder...............................................689 Extending/retracting the telescoping cylinder....................................692 Lock telescoping cylinder........................................................693 Unlocking the telescopic section................................................694 Telescoping the telescopic section..............................................696 Locking the telescopic section..................................................697 Locking the telescopic section for on-road driving..............................698 Telescoping with teleautomation..................................................699 Telescoping the main boom when horizontal........................................703 11.3.8 High-speed mode...............................................................704 Switch on function...............................................................704 Derricking gear/ telescoping mechanism...........................................704 Hoists...........................................................................705 11.3.9 Slewing gear..................................................................706 Maximum permissible slewing speed................................................706 Switching on the slewing gear...................................................706 Releasing the slewing gear brake.................................................707 Engaging the slewing gear brake..................................................707 Turning..........................................................................707 Braking the slewing movement.....................................................709 Slewing gear freewheel...........................................................710 Switching off the slewing gear..................................................710 11.3.10 Possible movement combinations...............................................711 11.3.11 Hydraulic oil cooling........................................................711 11.4 Settings and displays for crane operation...........................................713 11.4.1 Inclining the crane cab.......................................................713 11.4.2 Setting idling speed..........................................................713 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................714 11.4.4 Limiting the power unit speeds................................................715 11.4.5 Setting the characteristic curves for the control levers......................716 11.4.6 Critical load control.........................................................717 Function.........................................................................717 Switching on andoff............................................................717 11.4.7 Using the pivoting spotlights.................................................718 11.4.8 Displaying the operating hours................................................719 11.4.9 Warning submenu...............................................................720 Meaning of thesymbols...........................................................720 Exiting the submenu.............................................................724 11.4.10 Error submenu................................................................724 11.5 Working range limiter...............................................................725 11.5.1 Opening the working range limiter submenu.....................................726 11.5.2 Viewing current settings......................................................726 11.5.3 Entering limit values.........................................................728 Overall height/ working radius..................................................728 Slewing angle....................................................................729 Entering objects.................................................................731 11.5.4 Entering limit values/objects manually........................................734 Limit values.....................................................................734 Objects..........................................................................735 11.5.5 Switching monitoring functions on/off.........................................736 11.5.6 Shutdown by working range limiter.............................................737 11.6 Work break..........................................................................739 11.6.1 In case of short work breaks..................................................739 11.6.2 In case of work breaks of more than 8 hours...................................740 To secure the truck crane........................................................740 11.7 Heating and air-conditioning system.................................................741 11.7.1 Standard heating system.......................................................741 Switching on.....................................................................741 Heating..........................................................................741 Air distribution.................................................................742 Switching off....................................................................742 11.7.2 Air-conditioning system.......................................................743 Information......................................................................743 Switching on/off.................................................................743 Cooling..........................................................................744 Drying the air...................................................................744 11.7.3 Auxiliary water heater........................................................745 Preheating theengine...........................................................745 Preheating the crane cab........................................................746 Switching on.....................................................................747 Setting the day and time.........................................................748 Storing the heating start.......................................................748 Setting the heating period......................................................749 Switching heating start on/off...................................................750 Switching off....................................................................751 Setting the remaining run time..................................................751 11.7.4 Auxiliary air heater..........................................................752 Switching on.....................................................................752 Temperature......................................................................753 Switching off....................................................................753 Other functions..................................................................753 11.8 CraneSTAR system....................................................................754 11.8.1 Overview......................................................................754 11.8.2 Position of the components....................................................754 12 Rigging work..............................................................................757 12.1 Rigging work checklists for crane operation with the main boom......................757 12.1.1 CHECKLIST: Rigging............................................................757 12.1.2 CHECKLIST: Unrigging..........................................................762 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 trailer...........................................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 driving for rigging work....................................779 12.5.1 Starting/turning off the engine from the crane cab............................779 Prerequisites....................................................................779 Starting the engine..............................................................779 After starting theengine........................................................780 Switching off theengine.........................................................780 12.5.2 Starting/switching off the engine from the outrigger control units............782 Prerequisites....................................................................782 Starting the engine..............................................................782 Switch the engine off............................................................782 12.6 Outriggers..........................................................................783 12.6.1 CHECKLIST: Extending the outriggers...........................................783 12.6.2 CHECKLIST: Retracting the outriggers..........................................785 12.6.3 Permissible outrigger spans...................................................786 12.6.4 Preparing the truck crane.....................................................787 In the driver's cab..............................................................787 Outriggers control units........................................................787 12.6.5 Setting the outrigger spans...................................................788 For on-road driving..............................................................790 12.6.6 Extending/retracting outrigger beams..........................................791 From the control units...........................................................792 From the cranecab...............................................................793 12.6.7 Moving the outrigger pads into working/driving position.......................795 12.6.8 Enlarging the load-bearing area...............................................796 12.6.9 Extending/retracting supporting cylinders.....................................797 From the control units...........................................................798 From the crane cab...............................................................799 12.6.10 Levelling the truck crane on outriggers......................................802 Inclination indicators...........................................................802 Prerequisites....................................................................803 Manual alignment................................................................804 Automatic alignment..............................................................805 12.6.11 Levelling the free-on-wheels truck crane.....................................806 12.6.12 Outrigger pressure display...................................................808 12.7 Rigging/unrigging the counterweight.................................................809 12.7.1 Counterweight sections........................................................809 Version A........................................................................809 Version B........................................................................810 12.7.2 Identification................................................................811 12.7.3 Slinging points on the counterweight sections.................................812 12.7.4 CHECKLIST: Rigging the counterweight..........................................814 12.7.5 CHECKLIST: Unrigging the counterweight........................................816 12.7.6 Assembling counterweight combination..........................................818 Combinations for the basic equipment in version A................................819 Combinations for the additional equipment in version A...........................822 Combinations for the basic equipment in version B................................824 Combinations for the additional equipment in version B...........................827 12.7.7 Counterweight hoist unit......................................................831 Counterweight submenu...........................................................831 Extending/retracting the lifting cylinders.......................................832 Automatic mode rigging..........................................................833 Automatic mode unrigging........................................................834 Cancel automatic mode...........................................................836 12.7.8 Setting down counterweight for driving the truck crane........................837 Version A........................................................................837 Version B........................................................................837 12.7.9 Slewing with rigged counterweight.............................................839 12.8 Rigging work on the main boom.......................................................841 12.8.1 Hook block on the bumper......................................................841 Picking up the hook block........................................................841 Attaching the hook block.........................................................842 12.8.2 Hook block on a separate vehicle..............................................843 Picking up the hook block.......................................................844 Setting down the hook block.....................................................844 12.8.3 Hook block, separable.........................................................846 Rigging for on-road driving......................................................846 Rigging for crane operation......................................................847 12.8.4 Reeving and unreeving the hoist rope..........................................848 Rope end fitting.................................................................848 Reeving the hoist rope...........................................................849 Unreeving hoist rope............................................................852 12.8.5 Possible reeving methods on the main boom.....................................853 With 9 head sheaves..............................................................854 With 10 head sheaves.............................................................857 12.8.6 Installing/removing the lifting limit switch..................................862 Installing the lifting limit switch..............................................862 Removing the lifting limit switch................................................865 12.8.7 Locking/unlocking the lifting limit switch....................................866 Locking..........................................................................866 Removing the lock...............................................................867 12.8.8 Anemometer and air traffic control light......................................868 Installing.......................................................................868 Removing.........................................................................869 12.9 Other rigging work..................................................................871 12.9.1 Railings on the turntable.....................................................871 12.9.2 Cameras for crane operation...................................................873 Cameras on the hoists............................................................873 Camera on main boom..............................................................873 Turning the monitor on/off and switching.........................................876 12.9.3 Ladder on the counterweight...................................................877 12.9.4 Extendable step...............................................................878 12.9.5 Folding the mirrors in and out, and adjusting them............................879 13 Driving with a rigged truck crane.........................................................883 13.1 Driving path........................................................................883 13.2 Permissible rigging modes and axle loads............................................884 Axle load table.....................................................................884 13.3 Before driving......................................................................886 13.3.1 Securing the superstructure against slewing...................................886 13.3.2 Check the tyre pressure and the wind speed....................................886 13.3.3 Putting the truck crane on the wheels.........................................887 13.3.4 Gears/connections.............................................................889 Transmission.....................................................................889 Connections......................................................................889 13.4 Whilst driving......................................................................889 13.5 After driving.......................................................................891 13.6 Driving in combined operation.......................................................892 13.6.1 Switching combined operation on/off...........................................892 Prerequisites....................................................................892 Switching on.....................................................................893 Switching off....................................................................893 13.6.2 Starting/turning off the engine...............................................894 13.6.3 Preparing to drive............................................................895 Transmission.....................................................................895 Switching on separate steering...................................................895 Connections......................................................................895 13.6.4 While driving.................................................................896 14 Malfunctions during crane operation.......................................................899 14.1 Emergency stop switch...............................................................899 14.2 What to do when malfunctions occur during crane operation...........................901 The load can be set down.............................................................901 Load cannot be setdown..............................................................901 14.3 Fuses...............................................................................903 Information on replacing fuses.....................................................903 14.3.1 Fuses on the turntable........................................................904 Fuse groups F1/F2/F3............................................................904 Fuses on the circuit board.......................................................905 14.3.2 Fuses in the crane cab........................................................907 14.3.3 Fuses in the battery box......................................................909 14.3.4 RCL fuses.....................................................................910 14.4 Finding and eliminating malfunctions................................................911 14.4.1 Malfunctions on the engine....................................................911 14.4.2 Malfunctions in the exhaust system............................................912 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................913 14.4.4 Malfunctions in the hoist cameras.............................................914 14.4.5 Malfunctions in the main boom camera..........................................914 14.4.6 Malfunctions on the derricking gear...........................................915 14.4.7 Malfunctions in the telescoping mechanism.....................................916 Telescoping mechanism error messages.............................................917 14.4.8 Malfunctions in the slewing gear..............................................919 14.4.9 Malfunctions in the counterweight hoist unit..................................921 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................922 14.4.11 Malfunctions when inclining the crane cab....................................922 14.4.12 Malfunctions when operating with the hand-held control.......................922 14.4.13 Malfunctions of the outriggers...............................................923 14.4.14 Troubleshooting the RCL......................................................924 General malfunctions............................................................924 Error messages in the Monitoring submenu.........................................925 Displays in the Error submenu....................................................927 Table of error codes.............................................................929 Switch off the sensor/ tachogenerator...........................................932 14.4.15 Malfunctions ECOS – superstructure...........................................933 ECOS programme version...........................................................933 General malfunctions............................................................933 Error messages...................................................................934 Exiting the submenu.............................................................935 14.4.16 Malfunctions on CraneSTAR system.............................................936 14.5 Emergency operations and programs...................................................939 14.5.1 Mechanical emergency activation for retracting................................940 Prior to the emergency activation, check.........................................940 Procedure........................................................................940 Mechanical emergency activation.................................................941 14.5.2 Telescoping emergency program.................................................943 Swinging the swing-away lattice..................................................944 Checks...........................................................................945 Starting the emergency program..................................................945 Determining the type of error...................................................946 Error at the length indicator....................................................947 If there is an error at a proximity switch.......................................951 Terminating emergency programme.................................................952 Tables for approaching the locking points........................................953 14.5.3 Entering the current telescoping..............................................955 14.5.4 Emergency operation with the hand-held control................................957 Preparations.....................................................................957 Operating a power unit...........................................................958 Stopping movements..............................................................960 Stopping movements in emergencies................................................960 Switch the engineoff............................................................960 14.5.5 Switching on emergency operation in coolant circuit...........................961 14.6 Hydraulic emergency operation.......................................................963 14.6.1 Operating principle...........................................................963 14.6.2 Connecting/disconnecting hoses................................................964 Establishing connections.........................................................964 Disconnecting connections.......................................................965 14.6.3 Switching emergency operation on/off..........................................966 14.6.4 Establishing the hydraulic circuits required..................................967 Switching over valves............................................................967 For lifting/ lowering............................................................969 For slewing......................................................................970 14.6.5 Performing emergency operation................................................971 Turning..........................................................................971 Derricking.......................................................................972 Lifting/lowering.................................................................972 14.6.6 After emergency operation.....................................................973 Switching off emergency operation................................................973 Switching over to crane operation................................................973 Disconnecting thehoses..........................................................973 14.6.7 Emergency supply of another crane.............................................974 For emergency supply.............................................................974 After emergency supply...........................................................974 14.7 Other emergency operations..........................................................975 14.7.1 External starting socket......................................................975 Performing a jump start..........................................................976 14.7.2 Battery charger...............................................................977 Prerequisites....................................................................977 15 Index.....................................................................................981 A........................................................................................983 B........................................................................................983 C........................................................................................984 D........................................................................................985 E........................................................................................987 F........................................................................................989 H........................................................................................989 I........................................................................................990 K........................................................................................990 L........................................................................................991 M........................................................................................991 O........................................................................................992 P........................................................................................994 R........................................................................................994 S........................................................................................995 T........................................................................................997 V........................................................................................999 W........................................................................................999
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