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Grove Crane GMK 6300L-1 Driving Operating Manual 3302740 – PDF DOWNLOAD
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Grove Crane GMK 6300L-1 Driving Operating Manual 3302740 – PDF DOWNLOAD
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Description
Grove Crane GMK 6300L-1 Driving Operating Manual 3302740 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L-1 Driving Operating Manual 3302740 – PDF DOWNLOAD
Language : English
Pages : 980
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L-1 Driving Operating Manual 3302740 – PDF DOWNLOAD
Documentation supplied:
The precise number of documents supplied depends on the rigging mode
of the truck crane. The following documents are included in delivery:
– Operating Manual
Contains information on driving and crane operation.
– Lattice extension operating manual
Is only supplied when the truck crane is equipped with a lattice extension
or other parts for extending the main boom (e.g. auxiliary single-sheave
boom top and heavy load lattice extension).
– Operating manual for additional equipment
This is only supplied when the truck crane is supplied with additional
equipment which is not described in the operating manual for driving and
crane operation.
– Documents from other manufacturers
Original documentation for parts not manufactured by Manitowoc Crane
Group Germany GmbH, such as the engine and central lubrication
system, as well as the tachograph, auxiliary heaters, radio and, where
appropriate, other additional equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no
instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and
pneumatic systems are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes.
TABLE OF CONTENTS:
Grove Crane GMK 6300L-1 Driving Operating Manual 3302740 – PDF DOWNLOAD
Driving ......................................................................................... 1 Additional pages ............................................................................ 3 Counterweight version B.................................................................. 3 Information on weight specifications................................................. 3 1 Overview................................................................................... 9 1.1 Accidents............................................................................ 9 1.2 Branch offices....................................................................... 11 1.2.1 Manitowoc Crane Care........................................................... 11 1.2.2 Dealer list.................................................................... 11 1.3 Warranty specifications.............................................................. 11 1.4 Terms used........................................................................... 12 1.5 Technical data....................................................................... 15 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 15 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 16 Dimensions....................................................................... 17 Weight and axleloads............................................................ 17 1.5.3 Dimensions and weights of removable parts...................................... 18 Spare wheel...................................................................... 18 Outriggers....................................................................... 18 Driver's safety guard............................................................ 19 Hose drum........................................................................ 19 Hook blocks and hook tackle...................................................... 19 Auxiliary hoist.................................................................. 20 Main boom........................................................................ 20 Counterweight parts............................................................. 20 1.5.4 Carrier........................................................................ 21 Engine........................................................................... 21 Transmission..................................................................... 21 Transfer case.................................................................... 21 Axle lines....................................................................... 21 Steering......................................................................... 22 Tyres............................................................................ 22 Outriggers....................................................................... 22 Auxiliary supports............................................................... 23 Electrical system................................................................ 23 Tool............................................................................. 23 Towing coupling................................................................. 23 Driving speeds................................................................... 23 Climbing ability................................................................. 23 Turning radii.................................................................... 24 1.5.5 Superstructure................................................................. 25 Engine........................................................................... 25 Main hoist....................................................................... 25 Auxiliary hoist.................................................................. 25 Slewing gears.................................................................... 26 Derricking gear.................................................................. 26 Main boom........................................................................ 26 Lattice extension................................................................ 26 Operating speeds................................................................. 27 1.6 Documentation supplied............................................................... 29 1.6.1 Questions on documentation..................................................... 30 1.7 Notes on the operating manual........................................................ 31 1.7.1 What do the symbols used mean?................................................. 31 1.7.2 How is the operating manual structured?........................................ 33 Division......................................................................... 33 Structure of thechapters........................................................ 33 Structure of thepages........................................................... 34 1.7.3 How do I find the information I need?.......................................... 35 Cross-references example......................................................... 36 1.7.4 What information is available for operations planning?......................... 38 1.8 Conversion table for US measuring units.............................................. 39 1.9 Training – Information............................................................... 41 1.10 Identification...................................................................... 42 1.11 EC Declaration of Conformity........................................................ 44 2 Basic safety instructions.................................................................. 47 2.1 Intended use......................................................................... 47 2.1.1 Improper use................................................................... 48 2.2 Organisational measures.............................................................. 49 2.3 Personnel qualifications............................................................. 51 2.4 Safety instructions for driving the truck crane...................................... 53 2.5 Safety instructions for crane operation.............................................. 55 2.6 Instructions on transporting persons................................................. 59 Equipment for lifting persons........................................................ 59 Personnel............................................................................ 60 Operation............................................................................ 60 Truck crane.......................................................................... 61 3 Operating elements for driving............................................................. 65 3.1 Overview of the operating elements................................................... 65 3.1.1 On the outside of the truck crane.............................................. 66 3.1.2 Driver's cab................................................................... 70 Front overview................................................................... 70 Behind the cover................................................................ 74 Rear overview.................................................................... 75 3.1.3 Instrument panel............................................................... 76 Left/right....................................................................... 76 Middle........................................................................... 77 3.1.4 Display, driving mode.......................................................... 80 3.1.5 Steering column/steering wheel................................................. 81 3.1.6 Transmission operating elements................................................ 82 3.1.7 Tachograph, time correction.................................................... 83 3.1.8 ECOS control unit.............................................................. 84 3.1.9 ECOS display – main menu....................................................... 86 3.1.10 ECOS display – submenus....................................................... 88 Level adjustment system submenu................................................. 88 Settings submenu................................................................. 90 Monitoring submenu............................................................... 91 Operating hours submenu......................................................... 92 Warning submenu.................................................................. 92 Error submenu.................................................................... 93 3.1.11 Heating/Air-conditioning system............................................... 94 Standard heating system.......................................................... 94 Auxiliary water heating system.................................................. 95 3.1.12 Outrigger control units....................................................... 96 3.1.13 Rear supporting box control unit.............................................. 97 3.2 Short description of the operating elements.......................................... 99 3.2.1 Definition of direction information............................................ 99 Basic rule....................................................................... 99 Switches and buttons............................................................100 3.2.2 General notes on the operating elements........................................100 3.2.3 General rules for buttons and symbols on the display...........................101 3.2.4 Engine.........................................................................102 Steering column..................................................................102 Multipurpose switch..............................................................102 Instrument panel.................................................................103 Main menu........................................................................104 3.2.5 Carbamide system...............................................................105 Instrument panel.................................................................105 Display, driving mode............................................................106 ECOS display.....................................................................106 3.2.6 Electrical system..............................................................107 3.2.7 ECOS crane control.............................................................108 Control unit.....................................................................108 3.2.8 Transmission...................................................................111 Instrument panel, middle.........................................................111 Display, driving mode............................................................111 Transmission control unit........................................................111 3.2.9 Reverse camera.................................................................115 Reverse camera on/off............................................................115 3.2.10 Transfer case.................................................................116 3.2.11 Final drive...................................................................117 3.2.12 Brakes........................................................................118 Service brake....................................................................118 Additional brakes................................................................118 Parking brake....................................................................119 3.2.13 Steering/separate steering....................................................120 Instrument panel.................................................................120 ECOS display.....................................................................121 Driver's door....................................................................122 3.2.14 Suspension....................................................................123 3.2.15 Lighting/windscreen wipers/horn...............................................124 Steering column..................................................................124 Instrument panel.................................................................124 Roof.............................................................................127 3.2.16 Level adjustment system.......................................................128 3.2.17 Tachograph/speedometer........................................................131 Tachograph.......................................................................131 Speedometer......................................................................131 3.2.18 Rear supporting box control unit..............................................132 3.2.19 Diagnostics...................................................................133 Displays/ submenu................................................................133 3.2.20 Windows, doors, keys..........................................................134 Window winder....................................................................134 Doors............................................................................135 Keys.............................................................................135 3.2.21 Front flap....................................................................136 4 Starting the engine for driving / switching it off.........................................139 4.1 Starting the engine from the driver's cab............................................139 4.1.1 CHECKLIST: Starting the engine.................................................139 4.1.2 CHECKLIST: At low temperatures.................................................142 4.1.3 Ladders and access ladders.....................................................142 Fixed ladders....................................................................142 Ladders..........................................................................143 4.1.4 Refuel.........................................................................145 Fuel.............................................................................145 Carbamide........................................................................146 4.1.5 Checks before starting the engine..............................................148 At the hydraulic tank............................................................148 Battery master switch............................................................148 Checking the hand-held control...................................................149 4.1.6 Switch on the ignition.........................................................149 4.1.7 Lamp test/equalisation of the switching states.................................150 Lamp test........................................................................150 Switching state alignment........................................................151 4.1.8 Display – setting the brightness...............................................152 4.1.9 Starting the engine............................................................153 Without flame start system.......................................................154 With flame start system.........................................................154 4.1.10 Checks after starting the engine..............................................156 Checking in the main menu........................................................156 Indicator lamps on the instrument panel..........................................156 4.1.11 Monitoring elements...........................................................158 Instrument panel.................................................................158 4.1.12 Monitoring submenu............................................................159 4.1.13 Setting idling speed..........................................................160 4.2 Switch the engine off................................................................161 4.2.1 At the ignition lock and with the outrigger control units......................161 After switching off.............................................................161 4.2.2 Using the emergency stop switches..............................................162 Resetting the emergency stop switch..............................................162 4.3 Air intake inhibitor.................................................................163 Releasing the air intake inhibitor...................................................163 5 Driving....................................................................................167 5.1 Before driving.......................................................................167 5.1.1 CHECKLIST: Checks before on-road driving.......................................167 5.1.2 Checking the condition of the truck crane......................................173 Windscreen washing system........................................................173 Electrical system................................................................173 Adjusting themirrors............................................................174 Warning plates for vehicle width.................................................175 Displaying vehicle height........................................................175 Supply pressure..................................................................176 Parking brake....................................................................177 5.1.3 Adjusting the seats and steering column........................................179 Driver's seat....................................................................179 Passenger's seat.................................................................181 Adjusting the steering column...................................................182 5.1.4 Switching the suspension on/off................................................183 Opening the submenu..............................................................183 Switching the suspension on.....................................................184 Switching the suspension off....................................................184 5.1.5 Setting the tachograph.........................................................185 Prerequisites....................................................................185 In the event of malfunctions.....................................................185 Setting the tachograph..........................................................186 5.1.6 Displaying the operating hours.................................................191 5.1.7 Settings/indications on the driving display....................................192 5.2 Operating the transmission...........................................................193 5.2.1 Switching on...................................................................193 5.2.2 Switching the transmission to the neutral position.............................194 While driving....................................................................194 5.2.3 Changing the driving mode......................................................195 5.2.4 Selecting the driving direction................................................196 5.2.5 Changing highest gear/starting gear............................................198 5.2.6 Starting.......................................................................198 5.2.7 Driving and changing gears.....................................................199 5.2.8 Changing the driving direction.................................................200 5.2.9 Stopping.......................................................................201 Stopping for longer periods.....................................................201 5.2.10 On the roller type dynamometer................................................201 5.2.11 Oil level gauge...............................................................202 5.3 Driving the truck crane and switching it off.........................................205 5.3.1 Checks whilst driving..........................................................205 Immediately after you start to move..............................................205 While driving....................................................................207 5.3.2 Cruise control.................................................................208 Switching on.....................................................................208 Switching off....................................................................209 5.3.3 Temposet.......................................................................209 Switching on.....................................................................209 Switching off....................................................................209 5.3.4 Driving downhill...............................................................210 Starting.........................................................................210 Checks when driving downhill....................................................210 Shifting down from the highest gear..............................................211 Additional brakes................................................................212 5.3.5 Driving uphill.................................................................213 Starting.........................................................................213 Driving..........................................................................213 5.3.6 Warning submenu................................................................214 Meaning of thesymbols...........................................................214 Exiting the submenu.............................................................216 5.3.7 Warning or malfunction messages on the instrument panel........................217 Meaning of the lamps.............................................................217 5.3.8 Override torque reduction......................................................219 5.3.9 Error submenu..................................................................220 5.3.10 Switching the truck crane off.................................................220 Secure it against rolling away...................................................220 When stationary for more than 8hours............................................221 5.3.11 Folding berth.................................................................223 5.4 Off-road driving.....................................................................225 Adjustments to the transmission......................................................225 Connections..........................................................................225 Changing the vehicle level...........................................................225 Rocking the vehicle free andtowing..................................................225 5.4.1 Transfer case – switching the off-road gear on/off.............................226 Prerequisites....................................................................226 Switching on.....................................................................227 Switching off....................................................................227 Neutral position.................................................................227 5.4.2 Longitudinal and transverse differential locks.................................228 5.4.3 Operating the level adjustment system..........................................230 Opening the submenu..............................................................230 Setting the on-road level.......................................................231 Pre-selecting suspension struts.................................................231 Changing the vehicle level.......................................................232 Viewing the current inclination..................................................232 Exiting the submenu.............................................................233 5.4.4 Freeing truck crane stuck in terrain...........................................234 Rocking the truck crane free....................................................234 Towing free to thefront........................................................235 Towing free to therear.........................................................235 5.5 Separate steering....................................................................237 5.5.1 Switching to separate steering.................................................237 Manual...........................................................................238 Automatic........................................................................239 switching to normal steering mode................................................240 5.6 Heating and air-conditioning system..................................................241 5.6.1 Standard heating system........................................................241 Switching on.....................................................................241 Heating..........................................................................241 Air distribution.................................................................242 Examples.........................................................................243 Switching off....................................................................243 5.6.2 Air-conditioning system........................................................244 Information......................................................................244 Switching on/off.................................................................244 Cooling..........................................................................245 Drying...........................................................................245 5.6.3 Auxiliary water heater.........................................................246 Preheating theengine............................................................246 Preheating the driver's cab.....................................................247 Switching on the auxiliary heater................................................247 Switching off the auxiliary heater...............................................248 Setting time andweekday.........................................................248 Saving automatic heating start..................................................249 Setting the heating period......................................................250 Switching the automatic heating start on and off.................................251 Setting the remaining run time..................................................251 5.7 Towing a trailer.....................................................................253 Effects on the axleloads............................................................253 Coupling the trailer................................................................254 Connecting the supply lines.........................................................255 Removing supply lines..............................................................256 Uncoupling thetrailer..............................................................256 Checking the braking force...........................................................258 6 Driving modes..............................................................................261 6.1 Driving modes........................................................................261 Information about the axle loads.....................................................261 6.1.1 Information on how to use the tables...........................................262 6.1.2 Tables for a maximum axle load of 12 t.........................................263 For tyres 385/95 R25.............................................................263 For tyres 445/95 R25.............................................................264 For tyres 525/80 R25.............................................................265 6.1.3 Maximum permitted speeds with an axle load of over 12 t........................266 6.2 Weighing the truck crane.............................................................267 Determining..........................................................................267 Axle groups..........................................................................268 Weighing procedure...................................................................269 Evaluation...........................................................................270 6.3 Rigging work for driving with a trailer..............................................271 6.3.1 Switching on the slewing gear freewheel........................................272 6.3.2 Switching on the boom floating position........................................273 6.3.3 Switching on boom pre-tensioning...............................................274 6.3.4 Adjusting axle pressure........................................................275 Preselecting the axle pair.......................................................275 Adjusting axle pressure..........................................................276 Driving with changed axle pressures..............................................276 Adjusting axle pressure for on-road driving......................................276 6.3.5 Switching the superstructure driving lights on/off.............................277 Switching off....................................................................277 Switching on.....................................................................277 6.4 Main boom, removing/installing.......................................................279 Additional equipment required........................................................279 6.4.1 CHECKLIST: Removing the main boom..............................................280 Prerequisites....................................................................280 Checklist........................................................................280 6.4.2 CHECKLIST: Mounting the main boom..............................................283 Prerequisites....................................................................283 Checklist........................................................................283 6.4.3 Slinging the main boom.........................................................286 Marking..........................................................................286 Installing the lifting gear......................................................286 Removing the lifting gear........................................................287 6.4.4 Removing/attaching the clamps..................................................288 6.4.5 Switching the pressure relief on/off...........................................289 6.4.6 Connecting/disconnecting the derricking cylinder from the boom.................290 Retracting the derricking cylinder head axle.....................................291 Fitting the derricking cylinder head axle........................................292 6.4.7 Extending/retracting the boom pivot pin........................................293 Before pulling itout............................................................293 After pushing it in..............................................................293 Pulling out the pivot pin........................................................294 Pushing the pivot pin in.........................................................295 6.4.8 Disconnecting/connecting hydraulics/electrical.................................296 Disconnecting....................................................................296 Connecting.......................................................................297 6.4.9 Lifting the main boom off/on the turntable.....................................298 Lifting from the turntable.......................................................298 Lifting on to the turntable......................................................299 6.4.10 Aligning the connecting points................................................300 6.4.11 Securing/releasing the derricking cylinder....................................300 6.4.12 Transporting the main boom....................................................301 6.4.13 Inspections after main boom mounting..........................................302 6.4.14 Installing/removing the hose drum.............................................303 Installing.......................................................................303 Removing.........................................................................304 6.5 Installing/removing outrigger beams..................................................307 6.5.1 CHECKLIST: Removing the outrigger beams........................................308 6.5.2 CHECKLIST: Installing the outrigger beams......................................310 6.5.3 Preparing the truck crane......................................................312 Prerequisites....................................................................312 For removal......................................................................312 6.5.4 Removing/attaching outrigger pads..............................................313 Removing outrigger pads.........................................................313 Attaching outrigger pads........................................................314 6.5.5 Disconnecting/establishing the hydraulic connection............................315 6.5.6 Disconnecting/establishing the electrical connection...........................316 6.5.7 Unscrewing/screwing in the spacers.............................................317 Unscrewing.......................................................................317 Screwing in......................................................................318 6.5.8 Disconnecting/establishing the connections to the supporting box...............319 6.5.9 Extending/retracting the outrigger beam........................................319 Extending the outrigger beam....................................................319 Inserting the outrigger beam.....................................................321 6.5.10 Transporting the outrigger beams..............................................323 6.6 Installing/removing the supporting box...............................................325 6.6.1 CHECKLIST: Removing the supporting box.........................................326 6.6.2 CHECKLIST: Installing the supporting box.......................................329 6.6.3 Rig the outrigger span 7.98x8.50/1.00m......................................331 Front outrigger..................................................................332 Auxiliary supports...............................................................332 6.6.4 Establishing/disconnecting the pneumatic connection............................334 6.6.5 Disconnecting/establishing the electrical connection...........................335 6.6.6 Disconnecting/establishing the hydraulic connection............................336 6.6.7 Attaching/raising the supporting box with the truck crane......................337 Prerequisites:...................................................................337 Lifting..........................................................................338 Hanging..........................................................................339 6.6.8 Installing the reverse camera..................................................340 6.6.9 Crane movements during installation and removal................................341 Prerequisites....................................................................341 Before installation..............................................................341 After the removal...............................................................341 6.6.10 Slinging points on the supporting box.........................................342 6.6.11 Locking/unlocking the supporting box..........................................343 Locking..........................................................................343 Unlocking........................................................................344 6.6.12 Transporting the supporting box on the separate vehicle.......................345 Lashing eyelets..................................................................345 6.6.13 Installing / removing the rear bumper.........................................346 Prerequisites:...................................................................346 Installing.......................................................................347 Removing.........................................................................347 6.7 Rigging the auxiliary hoist..........................................................349 6.7.1 CHECKLIST: Auxiliary hoist, installing.........................................349 Prerequisites....................................................................349 6.7.2 CHECKLIST: Auxiliary hoist, removing...........................................351 Prerequisites....................................................................351 6.7.3 Slinging the auxiliary hoist...................................................353 6.7.4 Installing/removing the rigging frame..........................................354 Prerequisite.....................................................................354 6.7.5 Setting down the auxiliary hoist...............................................355 6.7.6 Making/breaking the hydraulic connection.......................................356 6.7.7 Establishing/disconnecting the electrical connection...........................357 6.7.8 Creating the connection to the turntable.......................................358 Establishing the connection......................................................358 Separating the connection........................................................360 6.7.9 Securing the hoist rope........................................................361 6.7.10 Transporting the auxiliary hoist..............................................362 6.7.11 Check that the auxiliary hoist is functioning properly........................363 Slewing direction................................................................363 Slewing indicator................................................................363 7 Malfunctions in driving mode...............................................................367 7.1 Emergency stop switch................................................................367 7.2 What to do when a malfunction occurs in road traffic.................................369 7.3 Towing the truck crane...............................................................371 7.3.1 Towing after engine/transmission damage........................................372 Compressed-air supply............................................................372 Electric power supply............................................................373 On the transmission..............................................................373 Axle drives......................................................................373 Transfer case....................................................................374 Parking brake....................................................................374 Towing the truck crane out of the danger area....................................375 7.3.2 Tow starting...................................................................375 7.3.3 External starting socket.......................................................376 Performing a jump start..........................................................376 7.3.4 Battery charger................................................................377 Prerequisites....................................................................377 7.4 Wheels and tyres.....................................................................379 7.4.1 Wheel change...................................................................379 Removing adamaged wheel.........................................................380 On the spare wheel holder........................................................380 Mounting a wheel.................................................................381 7.4.2 Inflating the tyres yourself...................................................383 Connecting the filling hose......................................................383 Inflating the tyres..............................................................384 Removing the filling hose........................................................384 7.5 Fuses................................................................................385 Information on replacing fuses.....................................................385 7.5.1 Fuses in the driver's cab......................................................386 Group F1.........................................................................386 Group F2.........................................................................387 Group F3.........................................................................387 Group F4.........................................................................388 Group F5.........................................................................388 Group F6.........................................................................389 Group F7.........................................................................389 Group F8.........................................................................389 Group F9.........................................................................390 Group F10........................................................................390 7.5.2 Fuses in the battery box.......................................................391 7.6 Troubleshooting......................................................................393 7.6.1 Malfunctions on the engine.....................................................393 7.6.2 Malfunctions in the exhaust system.............................................395 7.6.3 Malfunctions in the transmission...............................................396 7.6.4 Transfer case malfunctions.....................................................397 7.6.5 Malfunctions of the service brake..............................................397 7.6.6 Malfunctions of the steering...................................................398 7.6.7 Differential lock malfunctions.................................................399 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................399 7.6.9 Malfunctions on the suspension.................................................400 7.6.10 Malfunctions of the level adjustment system...................................400 7.6.11 Malfunctions on the ECOS carrier..............................................401 ECOS programme version...........................................................401 General malfunctions............................................................401 Error messages...................................................................402 Exiting the submenu.............................................................403 7.7 Procedure in the event of malfunctions...............................................404 7.7.1 Switching on emergency operation in coolant circuit............................404 7.7.2 Procedure during engine malfunctions...........................................405 7.7.3 Malfunctions in the transmission...............................................406 General malfunctions.............................................................406 Transmission malfunction.........................................................406 Reading out error codes.........................................................408 8 Index......................................................................................411 A........................................................................................413 B........................................................................................413 C........................................................................................414 D........................................................................................415 E........................................................................................417 F........................................................................................419 H........................................................................................419 I........................................................................................420 K........................................................................................420 L........................................................................................421 M........................................................................................421 O........................................................................................422 P........................................................................................424 R........................................................................................424 S........................................................................................425 T........................................................................................427 V........................................................................................429 W........................................................................................429 Crane Operation .................................................................................437 Additional pages ............................................................................435 Counterweight version B..................................................................435 Information on weight specifications.....................................................435 9 Operating elements for crane operation.....................................................441 9.1 Overview of the operating elements...................................................441 9.1.1 Exterior of the truck crane....................................................442 9.1.2 Crane cab......................................................................446 9.1.3 Front panel....................................................................448 9.1.4 Side panel.....................................................................449 Bottom...........................................................................449 Top..............................................................................450 Console, rear....................................................................452 Standard heating system..........................................................453 Auxiliary water heating system..................................................454 Auxiliary air heater............................................................455 9.1.5 Control panels.................................................................456 Left.............................................................................456 Right............................................................................457 9.1.6 Control lever configuration....................................................458 Version 1........................................................................458 Version 2........................................................................459 9.1.7 ECOS control unit..............................................................460 9.1.8 ECOS display – main menu.......................................................462 9.1.9 ECOS display – submenus........................................................464 Counterweight submenu...........................................................464 Slewing gear/ houselock submenu..................................................465 Outriggers submenu..............................................................466 Telescoping submenu.............................................................468 Power unit speeds submenu.....................................................470 Monitoring submenu..............................................................471 Settings submenu................................................................472 Operating hours submenu.........................................................473 Submenu Warning.................................................................474 Error submenu....................................................................477 Working range limiter submenu..................................................478 9.1.10 RCL control unit..............................................................480 9.1.11 RCL display – main menu.......................................................481 9.1.12 Display RCL – submenus........................................................483 Enter rigging mode submenu....................................................483 Monitoring submenu..............................................................484 Rigging mode monitoring submenu................................................486 Lifting capacity table submenu.................................................487 Working range submenu...........................................................488 Error submenu....................................................................489 Settings submenu.................................................................490 9.1.13 Hand-held control.............................................................491 9.1.14 Outrigger control units.......................................................492 Button...........................................................................492 Outrigger button.................................................................493 Inclination and outrigger pressure display.......................................494 Raise axle display...............................................................495 9.2 Short description of the operating elements..........................................497 9.2.1 Definition of direction information............................................497 Basic rule.......................................................................497 Switches.........................................................................498 9.2.2 General rules for buttons and symbols on the display...........................498 9.2.3 Engine for crane operation.....................................................499 Side panel......................................................................499 Console, rear....................................................................500 ECOS display.....................................................................500 9.2.4 Engine for driving.............................................................500 Side panel.......................................................................500 Main menu........................................................................500 Outriggers submenu..............................................................501 9.2.5 Seat contact switch and dead man's switch......................................502 9.2.6 ECOS crane control.............................................................503 Control unit.....................................................................503 9.2.7 Outriggers.....................................................................506 In the Outriggers submenu.......................................................506 In the Settings submenu..........................................................507 On the outrigger control units...................................................508 9.2.8 Inclination indicators.........................................................510 9.2.9 Raise axle.....................................................................511 Outrigger control units..........................................................511 9.2.10 Outrigger pressure displays...................................................513 Outriggers submenu..............................................................513 Outriggers controlunits........................................................513 9.2.11 Anemometer display............................................................513 9.2.12 Counterweight submenu.........................................................514 Counterweight submenu...........................................................514 9.2.13 Main hoist....................................................................518 9.2.14 Auxiliary hoist...............................................................520 9.2.15 Slewing gear..................................................................521 Submenu..........................................................................522 9.2.16 Derricking gear...............................................................524 9.2.17 Telescoping mechanism.........................................................526 Control panels...................................................................526 Submenu..........................................................................527 In the Settings submenu..........................................................532 9.2.18 Hydraulic system..............................................................533 9.2.19 House lock....................................................................534 9.2.20 Rated capacity limiter (RCL)..................................................535 Control unit.....................................................................535 Main menu........................................................................537 Submenu Rigging mode entry.......................................................538 Monitoring submenu...............................................................542 Submenu Lifting capacity table...................................................546 Working range submenu...........................................................547 RCL override.....................................................................548 External displays................................................................549 9.2.21 Electrical system.............................................................550 9.2.22 Lighting, windscreen wiper/washing system.....................................551 Lighting.........................................................................551 Windscreen wiper/washing system.................................................553 9.2.23 Hand-held control.............................................................554 Sockets for hand-held control....................................................554 Engine control panel.............................................................555 Horn.............................................................................555 9.2.24 Windows, doors, keys..........................................................558 Windscreen.......................................................................558 Rear window......................................................................558 Crane cab door...................................................................559 Keys.............................................................................560 9.2.25 Diagnostics...................................................................560 10 Starting/switching off the engine – for crane operation...................................563 10.1 Starting the engine – from the crane cab............................................563 10.1.1 CHECKLIST: Starting the engine................................................563 10.1.2 CHECKLIST: At low temperatures................................................566 10.1.3 Refuel........................................................................566 Fuel.............................................................................566 Carbamide........................................................................568 10.1.4 Checks before starting the engine.............................................569 At the hydraulic tank............................................................569 Battery master switch............................................................569 Checking the hand-held control...................................................570 10.1.5 Switch on the ignition........................................................570 10.1.6 Lamp test / switching state alignment.........................................571 Lamp test........................................................................571 10.1.7 Adjusting display brightness..................................................573 10.1.8 Starting the engine...........................................................574 Without flame start system.......................................................574 With flame start system..........................................................575 10.1.9 Checks after starting the engine..............................................576 10.1.10 Monitoring submenu...........................................................577 10.1.11 Setting idling speed.........................................................578 10.1.12 Override torque reduction....................................................579 10.2 Starting the engine – with the hand-held control....................................581 Prerequisites........................................................................581 Starting the engine..................................................................581 10.3 Switching off the engine............................................................583 10.3.1 During normal operation, with the ignition lock/with the hand-held control....583 After switching off.............................................................583 10.3.2 In emergencies, with the emergency stop switches..............................584 Resetting the emergency stop switch..............................................584 10.4 Air intake inhibitor................................................................585 Releasing the air intake inhibitor...................................................585 11 Crane operation...........................................................................589 11.1 Before operating the crane..........................................................589 11.1.1 CHECKLIST: Checks before operating the crane..................................589 11.1.2 Checking the condition of the truck crane.....................................593 Windscreen washing system – Tank.................................................593 Visual inspection................................................................593 Checking the position of the hoist ropes.........................................594 Checking the electrical system...................................................594 11.1.3 Adjusting the crane cab seat and front control panel..........................595 Crane cab seat...................................................................595 Front control panel..............................................................596 11.1.4 Checking the safety equipment.................................................597 Rated capacity limiter...........................................................597 Lifting limit switch............................................................597 Emergency stop switch............................................................598 Seat contact switch..............................................................599 11.1.5 Earthing the load.............................................................600 11.1.6 Preheating the hydraulic oil..................................................601 11.1.7 Locking/unlocking the turntable...............................................602 Locking points...................................................................602 11.1.8 Switching the houselock on/off................................................603 Switching on the houselock......................................................603 Switching off the houselock.....................................................605 11.2 Operation of the rated capacity limiter.............................................607 11.2.1 Switch on the RCL.............................................................608 Switching on.....................................................................608 Brightness of the displays.......................................................610 11.2.2 Enter rigging mode............................................................611 Entering individual components...................................................612 Entering the RCL code...........................................................616 Entering the reeving............................................................617 Accepting the rigging mode.......................................................617 11.2.3 Checks before operating the crane.............................................619 Opening the submenu..............................................................619 Checks...........................................................................620 11.2.4 Displays during crane operation...............................................622 11.2.5 RCL early warning.............................................................625 11.2.6 RCL shutdown..................................................................625 Shutdown due to overload.........................................................625 11.2.7 Display in the event of errors................................................627 11.2.8 RCL override..................................................................628 Table – error/ information codes.................................................634 11.2.9 Displaying the lifting capacity tables........................................635 11.2.10 Entering the time/date.......................................................637 11.3 Crane operation with main boom......................................................639 11.3.1 Checks during crane operation.................................................639 Horizontal alignment.............................................................639 Safe distances..................................................................639 Checking the windspeed..........................................................640 11.3.2 Permissible slewing ranges and working positions..............................641 360 slewing range...............................................................641 Working position 0 to the rear..................................................641 180 to the front rigging position...............................................641 11.3.3 Main hoist....................................................................642 Maximum permissible hoistrope speed.............................................642 Switching on the main hoist......................................................643 Lifting and lowering............................................................643 Switching off the main hoist....................................................644 11.3.4 Auxiliary hoist...............................................................645 Maximum permissible hoist rope speed.............................................645 Switching on the auxiliary hoist................................................646 Lifting and lowering............................................................647 Switching off the auxiliary hoist...............................................647 11.3.5 Lifting limit switch and lowering limit switch................................648 Lifting limit switch.............................................................648 Lowering limit switch............................................................649 11.3.6 Derricking gear...............................................................650 Switching on the derricking gear................................................650 Maximum permissible derricking speed.............................................650 raising and lowering.............................................................651 Re-enable raising function.......................................................652 Switching off the derricking gear................................................652 Lowering the main boom to ahorizontal position..................................653 11.3.7 Telescoping mechanism.........................................................654 Overview.........................................................................655 Telescoping process..............................................................655 Assignment for display...........................................................657 Fixed length, intermediate length, telescoping length...........................659 Telescoping......................................................................660 Telescoping sequence............................................................660 Checks before starting work.....................................................661 Switching on the telescoping mechanism...........................................662 Function of the control lever....................................................662 Telescoping with lattice extension folded at the side............................664 Switching off the telescoping mechanism..........................................664 Manual telescoping..............................................................665 Checking the initial position....................................................665 Unlocking the telescoping cylinder...............................................667 Extending/retracting the telescoping cylinder....................................670 Lock telescoping cylinder........................................................671 Unlocking the telescopic section................................................672 Telescoping the telescopic section..............................................674 Locking the telescopic section..................................................675 Locking the telescopic section for on-road driving..............................676 Telescoping with teleautomation..................................................677 Telescoping the main boom when horizontal........................................681 11.3.8 High-speed mode...............................................................682 Switch on function...............................................................682 Derricking gear/ telescoping mechanism...........................................682 Hoists...........................................................................683 11.3.9 Slewing gear..................................................................684 Maximum permissible slewing speed................................................684 Switching on the slewing gear...................................................684 Releasing the slewing gear brake.................................................685 Engaging the slewing gear brake..................................................685 Turning..........................................................................685 Braking the slewing movement.....................................................687 Slewing gear freewheel...........................................................688 Switching off the slewing gear..................................................688 11.3.10 Possible movement combinations...............................................689 11.3.11 Hydraulic oil cooling........................................................689 11.4 Settings and displays for crane operation...........................................691 11.4.1 Inclining the crane cab.......................................................691 11.4.2 Setting idling speed..........................................................691 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................692 11.4.4 Limiting the power unit speeds................................................693 11.4.5 Setting the characteristic curves for the control levers......................694 11.4.6 Critical load control.........................................................695 Function.........................................................................695 Switching on andoff............................................................695 11.4.7 Using the pivoting spotlights.................................................696 11.4.8 Displaying the operating hours................................................697 11.4.9 Warning submenu...............................................................698 Meaning of thesymbols...........................................................698 Exiting the submenu.............................................................702 11.4.10 Error submenu................................................................702 11.5 Working range limiter...............................................................703 11.5.1 Opening the working range limiter submenu.....................................704 11.5.2 Viewing current settings......................................................704 11.5.3 Entering limit values.........................................................706 Overall height/ working radius..................................................706 Slewing angle....................................................................707 Entering objects.................................................................709 11.5.4 Entering limit values/objects manually........................................712 Limit values.....................................................................712 Objects..........................................................................713 11.5.5 Switching monitoring functions on/off.........................................714 11.5.6 Shutdown by working range limiter.............................................715 11.6 Work break..........................................................................717 11.6.1 In case of short work breaks..................................................717 11.6.2 In case of work breaks of more than 8 hours...................................718 To secure the truck crane........................................................718 11.7 Heating and air-conditioning system.................................................719 11.7.1 Standard heating system.......................................................719 Switching on.....................................................................719 Heating..........................................................................719 Air distribution.................................................................720 Switching off....................................................................720 11.7.2 Air-conditioning system.......................................................721 Information......................................................................721 Switching on/off.................................................................721 Cooling..........................................................................722 Drying the air...................................................................722 11.7.3 Auxiliary water heater........................................................723 Preheating theengine...........................................................723 Preheating the crane cab........................................................724 Switching on.....................................................................725 Setting the day and time.........................................................726 Storing the heating start.......................................................726 Setting the heating period......................................................727 Switching heating start on/off...................................................728 Switching off....................................................................729 Setting the remaining run time..................................................729 11.7.4 Auxiliary air heater..........................................................730 Switching on.....................................................................730 Temperature......................................................................731 Switching off....................................................................731 Other functions..................................................................731 11.8 CraneSTAR system....................................................................732 11.8.1 Overview......................................................................732 11.8.2 Position of the components....................................................732 12 Rigging work..............................................................................735 12.1 Rigging work checklists for crane operation with the main boom......................735 12.1.1 CHECKLIST: Rigging............................................................735 12.1.2 CHECKLIST: Unrigging..........................................................740 12.2 Choice of a suitable positioning site...............................................743 12.2.1 Determining the required load-bearing area....................................743 12.2.2 Safe distance from slopes and pits............................................746 12.2.3 Earthing the truck crane......................................................747 12.2.4 Safe distance from overhead power lines.......................................748 12.3 Rigging work after driving with a trailer...........................................751 12.3.1 Switching off the boom floating position......................................751 12.3.2 Switching off the slewing gear freewheel......................................752 Before slewing...................................................................752 12.3.3 Switching off boom pre-tensioning.............................................753 12.4 Connecting/disconnecting the hand-held control......................................755 12.5 Starting the engine for driving for rigging work....................................757 12.5.1 Starting/turning off the engine from the crane cab............................757 Prerequisites....................................................................757 Starting the engine..............................................................757 After starting theengine........................................................758 Switching off theengine.........................................................758 12.5.2 Starting/switching off the engine from the outrigger control units............760 Prerequisites....................................................................760 Starting the engine..............................................................760 Switch the engine off............................................................760 12.6 Outriggers..........................................................................761 12.6.1 CHECKLIST: Extending the outriggers...........................................761 12.6.2 CHECKLIST: Retracting the outriggers..........................................763 12.6.3 Permissible outrigger spans...................................................764 12.6.4 Preparing the truck crane.....................................................765 In the driver's cab..............................................................765 Outriggers control units........................................................765 12.6.5 Setting the outrigger spans...................................................766 For on-road driving..............................................................768 12.6.6 Extending/retracting outrigger beams..........................................769 From the control units...........................................................770 From the cranecab...............................................................771 12.6.7 Moving the outrigger pads into working/driving position.......................773 12.6.8 Enlarging the load-bearing area...............................................774 12.6.9 Extending/retracting supporting cylinders.....................................775 From the control units...........................................................776 From the crane cab...............................................................777 12.6.10 Levelling the truck crane on outriggers......................................780 Inclination indicators...........................................................780 Prerequisites....................................................................781 Manual alignment................................................................782 Automatic alignment..............................................................783 12.6.11 Levelling the free-on-wheels truck crane.....................................784 12.6.12 Outrigger pressure display...................................................786 12.7 Rigging/unrigging the counterweight.................................................787 12.7.1 Counterweight sections........................................................787 Version A........................................................................787 Version B........................................................................788 12.7.2 Identification................................................................789 12.7.3 Slinging points on the counterweight sections.................................790 12.7.4 CHECKLIST: Rigging the counterweight..........................................792 12.7.5 CHECKLIST: Unrigging the counterweight........................................794 12.7.6 Assembling counterweight combination..........................................796 Combinations for the basic equipment in version A................................797 Combinations for the additional equipment in version A...........................800 Combinations for the basic equipment in version B................................802 Combinations for the additional equipment in version B...........................805 12.7.7 Counterweight hoist unit......................................................809 Counterweight submenu...........................................................809 Extending/retracting the lifting cylinders.......................................810 Automatic mode rigging..........................................................811 Automatic mode unrigging........................................................812 Cancel automatic mode...........................................................814 12.7.8 Setting down counterweight for driving the truck crane........................815 Version A........................................................................815 Version B........................................................................815 12.7.9 Slewing with rigged counterweight.............................................817 12.8 Rigging work on the main boom.......................................................819 12.8.1 Hook block on the bumper......................................................819 Picking up the hook block........................................................819 Attaching the hook block.........................................................820 12.8.2 Hook block on a separate vehicle..............................................821 Picking up the hook block.......................................................822 Setting down the hook block.....................................................822 12.8.3 Hook block, separable.........................................................824 Rigging for on-road driving......................................................824 Rigging for crane operation......................................................825 12.8.4 Reeving and unreeving the hoist rope..........................................826 Rope end fitting.................................................................826 Reeving the hoist rope...........................................................827 Unreeving hoist rope............................................................830 12.8.5 Possible reeving methods on the main boom.....................................831 With 9 head sheaves..............................................................832 With 10 head sheaves.............................................................835 12.8.6 Installing/removing the lifting limit switch..................................840 Installing the lifting limit switch..............................................840 Removing the lifting limit switch................................................843 12.8.7 Locking/unlocking the lifting limit switch....................................844 Locking..........................................................................844 Removing the lock...............................................................845 12.8.8 Anemometer and air traffic control light......................................846 Installing.......................................................................846 Removing.........................................................................847 12.9 Other rigging work..................................................................849 12.9.1 Railings on the turntable.....................................................849 12.9.2 Cameras for crane operation...................................................851 Cameras on the hoists............................................................851 Camera on main boom..............................................................851 Turning the monitor on/off and switching.........................................854 12.9.3 Ladder on the counterweight...................................................855 12.9.4 Extendable step...............................................................856 12.9.5 Folding the mirrors in and out, and adjusting them............................857 13 Driving with a rigged truck crane.........................................................861 13.1 Driving path........................................................................861 13.2 Permissible rigging modes and axle loads............................................862 Axle load table.....................................................................862 13.3 Before driving......................................................................864 13.3.1 Securing the superstructure against slewing...................................864 13.3.2 Check the tyre pressure and the wind speed....................................864 13.3.3 Putting the truck crane on the wheels.........................................865 13.3.4 Gears/connections.............................................................867 Transmission.....................................................................867 Connections......................................................................867 13.4 Whilst driving......................................................................867 13.5 After driving.......................................................................869 13.6 Driving in combined operation.......................................................870 13.6.1 Switching combined operation on/off...........................................870 Prerequisites....................................................................870 Switching on.....................................................................871 Switching off....................................................................871 13.6.2 Starting/turning off the engine...............................................872 13.6.3 Preparing to drive............................................................873 Transmission.....................................................................873 Switching on separate steering...................................................873 Connections......................................................................873 13.6.4 While driving.................................................................874 14 Malfunctions during crane operation.......................................................877 14.1 Emergency stop switch...............................................................877 14.2 What to do when malfunctions occur during crane operation...........................879 The load can be set down.............................................................879 Load cannot be setdown..............................................................879 14.3 Fuses...............................................................................881 Information on replacing fuses.....................................................881 14.3.1 Fuses on the turntable........................................................882 Fuse groups F1/F2/F3............................................................882 Fuses on the circuit board.......................................................883 14.3.2 Fuses in the crane cab........................................................885 14.3.3 Fuses in the battery box......................................................887 14.3.4 RCL fuses.....................................................................888 14.4 Finding and eliminating malfunctions................................................889 14.4.1 Malfunctions on the engine....................................................889 14.4.2 Malfunctions in the exhaust system............................................890 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................891 14.4.4 Malfunctions in the hoist cameras.............................................892 14.4.5 Malfunctions in the main boom camera..........................................892 14.4.6 Malfunctions on the derricking gear...........................................893 14.4.7 Malfunctions in the telescoping mechanism.....................................894 Telescoping mechanism error messages.............................................895 14.4.8 Malfunctions in the slewing gear..............................................897 14.4.9 Malfunctions in the counterweight hoist unit..................................899 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................900 14.4.11 Malfunctions when inclining the crane cab....................................900 14.4.12 Malfunctions when operating with the hand-held control.......................900 14.4.13 Malfunctions of the outriggers...............................................901 14.4.14 Troubleshooting the RCL......................................................902 General malfunctions............................................................902 Error messages in the Monitoring submenu.........................................903 Displays in the Error submenu....................................................905 Table of error codes.............................................................907 Switch off the sensor/ tachogenerator...........................................910 14.4.15 Malfunctions ECOS – superstructure...........................................911 ECOS programme version...........................................................911 General malfunctions............................................................911 Error messages...................................................................912 Exiting the submenu.............................................................913 14.4.16 Malfunctions on CraneSTAR system.............................................914 14.5 Emergency operations and programs...................................................917 14.5.1 Mechanical emergency activation for retracting................................918 Prior to the emergency activation, check.........................................918 Procedure........................................................................918 Mechanical emergency activation.................................................919 14.5.2 Telescoping emergency program.................................................921 Swinging the swing-away lattice..................................................922 Checks...........................................................................923 Starting the emergency program..................................................923 Determining the type of error...................................................924 Error at the length indicator....................................................925 If there is an error at a proximity switch.......................................929 Terminating emergency programme.................................................930 Tables for approaching the locking points........................................931 14.5.3 Entering the current telescoping..............................................933 14.5.4 Emergency operation with the hand-held control................................935 Preparations.....................................................................935 Operating a power unit...........................................................936 Stopping movements..............................................................938 Stopping movements in emergencies................................................938 Switch the engineoff............................................................938 14.5.5 Switching on emergency operation in coolant circuit...........................939 14.6 Hydraulic emergency operation.......................................................941 14.6.1 Operating principle...........................................................941 14.6.2 Connecting/disconnecting hoses................................................942 Establishing connections.........................................................942 Disconnecting connections.......................................................943 14.6.3 Switching emergency operation on/off..........................................944 14.6.4 Establishing the hydraulic circuits required..................................945 Switching over valves............................................................945 For lifting/ lowering............................................................947 For slewing......................................................................948 14.6.5 Performing emergency operation................................................949 Turning..........................................................................949 Derricking.......................................................................950 Lifting/lowering.................................................................950 14.6.6 After emergency operation.....................................................951 Switching off emergency operation................................................951 Switching over to crane operation................................................951 Disconnecting thehoses..........................................................951 14.6.7 Emergency supply of another crane.............................................952 For emergency supply.............................................................952 After emergency supply...........................................................952 14.7 Other emergency operations..........................................................953 14.7.1 External starting socket......................................................953 Performing a jump start..........................................................954 14.7.2 Battery charger...............................................................955 Prerequisites....................................................................955 15 Index.....................................................................................959 A........................................................................................961 B........................................................................................961 C........................................................................................962 D........................................................................................963 E........................................................................................965 F........................................................................................967 H........................................................................................967 I........................................................................................968 K........................................................................................968 L........................................................................................969 M........................................................................................969 O........................................................................................970 P........................................................................................972 R........................................................................................972 S........................................................................................973 T........................................................................................975 V........................................................................................977 W........................................................................................977
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