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Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112805 – PDF DOWNLOAD
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Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112805 – PDF DOWNLOAD
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Description
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112805 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112805 – PDF DOWNLOAD
Language : English
Pages : 934
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112805 – PDF DOWNLOAD
Intended use:
The GMK 6300L is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 6300L truck crane may only be used when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 6300L truck crane may only be operated without the correspond- ing special equipment within
the permitted temperature range; à Technical
data, p. 1 – 9. - The GMK 6300L truck crane is designed solely for lifting loads which are within the permitted GMK
6300L lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes
– Observing the entire crane documentation, consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– Adhering to the inspection and maintenance requirements specified in the maintenance manual.
The GMK 6300L may only be operated with parts of equipment which are permitted by Manitowoc Crane
Group Germany GmbH and which are labelled with the serial number of the GMK 6300L.
The manufacturer is not liable for any damage caused by improper or unau- thorized use of the GMK
6300L truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112805 – PDF DOWNLOAD
Correction sheet............................................................................... 3 Accepting the telescope status............................................................. 3 Crane operation with auxiliary hoist........................................................... 5 1 Overview..................................................................................... 11 1.1 Accidents.............................................................................. 11 1.2 Branches............................................................................... 12 1.2.1 Manitowoc Crane Care............................................................. 12 1.2.2 Dealer list...................................................................... 12 1.3 Warranty specifications................................................................ 13 1.4 Terms used............................................................................. 16 1.5 Technical data......................................................................... 19 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................ 19 1.5.2 Dimensions and weights of the truck crane, axle loads............................ 20 Dimensions......................................................................... 21 Weight and axleloads.............................................................. 21 1.5.3 Dimensions and weights of removable parts........................................ 22 Spare wheel........................................................................ 22 Outriggers......................................................................... 22 Hose drum.......................................................................... 22 Main boom.......................................................................... 23 Hook blocks and hook tackle........................................................ 23 Auxiliary hoist.................................................................... 23 Counterweight parts................................................................ 24 1.5.4 Carrier.......................................................................... 25 Engine............................................................................. 25 Transmission....................................................................... 25 Transfer case...................................................................... 25 Axle lines......................................................................... 25 Steering........................................................................... 26 Tyres.............................................................................. 26 Outriggers......................................................................... 26 Auxiliary supports................................................................. 27 Electrical system.................................................................. 27 Tool............................................................................... 27 Towing couplings................................................................... 27 Driving speeds..................................................................... 27 Climbing ability................................................................... 27 Turning circle radiuses............................................................ 28 1.5.5 Superstructure................................................................... 28 Engine............................................................................. 28 Main hoist......................................................................... 29 Auxiliary hoist.................................................................... 29 Slewing gears...................................................................... 29 Derricking gear.................................................................... 30 Main boom.......................................................................... 30 Lattice extension.................................................................. 30 Operating speeds................................................................... 30 1.6 Documentation supplied................................................................. 31 1.6.1 Questions concerning the documentation........................................... 32 1.7 Information about the operating instructions........................................... 33 1.7.1 What do the symbols used mean?................................................... 33 1.7.2 How are the operating instructions structured?................................... 35 Division........................................................................... 35 Structure of the chapters.......................................................... 35 Structure of the pages............................................................. 36 1.7.3 How do I find the information I need?............................................ 37 Cross-references example........................................................... 38 1.7.4 What information is available for operations planning?........................... 40 1.8 Conversion table for US measurements................................................... 41 1.9 Training – Information................................................................. 43 1.10 Identification........................................................................ 44 1.11 EC Declaration of Conformity.......................................................... 46 2 Basic safety instructions.................................................................... 49 2.1 Intended use........................................................................... 49 2.1.1 Improper use..................................................................... 50 2.2 Organisational measures................................................................ 51 2.3 Qualifications of the personnel........................................................ 53 2.4 Safety instructions for driving the truck crane........................................ 54 2.5 Safety instructions for crane operation................................................ 54 2.6 Information on transporting persons.................................................... 56 Equipment for lifting persons......................................................... 56 Personnel.............................................................................. 57 Operation.............................................................................. 57 Truck crane............................................................................ 58 3 Operating elements for driving............................................................... 61 3.1 Overview of the operating elements..................................................... 61 3.1.1 On the outside of the truck crane................................................ 62 3.1.2 Driver's cab..................................................................... 64 Overview........................................................................... 64 Behind the cover................................................................... 66 3.1.3 Instrument panel................................................................. 67 Left/right......................................................................... 67 Middle............................................................................. 68 3.1.4 Display, driving mode............................................................ 71 3.1.5 Steering column/steering wheel................................................... 72 3.1.6 Transmission operating elements.................................................. 73 3.1.7 Tachograph....................................................................... 74 Tachograph Version 1............................................................... 75 3.1.8 ECOS control unit................................................................ 76 3.1.9 ECOS display – main menu......................................................... 78 3.1.10 ECOS display – submenus......................................................... 80 Level adjustment system submenu.................................................... 80 Settings submenu................................................................... 82 Monitoring submenu................................................................. 83 Operating hours submenu............................................................ 84 Warning submenu.................................................................... 84 Error submenu...................................................................... 85 3.1.11 Heating/Air-conditioning system................................................. 86 Standard heating system............................................................ 86 Auxiliary water heating system..................................................... 87 3.1.12 Sockets for hand-held control................................................... 88 3.1.13 Outrigger control units......................................................... 89 3.1.14 Control unit of the rear outrigger box.......................................... 90 3.2 Short description of the controls...................................................... 91 3.2.1 Definition of information relating to directions of movement..................... 91 Basic rule......................................................................... 91 Switches and buttons............................................................... 92 3.2.2 General information on the operating elements.................................... 92 3.2.3 General rules for buttons and symbols on the display............................. 93 3.2.4 Engine........................................................................... 94 Steering column.................................................................... 94 Multipurpose switch................................................................ 94 Instrument panel................................................................... 95 Main menu.......................................................................... 96 3.2.5 Carbamide system................................................................. 97 Instrument panel................................................................... 97 Display, driving mode.............................................................. 98 ECOS display....................................................................... 98 3.2.6 Electrical system................................................................ 99 3.2.7 ECOS crane control............................................................... 99 Control unit....................................................................... 99 3.2.8 Transmission.....................................................................102 Display, driving mode..............................................................102 Transmission control unit..........................................................102 3.2.9 Reverse camera...................................................................105 3.2.10 Transfer case...................................................................106 3.2.11 Final drive.....................................................................107 3.2.12 Brakes..........................................................................108 Service brake......................................................................108 Additional brakes..................................................................108 Parking brake......................................................................109 3.2.13 Steering/separate steering......................................................110 Instrument panel...................................................................110 ECOS display.......................................................................111 Driver's door......................................................................112 3.2.14 Suspension......................................................................113 3.2.15 Lighting/windscreen wipers/horn.................................................114 Steering column....................................................................114 Instrument panel...................................................................114 Roof...............................................................................117 3.2.16 Level adjustment system.........................................................117 3.2.17 Tachograph/speedometer..........................................................119 Tachograph.........................................................................119 Speedometer........................................................................119 3.2.18 Control unit of the rear outrigger box..........................................120 3.2.19 Diagnostics.....................................................................121 Displays/ submenu..................................................................121 3.2.20 Windows, doors, keys............................................................122 Window winder......................................................................122 Doors..............................................................................123 Keys...............................................................................123 3.2.21 Front flap......................................................................124 4 Starting/turning off the engine for driving..................................................127 4.1 Starting the engine from the driver's cab..............................................127 4.1.1 CHECKLIST: Starting the engine...................................................127 4.1.2 CHECKLIST: At low temperatures...................................................130 4.1.3 Ladders and access ladders.......................................................130 Access ladders.....................................................................130 Ladders............................................................................131 4.1.4 Refuelling.......................................................................133 Fuel...............................................................................133 Carbamide..........................................................................134 4.1.5 Inspections before starting the engine...........................................136 On the hydraulic tank..............................................................136 Battery master switch..............................................................137 Checking the hand-held control.....................................................137 4.1.6 Switch on the ignition...........................................................137 4.1.7 Lamp test/equalisation of the switching states...................................138 Lamp test..........................................................................138 Equalisation of the switching states...............................................139 4.1.8 Display – setting the brightness.................................................140 4.1.9 Start the engine.................................................................141 Without flame start system.........................................................142 With flame start system............................................................143 4.1.10 Inspections after starting the engine...........................................144 Checking in the main menu..........................................................144 Indicator lamps on the instrument panel............................................145 4.1.11 Monitoring elements.............................................................147 Instrument panel...................................................................147 4.1.12 Monitoring submenu..............................................................148 4.1.13 Setting the idling speed........................................................149 4.2 Turning off the engine.................................................................150 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.......150 After turning off..................................................................150 4.2.2 With emergency stop switches.....................................................151 Resetting the emergency stop switch................................................151 4.3 Air intake inhibitor...................................................................152 Releasing the air intake inhibitor.....................................................152 5 Driving......................................................................................155 5.1 Before driving.........................................................................155 5.1.1 CHECKLIST: Checks before on-road driving.........................................155 5.1.2 Checking the condition of the truck crane........................................160 Windscreen washing system..........................................................160 Electrical system..................................................................160 Adjusting the mirrors..............................................................161 Warning plates for vehicle width...................................................162 Displaying the vehicle height......................................................162 Supply pressure....................................................................163 Parking brake......................................................................164 5.1.3 Adjusting the seat and the steering column.......................................165 Driver's seat......................................................................165 Passenger's seat...................................................................166 Adjusting the steering column......................................................167 5.1.4 Switching the suspension on/off..................................................168 Opening the submenu................................................................168 Switching on the suspension........................................................169 Switching off the suspension.......................................................169 5.1.5 Adjusting the tachograph.........................................................170 Preconditions......................................................................170 In the event of malfunctions.......................................................170 Adjusting the tachograph...........................................................171 5.1.6 Displaying the operating hours...................................................175 5.1.7 Settings/indications on the Driving display......................................176 5.2 Operating the transmission.............................................................177 5.2.1 Switching on.....................................................................177 5.2.2 Switching the transmission to neutral position...................................178 While driving......................................................................178 5.2.3 Changing the driving mode........................................................179 5.2.4 Selecting the driving direction..................................................180 5.2.5 Changing highest gear/starting gear..............................................182 5.2.6 Starting.........................................................................182 5.2.7 Driving and changing gears.......................................................183 5.2.8 Changing the driving direction...................................................184 5.2.9 Stopping.........................................................................185 Stopping for a long period of time.................................................185 5.2.10 On the roller type dynamometer..................................................185 5.2.11 Oil level gauge.................................................................186 5.3 Driving and turning off the truck crane................................................189 5.3.1 Checks while driving.............................................................189 Immediately after you start to move................................................189 While driving......................................................................191 5.3.2 Tempomat.........................................................................192 Switching on.......................................................................192 Switching off......................................................................193 5.3.3 Temposet.........................................................................193 Switching on.......................................................................193 Switching off......................................................................193 5.3.4 Driving downhill.................................................................194 Starting...........................................................................194 Inspections when driving downhill..................................................194 Shifting down from the highest gear................................................195 Additional brakes..................................................................196 5.3.5 Driving uphill...................................................................197 Starting...........................................................................197 Driving............................................................................197 5.3.6 Warning submenu..................................................................198 Meaning of the symbols.............................................................198 Exiting the submenu................................................................200 5.3.7 Warning or malfunction messages on the instrument panel..........................201 Meaning of the lamps...............................................................201 5.3.8 Override the torque reduction....................................................203 5.3.9 Error submenu....................................................................204 5.3.10 Turning off the truck crane.....................................................204 Secure against rolling away........................................................204 When stationary for more than 8hours..............................................205 5.3.11 Folding berth...................................................................207 5.4 Off-road driving.......................................................................208 Adjustments to the transmission........................................................208 Connections............................................................................208 Changing the vehicle level.............................................................208 Rocking the vehicle free and towing....................................................208 5.4.1 Transfer case – switching the off-road gear on/off...............................209 Preconditions......................................................................209 Switching on.......................................................................209 Switching off......................................................................210 Neutral position...................................................................210 5.4.2 Longitudinal and transverse differential locks...................................211 5.4.3 Operating the level adjustment system............................................213 Opening the submenu................................................................213 Setting the onroad level..........................................................214 Pre-selecting suspension struts....................................................214 Changing the vehicle level.........................................................215 Viewing the current inclination....................................................215 Exiting the submenu................................................................216 5.4.4 Freeing the truck crane stuck in terrain.........................................217 Rocking the truck crane free.......................................................217 Towing free forwards...............................................................218 Towing free in reverse gear........................................................218 5.5 Separate steering......................................................................219 5.5.1 Switching to separate steering...................................................219 Manually...........................................................................220 Automatically......................................................................221 Switching to normal steering mode..................................................222 5.6 Heating and air-conditioning system....................................................223 5.6.1 Standard heating system..........................................................223 Switching on.......................................................................223 Heating............................................................................223 Air distribution...................................................................224 Examples...........................................................................225 Switching off......................................................................225 5.6.2 Air-conditioning system..........................................................226 Warnings...........................................................................226 Switching on/off...................................................................226 Cooling............................................................................227 Drying.............................................................................227 5.6.3 Auxiliary water heating system...................................................228 Preheating the engine..............................................................228 Preheating the driver's cab........................................................229 Switching on the auxiliary heater..................................................229 Switching off the auxiliary heater.................................................230 Setting time and weekday...........................................................230 Saving automatic heating start.....................................................231 Setting the heating period.........................................................232 Switching the automatic heating start on and off...................................233 Setting the remaining time.........................................................233 5.7 Towing a trailer.......................................................................234 Effects on the axleloads..............................................................234 Coupling the trailer...................................................................235 Connecting the supply lines............................................................236 Removing the supply lines..............................................................237 Uncoupling the trailer.................................................................237 Checking the braking force.............................................................239 6 Driving modes................................................................................243 6.1 Driving modes..........................................................................243 Information about the axle loads.......................................................243 6.1.1 Information on how to use the tables.............................................244 6.1.2 Tables for a maximum axle load of 12 t...........................................245 For 445/95 R25 tyres...............................................................245 For 445/95 R25 and 525/80 R25 tyres................................................246 6.1.3 Maximum permitted speeds with an axle load of over 12t..........................247 6.2 Rigging work for driving with a trailer................................................248 6.2.1 Switching on the slewing gear freewheel..........................................249 6.2.2 Switching on boom floating position..............................................250 6.2.3 Switching on boom pre-tensioning.................................................251 6.2.4 Switching the superstructure driving lights on/off...............................252 Switching off......................................................................252 Switching on.......................................................................252 6.3 Removing/installing the main boom......................................................253 Additional equipment required..........................................................253 6.3.1 CHECKLIST: Removing the main boom................................................254 Preconditions......................................................................254 Checklist..........................................................................254 6.3.2 CHECKLIST: Mounting the main boom................................................257 Prerequisites......................................................................257 Checklist..........................................................................257 6.3.3 Slinging the main boom...........................................................260 Marking............................................................................260 Installing the lifting gear........................................................260 Removing the lifting gear..........................................................261 6.3.4 Removing/attaching the clamps....................................................262 6.3.5 Switching the pressure relief on/off.............................................263 6.3.6 Connecting/disconnecting the derricking cylinder from the boom...................264 Retracting the derricking cylinder head axle.......................................265 Fitting the derricking cylinder head axle..........................................266 6.3.7 Pulling out/pushing in the boom pivot pin........................................267 Before pulling it out..............................................................267 After pushing it in................................................................267 Pulling out the pivot pin..........................................................268 Pushing the pivot pin in...........................................................269 6.3.8 Disconnecting/making the hydraulic/electrical connection.........................270 Disconnecting......................................................................270 Establishing.......................................................................271 6.3.9 Lifting the main boom off/onto the turntable.....................................272 Lifting from the turntable.........................................................272 Lifting on to the turntable........................................................273 6.3.10 Aligning the connecting points..................................................274 6.3.11 Securing/releasing the derricking cylinder......................................274 6.3.12 Transporting the main boom......................................................275 6.3.13 Inspections after main boom mounting............................................276 6.4 Installing/removing the hose drum......................................................277 installing the hose drum...............................................................277 Removing the hose drum.................................................................278 6.5 Installing/removing outrigger beams....................................................279 6.5.1 CHECKLIST: Removing the outrigger beams..........................................280 6.5.2 CHECKLIST: Installing the outrigger beams........................................282 6.5.3 Preparing the truck crane........................................................284 Prerequisites......................................................................284 For removal........................................................................284 6.5.4 Removing/attaching outrigger pads................................................285 Removing the outrigger pads........................................................285 Attaching the outrigger pads.......................................................286 6.5.5 Disconnecting/establishing the hydraulic connection..............................287 6.5.6 Establishing/disconnecting the electrical connection.............................288 6.5.7 Unscrewing/screwing in the spacers...............................................289 Unscrewing.........................................................................289 Screwing in........................................................................290 6.5.8 Disconnecting/establishing the connections to the outrigger box..................291 6.5.9 Extending/Retracting the outrigger beam..........................................291 Extending the outrigger beam.......................................................291 Inserting the outrigger beam.......................................................293 6.5.10 Transporting the outrigger beams................................................295 6.6 Installing/removing supporting boxes...................................................296 6.6.1 CHECKLIST: Removing the outrigger box............................................297 6.6.2 CHECKLIST: Installing the outrigger box..........................................300 6.6.3 Rig the outrigger span 7.98x8.50/1.00m........................................302 Front outrigger....................................................................303 Auxiliary supports.................................................................303 6.6.4 Establishing/disconnecting the pneumatic connection..............................305 6.6.5 Establishing/disconnecting the electrical connection.............................306 6.6.6 Disconnecting/establishing the hydraulic connection..............................307 6.6.7 Raising/attaching the outrigger box with the truck crane.........................308 Prerequisites......................................................................308 Lifting............................................................................309 Hanging............................................................................310 6.6.8 Installing the reverse camera....................................................311 6.6.9 Crane movements during the installation and removal procedures..................312 Prerequisites......................................................................312 Before the installation............................................................312 After the removal..................................................................312 6.6.10 Slinging points on the outrigger box............................................313 6.6.11 Fixing/releasing the outrigger pins.............................................314 Locking............................................................................314 Releasing the locking pin..........................................................315 6.6.12 Transporting the outrigger box on the separate vehicle..........................316 Lashing eyelets....................................................................316 6.7 Rig the auxiliary hoist................................................................317 6.7.1 CHECKLIST: Installing the auxiliary hoist........................................317 Prerequisites......................................................................317 6.7.2 CHECKLIST: Removing the auxiliary hoist..........................................319 Prerequisites......................................................................319 6.7.3 Slinging the auxiliary hoist.....................................................321 6.7.4 Slinging the rigging frame.......................................................321 6.7.5 Placing the auxiliary hoist on the counterweight combination.....................322 6.7.6 Rig auxiliary hoist with rigging frame...........................................322 Prerequisite.......................................................................322 6.7.7 Establishing/disconnecting the hydraulic connections.............................323 6.7.8 Making/breaking the electrical connection........................................324 6.7.9 Creating the connection to the turntable.........................................325 Establishing aconnection..........................................................325 Disconnecting......................................................................327 6.7.10 Securing the hoist rope.........................................................328 6.7.11 Transporting the auxiliary hoist................................................329 6.7.12 Check that the auxiliary hoist is functioning properly..........................330 Slewing direction..................................................................330 Slewing indicator..................................................................330 7 Malfunctions in driving mode.................................................................333 7.1 Emergency stop switch..................................................................333 7.2 What to do when a malfunction occurs in road traffic...................................335 7.3 Towing the truck crane.................................................................337 7.3.1 Towing in the event of engine or transmission damage.............................338 Compressed-air supply..............................................................338 Electric power supply..............................................................339 On the transmission................................................................339 Axle drives........................................................................339 Transfer case......................................................................340 Parking brake......................................................................340 Towing the truck crane out of the danger area......................................341 7.3.2 Tow starting.....................................................................341 7.4 Other emergency operations.............................................................343 7.4.1 Externally starting the truck crane..............................................343 7.4.2 Battery charger..................................................................343 7.5 Wheels and tyres.......................................................................345 7.5.1 Wheel change.....................................................................345 Removing a damaged wheel...........................................................346 On the spare wheel holder..........................................................346 Mounting a wheel...................................................................347 7.5.2 Filling the tyres yourself.......................................................349 Connecting the filling hose........................................................349 Filling the tyres..................................................................350 Removing the filling hose..........................................................350 7.6 Fuses..................................................................................351 Notes on changing fuses................................................................351 7.6.1 Fuses in the driver's cab........................................................352 Group F1...........................................................................352 Group F2...........................................................................353 Group F3...........................................................................353 Group F4...........................................................................354 Group F5...........................................................................354 Group F6...........................................................................355 Group F7...........................................................................355 Group F8...........................................................................355 7.6.2 Fuses in the battery box.........................................................356 7.7 Troubleshooting........................................................................357 7.7.1 Malfunctions on the engine.......................................................357 7.7.2 Exhaust system malfunctions......................................................359 7.7.3 Malfunctions to the transmission.................................................360 7.7.4 Transfer case malfunctions.......................................................361 7.7.5 Malfunctions of the service brake................................................361 7.7.6 Malfunctions of the steering.....................................................362 7.7.7 Differential lock malfunctions...................................................363 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler........................363 7.7.9 Malfunctions on the suspension...................................................364 7.7.10 Malfunctions of the level adjustment system.....................................364 7.7.11 Malfunctions on the ECOS carrier................................................365 ECOS program version...............................................................365 General malfunctions...............................................................365 Error messages.....................................................................366 Exiting the submenu................................................................367 7.8 Procedure in the event of malfunctions.................................................368 7.8.1 Switching on emergency operation in coolant circuit..............................368 7.8.2 Procedure in the event of engine malfunctions....................................369 7.8.3 Malfunctions to the transmission.................................................370 General malfunctions...............................................................370 Transmission malfunction...........................................................370 Reading out error codes............................................................372 8 Index........................................................................................375 A..........................................................................................377 B..........................................................................................377 C..........................................................................................378 D..........................................................................................379 E..........................................................................................381 F..........................................................................................383 H..........................................................................................383 I..........................................................................................384 K..........................................................................................384 L..........................................................................................384 M..........................................................................................385 O..........................................................................................386 P..........................................................................................387 R..........................................................................................387 S..........................................................................................389 T..........................................................................................390 V..........................................................................................392 W..........................................................................................392 Correction sheet...............................................................................399 Accepting the telescope status.............................................................399 Crane operation with auxiliary hoist...........................................................401 9 Operating elements for crane operation.......................................................407 9.1 Overview of the operating elements.....................................................407 9.1.1 On the outside of the truck crane................................................408 9.1.2 Crane cab........................................................................412 9.1.3 Front panel......................................................................414 9.1.4 Side panel.......................................................................415 Bottom.............................................................................415 Top................................................................................416 Console, rear......................................................................418 Standard heating system............................................................419 Auxiliary water heating system.....................................................420 Auxiliary air heater...............................................................421 9.1.5 Control panels...................................................................422 Left...............................................................................422 Right..............................................................................423 9.1.6 Control lever assignment.........................................................424 Version 1..........................................................................424 Version 2..........................................................................425 9.1.7 ECOS control unit................................................................426 9.1.8 ECOS display – main menu.........................................................428 9.1.9 ECOS display – submenus..........................................................430 Counterweight submenu..............................................................430 Slewing gear/ Houselock submenu....................................................431 Outrigger submenu..................................................................432 Telescoping submenu................................................................434 Power unit speeds submenu..........................................................436 Monitoring submenu.................................................................437 Settings submenu...................................................................438 Operating hours submenu............................................................440 Warning submenu....................................................................441 Error submenu......................................................................443 Working range limitation submenu...................................................444 9.1.10 RCL control unit................................................................446 9.1.11 RCL display – main menu.........................................................448 9.1.12 RCL display – submenus..........................................................449 Rigging mode entry submenu.........................................................449 Monitoring submenu.................................................................450 Rigging mode monitoring submenu....................................................452 Lifting capacity table submenu.....................................................453 working range submenu..............................................................454 Error submenu......................................................................455 Settings submenu...................................................................457 9.1.13 Hand-held control...............................................................458 Outriggers control panel...........................................................459 9.1.14 Outriggers control units........................................................460 Button.............................................................................460 Outrigger button...................................................................461 Inclination and outrigger pressure display.........................................462 Raise axle display.................................................................463 9.2 Short description of the controls......................................................465 9.2.1 Definition of information relating to directions of movement.....................465 Basic rule.........................................................................465 Switch.............................................................................465 9.2.2 General rules for buttons and symbols on the display.............................466 9.2.3 Engine for crane operation.......................................................467 Side panel.........................................................................467 Console, rear......................................................................468 ECOS display.......................................................................468 9.2.4 Engine for driving...............................................................468 Side panel.........................................................................468 Main menu..........................................................................468 Outrigger submenu..................................................................469 9.2.5 Seat contact switch and dead man's switch........................................470 9.2.6 ECOS crane control...............................................................471 Control unit.......................................................................471 9.2.7 Outrigger........................................................................474 Hand-held control..................................................................474 In the Outriggers submenu..........................................................475 In the settings submenu............................................................476 On the Outriggers control units....................................................477 9.2.8 Inclination indicators...........................................................479 9.2.9 Raise axle.......................................................................480 Outriggers control units...........................................................480 9.2.10 Outrigger pressure displays.....................................................482 Outrigger submenu..................................................................482 Outriggers control units...........................................................482 9.2.11 Anemometer display..............................................................482 9.2.12 Counterweight submenu...........................................................483 Counterweight submenu..............................................................483 9.2.13 Main hoist......................................................................486 9.2.14 Auxiliary hoist.................................................................488 9.2.15 Slewing gear....................................................................489 Submenu............................................................................490 9.2.16 Derricking gear.................................................................492 9.2.17 Telescoping mechanism...........................................................494 Control panels.....................................................................494 Submenu............................................................................495 In the settings submenu............................................................500 9.2.18 Hydraulic system................................................................501 9.2.19 Houselock.......................................................................502 9.2.20 Rated capacity limiter (RCL)....................................................502 Control unit.......................................................................502 Main menu..........................................................................505 Enter rigging mode submenu.........................................................506 Monitoring submenu.................................................................509 Lifting capacity table submenu.....................................................513 Working range submenu..............................................................514 Other..............................................................................515 9.2.21 Electrical system...............................................................516 9.2.22 Lighting, windscreen wiper/washing system.......................................516 Lighting...........................................................................516 Windscreen wiper/washing system....................................................518 9.2.23 Hand-held control...............................................................519 Sockets for hand- held control.....................................................519 Engine control panel...............................................................520 Horn...............................................................................520 Outriggers control panel...........................................................521 9.2.24 Windows, doors, keys............................................................523 Windows............................................................................523 Crane cab door.....................................................................523 Keys...............................................................................524 9.2.25 Diagnostics.....................................................................525 10 Starting/stopping the engine – for crane operation..........................................529 10.1 Starting the engine – from the crane cab..............................................529 10.1.1 CHECKLIST: Starting the engine..................................................529 10.1.2 CHECKLIST: At low temperatures..................................................532 10.1.3 Refuelling......................................................................532 Fuel...............................................................................532 Carbamide..........................................................................534 10.1.4 Inspections before starting the engine..........................................535 On the hydraulic tank..............................................................535 Battery master switch..............................................................535 Checking the hand-held control.....................................................536 10.1.5 Switch on the ignition..........................................................536 10.1.6 Lamp test/equalisation of the switching states..................................537 Lamp test..........................................................................537 10.1.7 Setting the display brightness..................................................539 10.1.8 Start the engine................................................................540 Without flame start system.........................................................540 With flame start system............................................................541 10.1.9 Inspections after starting the engine...........................................542 10.1.10 Monitoring submenu.............................................................543 10.1.11 Setting the idling speed.......................................................544 10.1.12 Override the torque reduction..................................................545 10.2 Starting the engine – with the hand-held control......................................546 Prerequisites..........................................................................546 Start the engine.......................................................................546 10.3 Turning off the engine................................................................548 10.3.1 During normal operation, with the ignition lock/with the hand- held control....548 After turning off..................................................................548 10.3.2 In emergencies, with the emergency stop switches................................549 Resetting the emergency stop switch................................................549 10.4 Air intake inhibitor..................................................................550 Releasing the air intake inhibitor.....................................................550 11 Crane operation.............................................................................553 11.1 Before crane operation................................................................553 11.1.1 CHECKLIST: Inspections prior to crane operation.................................553 11.1.2 Checking the condition of the truck crane.......................................557 Windscreen washing system – receptacle.............................................557 Visual inspection..................................................................557 Checking the position of the hoist ropes...........................................558 Checking the electrical system.....................................................558 11.1.3 Adjusting the crane cab seat and front panel....................................559 Crane cab seat.....................................................................559 Front panel........................................................................560 11.1.4 Checking the safety devices.....................................................561 Rated capacity limiter.............................................................561 Lifting limit switch...............................................................561 Emergency stop switch..............................................................562 Seat contact switch................................................................563 11.1.5 Load, earthing..................................................................564 11.1.6 Preheating the hydraulic oil....................................................565 11.1.7 Locking/unlocking the turntable.................................................566 Locking points.....................................................................566 11.1.8 Switching the houselock on/off..................................................568 Switching on the houselock.........................................................568 Switching off the houselock........................................................570 11.2 Operation of the rated capacity limiter...............................................571 11.2.1 Switching on the RCL............................................................572 Switching on.......................................................................572 Brightness of the displays.........................................................574 11.2.2 Entering the rigging mode.......................................................575 Entering individual components.....................................................576 Entering the RCLcode..............................................................579 Entering the reeving...............................................................580 Accepting the rigging mode.........................................................580 11.2.3 Inspections prior to crane operation............................................582 Opening the submenu................................................................582 Inspections........................................................................583 11.2.4 Displays during crane operation.................................................585 11.2.5 RCL early warning...............................................................588 11.2.6 RCL shutdown....................................................................588 Shutdown due to overload...........................................................588 11.2.7 Display in the event of errors..................................................590 11.2.8 RCL override....................................................................591 Table – error/ information codes...................................................599 11.2.9 Displaying the lifting capacity tables..........................................600 11.2.10 Entering the time/date.........................................................602 11.3 Crane operation with main boom........................................................603 11.3.1 Checks during crane operation...................................................603 Horizontal alignment...............................................................603 Safe distances.....................................................................603 Checking the wind speed............................................................604 11.3.2 Permissible slewing ranges and working positions................................605 360 slewing range.................................................................605 Working position 0 to the rear....................................................605 180 to the front rigging position.................................................605 11.3.3 Main hoist......................................................................606 Switching on the main hoist........................................................607 Lifting and lowering...............................................................607 Switching off the main hoist.......................................................608 11.3.4 Auxiliary hoist.................................................................609 Switching on the auxiliary hoist...................................................609 Lifting and lowering...............................................................610 Switching off the auxiliary hoist..................................................611 11.3.5 Lifting limit switch and lowering limit switch..................................612 Lifting limit switch...............................................................612 Lowering limit switch..............................................................613 11.3.6 Derricking gear.................................................................614 Switching on the derricking gear...................................................614 Raising and lowering...............................................................615 Re-enable raising function.........................................................616 Switching off the derricking gear..................................................616 Lowering the main boom to ahorizontal position....................................617 11.3.7 Telescoping mechanism...........................................................618 Overview...........................................................................619 Telescoping process................................................................619 Assignment for display.............................................................621 Fixed length, intermediate length, telescoping length..............................623 Telescoping........................................................................624 Telescoping sequence...............................................................624 Inspections prior to starting operations...........................................625 Switching on the telescoping mechanism.............................................626 Function of the control lever......................................................626 Telescoping with lattice extension folded at the side..............................628 Switching off the telescoping mechanism............................................628 Manual telescoping.................................................................629 Checking the initial position......................................................629 Unlock the telescoping cylinder....................................................631 Extending/ retracting the telescoping cylinder.....................................634 Lock telescoping cylinder..........................................................635 Unlocking the telescopic section...................................................636 Telescoping the telescopic section.................................................638 Locking the telescopic section.....................................................639 Locking the telescopic section for on-road driving.................................640 Telescoping with teleautomation....................................................641 Telescoping the main boom in horizontal position...................................645 11.3.8 High-speed mode.................................................................646 Switch on function................................................................646 Derricking gear/ Telescoping mechanism.............................................646 Hoists.............................................................................647 11.3.9 Slewing gear....................................................................648 Slewing gear brake.................................................................648 Switching on the slewing gear......................................................649 Releasing the slewing gear brake...................................................649 Engaging the slewing gear brake....................................................649 Slewing............................................................................650 Braking the slewing movement.......................................................652 Slewing gear freewheel.............................................................652 Switch off the slewing gear........................................................653 11.3.10 Possible movement combinations.................................................653 11.3.11 Hydraulic oil cooling..........................................................654 11.4 Settings and displays for crane operation.............................................655 11.4.1 Inclining the crane cab.........................................................655 11.4.2 Setting the idling speed........................................................655 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.....................656 11.4.4 Limiting the power unit speeds..................................................656 11.4.5 Setting the characteristic curves for the control levers........................658 11.4.6 Critical load control...........................................................659 Function...........................................................................659 Switching on andoff...............................................................659 11.4.7 Operation of the directional spotlights.........................................660 11.4.8 Displaying the operating hours..................................................661 11.4.9 Warning submenu.................................................................662 Meaning of the symbols.............................................................662 Exiting the submenu................................................................665 11.4.10 Error submenu..................................................................665 11.5 Working range limiter.................................................................666 11.5.1 Opening the Working range limiter submenu.......................................667 11.5.2 Viewing current settings........................................................667 11.5.3 Entering limit values...........................................................669 Overall height/ working radius.....................................................669 Slewing angle......................................................................670 Entering objects...................................................................672 11.5.4 Entering limit values/objects manually..........................................675 Limit values.......................................................................675 Objects............................................................................676 11.5.5 Switching monitoring functions on/off...........................................677 11.5.6 Shutdown by working range limiter...............................................678 11.6 Work break............................................................................679 11.6.1 In case of short work breaks....................................................679 11.6.2 In case of work breaks of more than 8 hours.....................................680 To secure the truck crane..........................................................680 11.7 Heating and air-conditioning system...................................................681 11.7.1 Standard heating system.........................................................681 Switching on.......................................................................681 Heating............................................................................681 Air distribution...................................................................682 Switching off......................................................................682 11.7.2 Air-conditioning system.........................................................683 Warnings...........................................................................683 Switching on/off...................................................................683 Cooling............................................................................684 Drying the air.....................................................................684 11.7.3 Auxiliary water heating system..................................................685 Preheating the engine..............................................................685 Preheating the crane cab...........................................................686 Switching on.......................................................................687 Setting the day and time...........................................................688 Storing the heating start..........................................................689 Setting the heating period.........................................................690 Switching heating start on/off.....................................................690 Switching off......................................................................691 Setting the remaining time.........................................................691 11.7.4 Auxiliary air heater............................................................692 Switching on.......................................................................692 Temperature........................................................................693 Switching off......................................................................693 Other functions....................................................................693 11.8 CraneSTAR system......................................................................695 12 Rigging work................................................................................699 12.1 Rigging work checklists for crane operation with the main boom........................699 12.1.1 CHECKLIST: Rigging..............................................................699 12.1.2 CHECKLIST: Unrigging............................................................703 12.2 Choosing a suitable site..............................................................707 12.2.1 Determining the required ground bearing area....................................707 12.2.2 Safe distance from slopes and pits..............................................710 12.2.3 Earthing the truck crane........................................................711 12.2.4 Safe distance from electrical cables............................................712 12.3 Rigging work after driving with a trailer.............................................715 12.3.1 Switching off the boom floating position........................................715 12.3.2 Switching off the slewing gear freewheel........................................716 Before slewing.....................................................................716 12.3.3 Switching off boom pre-tensioning...............................................717 12.4 Connecting/disconnecting the hand-held control........................................719 12.5 Starting the engine for driving for rigging work......................................721 12.5.1 Starting/turning off the engine with the hand-held control......................721 Prerequisites......................................................................721 Start the engine...................................................................722 Turning off the engine.............................................................722 12.5.2 Starting/turning off the engine from the crane cab..............................723 Prerequisites......................................................................723 Start the engine...................................................................723 After starting the engine..........................................................724 Turning off the engine.............................................................724 12.5.3 Starting/turning off the engine from the outrigger control units................725 Prerequisites......................................................................725 Start the engine...................................................................725 Turning off the engine.............................................................725 12.6 Outrigger.............................................................................727 12.6.1 CHECKLIST: Extending the outriggers.............................................727 12.6.2 CHECKLIST: Retracting the outriggers............................................729 12.6.3 Permissible outrigger spans.....................................................730 12.6.4 Preparing the truck crane.......................................................731 In the driver's cab................................................................731 Outrigger control units............................................................731 12.6.5 Setting the spans...............................................................732 For on-road driving................................................................734 12.6.6 Extending/retracting outriggers.................................................735 From the control units.............................................................736 With the hand- held control........................................................737 From the crane cab.................................................................739 12.6.7 Moving the outrigger pads into working/driving position.........................741 12.6.8 Enlarging the ground bearing area...............................................742 12.6.9 Extending/retracting supporting cylinders.......................................743 From the control units.............................................................744 With the hand- held control........................................................745 From the crane cab.................................................................746 12.6.10 Levelling the truck crane on outriggers horizontally...........................748 Inclination indicators.............................................................748 Prerequisites......................................................................749 Manual alignment...................................................................750 Automatic alignment................................................................751 12.6.11 Levelling the free-standing truck crane........................................753 12.6.12 Outrigger pressure display.....................................................755 12.7 Rigging/unrigging the counterweight...................................................756 12.7.1 Counterweight sections..........................................................756 Version A..........................................................................756 Version B..........................................................................757 12.7.2 Identification..................................................................758 12.7.3 Slinging points on the counterweight sections...................................759 12.7.4 CHECKLIST: Rigging the counterweight............................................761 12.7.5 CHECKLIST: Unrigging the counterweight..........................................763 12.7.6 Assembling counterweight combination............................................765 Combinations forthe basic equipment in version A..................................766 Combinations forthe additional equipment in version A.............................769 Combinations forthe basic equipment in version B..................................771 Combinations forthe additional equipment in version B.............................774 12.7.7 Counterweight hoist unit........................................................779 Counterweight submenu..............................................................779 Extending/ retracting the lifting cylinders........................................780 automatic mode, rigging............................................................781 automatic mode, unrigging..........................................................782 Cancel automatic mode..............................................................784 12.7.8 Setting down counterweight for driving the truck crane..........................785 Version A..........................................................................785 Version B..........................................................................785 12.7.9 Slewing with rigged counterweight...............................................787 12.8 Rigging work on the main boom.........................................................789 12.8.1 Hook block on the bumper........................................................789 Picking up the hook block..........................................................789 Attaching the hook block...........................................................790 12.8.2 Hook block on a separate vehicle................................................791 Picking up the hook block..........................................................792 Setting down the hook block........................................................792 12.8.3 Reeving and unreeving the hoist rope............................................794 Rope end fitting...................................................................794 Reeving the hoist rope.............................................................795 Unreeving the hoist rope...........................................................798 12.8.4 Possible reeving methods on the main boom.......................................799 With 9 head sheaves................................................................799 With 10 head sheaves...............................................................803 12.8.5 Installing/removing the lifting limit switch....................................806 Installing the lifting limit switch................................................806 Removing the lifting limit switch..................................................809 12.8.6 Locking/Unlocking the lifting limit switch......................................810 Locking............................................................................810 Removing the lock..................................................................811 12.8.7 Anemometer and air traffic control light........................................812 Installing.........................................................................812 Removing...........................................................................813 12.9 Other rigging work....................................................................815 12.9.1 Railings on the turntable.......................................................815 12.9.2 Mirror for crane operation......................................................816 12.9.3 Access ladder on the counterweight..............................................817 13 Driving with rigged truck crane.............................................................821 13.1 Driving distance......................................................................821 13.2 Permissible rigging modes and axle loads..............................................822 Axle load table........................................................................822 13.3 Before driving........................................................................824 13.3.1 Securing the superstructure against slewing.....................................824 13.3.2 Checking the tyre pressure and the wind speed...................................824 13.3.3 Putting the truck crane on the wheels...........................................825 13.3.4 Transmission/Connections........................................................827 Transmission.......................................................................827 Connections........................................................................827 13.4 While driving.........................................................................827 13.5 After driving.........................................................................829 13.6 Driving in combined operation.........................................................830 13.6.1 Switching combined operation on/off.............................................830 Prerequisites......................................................................830 Switching on.......................................................................831 Switching off......................................................................831 13.6.2 Starting/turning off the engine.................................................832 13.6.3 Preparing to drive..............................................................833 Transmission.......................................................................833 Switching on separate steering.....................................................833 Connections........................................................................833 13.6.4 While driving...................................................................834 14 Malfunctions during crane operation.........................................................837 14.1 Emergency stop switch.................................................................837 14.2 What to do when malfunctions occur during crane operation.............................839 Load can be lowered....................................................................839 Load cannot be lowered.................................................................839 14.3 Fuses.................................................................................841 Notes on changing fuses................................................................841 14.3.1 Fuses on the turntable..........................................................842 Fuse groups F1/F2/F3...............................................................842 Fuses on the circuit board.........................................................843 14.3.2 Fuses in the crane cab..........................................................845 14.3.3 Fuses in the battery box........................................................847 14.3.4 RCL fuses.......................................................................848 14.4 Finding and eliminating malfunctions..................................................849 14.4.1 Malfunctions on the engine......................................................849 14.4.2 Exhaust system malfunctions.....................................................850 14.4.3 Malfunctions on the main hoist/auxiliary hoist..................................851 14.4.4 Malfunctions on the derricking gear.............................................852 14.4.5 Malfunctions in the telescoping mechanism.......................................853 Telescoping mechanism error messages...............................................854 14.4.6 Malfunctions on the slewing gear................................................856 14.4.7 Malfunctions on the counterweight hoist unit....................................857 14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.......................858 14.4.9 Malfunctions when inclining the crane cab.......................................858 14.4.10 Malfunctions when operating with the hand-held control.........................858 14.4.11 Malfunctions of the outriggers.................................................859 14.4.12 Troubleshooting the RCL........................................................860 General malfunctions...............................................................860 Error messages in the monitoring submenu...........................................861 Displays in the Error submenu......................................................863 Table – Error codes................................................................865 Switching off the sensor/ tachogenerator..........................................868 14.4.13 Malfunctions ECOS – superstructure.............................................869 ECOS program version...............................................................869 General malfunctions...............................................................869 Error messages.....................................................................870 Exiting the submenu................................................................871 14.4.14 Malfunctions on the CraneSTAR system...........................................872 14.5 Emergency operations and programs.....................................................877 14.5.1 Mechanical emergency activation for retracting..................................878 Prior to the emergency operation, check............................................878 Procedure..........................................................................878 Mechanical emergency activation....................................................879 14.5.2 Telescoping emergency program...................................................881 Start the emergency program........................................................881 Determining the error type.........................................................882 If there is an error on the length indicator.......................................883 If there is an error at a proximity switch.........................................887 Terminating the emergency program..................................................888 Tables for approaching the locking points..........................................889 14.5.3 Entering the current telescoping................................................891 14.5.4 Emergency operation with the hand-held control..................................893 Preparations.......................................................................893 Operating a power unit.............................................................894 Stopping movements.................................................................896 Stopping movements in emergencies..................................................896 Turning off the engine.............................................................896 14.5.5 Switching on emergency operation in coolant circuit.............................897 14.6 Hydraulic emergency operation.........................................................899 14.6.1 Operating principle.............................................................899 14.6.2 Connecting/disconnecting hoses..................................................900 Establishing connections...........................................................900 Disconnecting......................................................................901 14.6.3 Switching emergency operation on/off............................................902 14.6.4 Establishing the hydraulic circuits required....................................903 Switching over valves..............................................................903 For lifting/ lowering..............................................................905 For slewing........................................................................906 14.6.5 Carrying out emergency operation................................................907 Slewing............................................................................907 Derricking.........................................................................908 Lifting/lowering...................................................................908 14.6.6 After emergency operation.......................................................909 Switch off emergency operation.....................................................909 Switch over to crane operation.....................................................909 Disconnect the hoses...............................................................909 14.6.7 Emergency supply of another crane...............................................910 For emergency supply...............................................................910 After emergency supply.............................................................910 15 Index.......................................................................................913 A..........................................................................................915 B..........................................................................................915 C..........................................................................................916 D..........................................................................................917 E..........................................................................................919 F..........................................................................................921 H..........................................................................................921 I..........................................................................................922 K..........................................................................................922 L..........................................................................................922 M..........................................................................................923 O..........................................................................................924 P..........................................................................................925 R..........................................................................................925 S..........................................................................................927 T..........................................................................................928 V..........................................................................................930 W..........................................................................................930
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