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Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112963 – PDF DOWNLOAD
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Description
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112963 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112963 – PDF DOWNLOAD
Language : English
Pages : 972
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112963 – 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 3112963 – PDF DOWNLOAD
Correction sheets ............................................................................. 3 Possible reeving methods on the main boom.................................................. 3 Telescoping emergency program – Telescoping with folded lattice extension.................. 15 Swinging the swing-away lattice........................................................ 16 Checks before telescoping.............................................................. 17 Rope grab modification .................................................................... 19 7 sheave hook block ....................................................................... 21 3_112_833_EN_20150220.pdf...................................................................... 13 Error messages............................................................................. 14 1 Overview..................................................................................... 27 1.1 Accidents.............................................................................. 27 1.2 Branches............................................................................... 28 1.2.1 Manitowoc Crane Care............................................................. 28 1.2.2 Dealer list...................................................................... 28 1.3 Warranty specifications................................................................ 29 1.4 Terms used............................................................................. 32 1.5 Technical data......................................................................... 35 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................ 35 1.5.2 Dimensions and weights of the truck crane, axle loads............................ 36 Dimensions......................................................................... 37 Weight and axleloads.............................................................. 37 1.5.3 Dimensions and weights of removable parts........................................ 38 Spare wheel........................................................................ 38 Outriggers......................................................................... 38 Hose drum.......................................................................... 38 Main boom.......................................................................... 39 Hook blocks and hook tackle........................................................ 39 Auxiliary hoist.................................................................... 39 Counterweight parts................................................................ 40 1.5.4 Carrier.......................................................................... 41 Engine............................................................................. 41 Transmission....................................................................... 41 Transfer case...................................................................... 41 Axle lines......................................................................... 41 Steering........................................................................... 42 Tyres.............................................................................. 42 Outriggers......................................................................... 42 Auxiliary supports................................................................. 43 Electrical system.................................................................. 43 Tool............................................................................... 43 Towing couplings................................................................... 43 Driving speeds..................................................................... 43 Climbing ability................................................................... 43 Turning circle radiuses............................................................ 44 1.5.5 Superstructure................................................................... 44 Engine............................................................................. 44 Main hoist......................................................................... 45 Auxiliary hoist.................................................................... 45 Slewing gears...................................................................... 45 Derricking gear.................................................................... 46 Main boom.......................................................................... 46 Lattice extension.................................................................. 46 Operating speeds................................................................... 46 1.6 Documentation supplied................................................................. 47 1.6.1 Questions concerning the documentation........................................... 48 1.7 Information about the operating instructions........................................... 49 1.7.1 What do the symbols used mean?................................................... 49 1.7.2 How are the operating instructions structured?................................... 51 Division........................................................................... 51 Structure of the chapters.......................................................... 51 Structure of the pages............................................................. 52 1.7.3 How do I find the information I need?............................................ 53 Cross-references example........................................................... 54 1.7.4 What information is available for operations planning?........................... 56 1.8 Conversion table for US measurements................................................... 57 1.9 Training – Information................................................................. 59 1.10 Identification........................................................................ 60 1.11 EC Declaration of Conformity.......................................................... 62 2 Basic safety instructions.................................................................... 65 2.1 Intended use........................................................................... 65 2.1.1 Improper use..................................................................... 66 2.2 Organisational measures................................................................ 67 2.3 Qualifications of the personnel........................................................ 69 2.4 Safety instructions for driving the truck crane........................................ 70 2.5 Safety instructions for crane operation................................................ 70 2.6 Information on transporting persons.................................................... 72 Equipment for lifting persons......................................................... 72 Personnel.............................................................................. 73 Operation.............................................................................. 73 Truck crane............................................................................ 74 3 Operating elements for driving............................................................... 77 3.1 Overview of the operating elements..................................................... 77 3.1.1 On the outside of the truck crane................................................ 78 3.1.2 Driver's cab..................................................................... 80 Overview........................................................................... 80 Behind the cover................................................................... 82 3.1.3 Instrument panel................................................................. 83 Left/right......................................................................... 83 Middle............................................................................. 84 3.1.4 Display, driving mode............................................................ 87 3.1.5 Steering column/steering wheel................................................... 88 3.1.6 Transmission operating elements.................................................. 89 3.1.7 Tachograph....................................................................... 90 Tachograph Version 1............................................................... 91 3.1.8 ECOS control unit................................................................ 92 3.1.9 ECOS display – main menu......................................................... 94 3.1.10 ECOS display – submenus......................................................... 96 Level adjustment system submenu.................................................... 96 Settings submenu................................................................... 98 Monitoring submenu................................................................. 99 Operating hours submenu............................................................100 Warning submenu....................................................................100 Error submenu......................................................................101 3.1.11 Heating/Air-conditioning system.................................................102 Standard heating system............................................................102 Auxiliary water heating system.....................................................103 3.1.12 Sockets for hand-held control...................................................104 3.1.13 Outrigger control units.........................................................105 3.1.14 Control unit of the rear outrigger box..........................................106 3.2 Short description of the controls......................................................107 3.2.1 Definition of information relating to directions of movement.....................107 Basic rule.........................................................................107 Switches and buttons...............................................................108 3.2.2 General information on the operating elements....................................108 3.2.3 General rules for buttons and symbols on the display.............................109 3.2.4 Engine...........................................................................110 Steering column....................................................................110 Multipurpose switch................................................................110 Instrument panel...................................................................111 Main menu..........................................................................112 3.2.5 Carbamide system.................................................................113 Instrument panel...................................................................113 Display, driving mode..............................................................114 ECOS display.......................................................................114 3.2.6 Electrical system................................................................115 3.2.7 ECOS crane control...............................................................115 Control unit.......................................................................115 3.2.8 Transmission.....................................................................118 Display, driving mode..............................................................118 Transmission control unit..........................................................118 3.2.9 Reverse camera...................................................................121 3.2.10 Transfer case...................................................................122 3.2.11 Final drive.....................................................................123 3.2.12 Brakes..........................................................................124 Service brake......................................................................124 Additional brakes..................................................................124 Parking brake......................................................................125 3.2.13 Steering/separate steering......................................................126 Instrument panel...................................................................126 ECOS display.......................................................................127 Driver's door......................................................................128 3.2.14 Suspension......................................................................129 3.2.15 Lighting/windscreen wipers/horn.................................................130 Steering column....................................................................130 Instrument panel...................................................................130 Roof...............................................................................133 3.2.16 Level adjustment system.........................................................133 3.2.17 Tachograph/speedometer..........................................................135 Tachograph.........................................................................135 Speedometer........................................................................135 3.2.18 Control unit of the rear outrigger box..........................................136 3.2.19 Diagnostics.....................................................................137 Displays/ submenu..................................................................137 3.2.20 Windows, doors, keys............................................................138 Window winder......................................................................138 Doors..............................................................................139 Keys...............................................................................139 3.2.21 Front flap......................................................................140 4 Starting/turning off the engine for driving..................................................143 4.1 Starting the engine from the driver's cab..............................................143 4.1.1 CHECKLIST: Starting the engine...................................................143 4.1.2 CHECKLIST: At low temperatures...................................................146 4.1.3 Ladders and access ladders.......................................................146 Access ladders.....................................................................146 Ladders............................................................................147 4.1.4 Refuelling.......................................................................150 Fuel...............................................................................150 Carbamide..........................................................................151 4.1.5 Inspections before starting the engine...........................................153 On the hydraulic tank..............................................................153 Battery master switch..............................................................153 Checking the hand-held control.....................................................154 4.1.6 Switch on the ignition...........................................................154 4.1.7 Lamp test/equalisation of the switching states...................................155 Lamp test..........................................................................155 Equalisation of the switching states...............................................156 4.1.8 Display – setting the brightness.................................................157 4.1.9 Start the engine.................................................................158 Without flame start system.........................................................159 With flame start system............................................................159 4.1.10 Inspections after starting the engine...........................................161 Checking in the main menu..........................................................161 Indicator lamps on the instrument panel............................................161 4.1.11 Monitoring elements.............................................................163 Instrument panel...................................................................163 4.1.12 Monitoring submenu..............................................................164 4.1.13 Setting the idling speed........................................................165 4.2 Turning off the engine.................................................................166 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.......166 After turning off..................................................................166 4.2.2 With emergency stop switches.....................................................167 Resetting the emergency stop switch................................................167 4.3 Air intake inhibitor...................................................................168 Releasing the air intake inhibitor.....................................................168 5 Driving......................................................................................171 5.1 Before driving.........................................................................171 5.1.1 CHECKLIST: Checks before on-road driving.........................................171 5.1.2 Checking the condition of the truck crane........................................176 Windscreen washing system..........................................................176 Electrical system..................................................................176 Adjusting the mirrors..............................................................177 Warning plates for vehicle width...................................................178 Displaying the vehicle height......................................................178 Supply pressure....................................................................179 Parking brake......................................................................180 5.1.3 Adjusting the seat and the steering column.......................................181 Driver's seat......................................................................181 Passenger's seat...................................................................182 Adjusting the steering column......................................................183 5.1.4 Switching the suspension on/off..................................................184 Opening the submenu................................................................184 Switching on the suspension........................................................185 Switching off the suspension.......................................................185 5.1.5 Adjusting the tachograph.........................................................186 Preconditions......................................................................186 In the event of malfunctions.......................................................186 Adjusting the tachograph...........................................................187 5.1.6 Displaying the operating hours...................................................191 5.1.7 Settings/indications on the Driving display......................................192 5.2 Operating the transmission.............................................................193 5.2.1 Switching on.....................................................................193 5.2.2 Switching the transmission to neutral position...................................194 While driving......................................................................194 5.2.3 Changing the driving mode........................................................195 5.2.4 Selecting the driving direction..................................................196 5.2.5 Changing highest gear/starting gear..............................................198 5.2.6 Starting.........................................................................198 5.2.7 Driving and changing gears.......................................................199 5.2.8 Changing the driving direction...................................................200 5.2.9 Stopping.........................................................................201 Stopping for a long period of time.................................................201 5.2.10 On the roller type dynamometer..................................................201 5.2.11 Oil level gauge.................................................................202 5.3 Driving and turning off the truck crane................................................205 5.3.1 Checks while driving.............................................................205 Immediately after you start to move................................................205 While driving......................................................................207 5.3.2 Tempomat.........................................................................208 Switching on.......................................................................208 Switching off......................................................................209 5.3.3 Temposet.........................................................................209 Switching on.......................................................................209 Switching off......................................................................209 5.3.4 Driving downhill.................................................................210 Starting...........................................................................210 Inspections when driving downhill..................................................210 Shifting down from the highest gear................................................211 Additional brakes..................................................................212 5.3.5 Driving uphill...................................................................213 Starting...........................................................................213 Driving............................................................................213 5.3.6 Warning submenu..................................................................214 Meaning of the symbols.............................................................214 Exiting the submenu................................................................216 5.3.7 Warning or malfunction messages on the instrument panel..........................217 Meaning of the lamps...............................................................217 5.3.8 Override the torque reduction....................................................219 5.3.9 Error submenu....................................................................220 5.3.10 Turning off the truck crane.....................................................220 Secure against rolling away........................................................220 When stationary for more than 8hours..............................................221 5.3.11 Folding berth...................................................................223 5.4 Off-road driving.......................................................................224 Adjustments to the transmission........................................................224 Connections............................................................................224 Changing the vehicle level.............................................................224 Rocking the vehicle free and towing....................................................224 5.4.1 Transfer case – switching the off-road gear on/off...............................225 Preconditions......................................................................225 Switching on.......................................................................225 Switching off......................................................................226 Neutral position...................................................................226 5.4.2 Longitudinal and transverse differential locks...................................227 5.4.3 Operating the level adjustment system............................................229 Opening the submenu................................................................229 Setting the onroad level..........................................................230 Pre-selecting suspension struts....................................................230 Changing the vehicle level.........................................................231 Viewing the current inclination....................................................231 Exiting the submenu................................................................232 5.4.4 Freeing the truck crane stuck in terrain.........................................233 Rocking the truck crane free.......................................................233 Towing free forwards...............................................................234 Towing free in reverse gear........................................................234 5.5 Separate steering......................................................................235 5.5.1 Switching to separate steering...................................................235 Manually...........................................................................236 Automatically......................................................................237 Switching to normal steering mode..................................................238 5.6 Heating and air-conditioning system....................................................239 5.6.1 Standard heating system..........................................................239 Switching on.......................................................................239 Heating............................................................................239 Air distribution...................................................................240 Examples...........................................................................241 Switching off......................................................................241 5.6.2 Air-conditioning system..........................................................242 Warnings...........................................................................242 Switching on/off...................................................................242 Cooling............................................................................243 Drying.............................................................................243 5.6.3 Auxiliary water heating system...................................................244 Preheating the engine..............................................................244 Preheating the driver's cab........................................................245 Switching on the auxiliary heater..................................................245 Switching off the auxiliary heater.................................................246 Setting time and weekday...........................................................246 Saving automatic heating start.....................................................247 Setting the heating period.........................................................248 Switching the automatic heating start on and off...................................249 Setting the remaining time.........................................................249 5.7 Towing a trailer.......................................................................250 Effects on the axleloads..............................................................250 Coupling the trailer...................................................................251 Connecting the supply lines............................................................252 Removing the supply lines..............................................................253 Uncoupling the trailer.................................................................253 Checking the braking force.............................................................255 6 Driving modes................................................................................259 6.1 Driving modes..........................................................................259 Information about the axle loads.......................................................259 6.1.1 Information on how to use the tables.............................................260 6.1.2 Tables for a maximum axle load of 12 t...........................................261 For 385/95 R25 tyres...............................................................261 For 445/95 R25 tyres...............................................................262 For 525/80 R25 tyres...............................................................263 6.1.3 Maximum permitted speeds with an axle load of over 12t..........................265 6.2 Rigging work for driving with a trailer................................................267 6.2.1 Switching on the slewing gear freewheel..........................................268 6.2.2 Switching on boom floating position..............................................269 6.2.3 Switching on boom pre-tensioning.................................................270 6.2.4 Switching the superstructure driving lights on/off...............................271 Switching off......................................................................271 Switching on.......................................................................271 6.3 Removing/installing the main boom......................................................273 Additional equipment required..........................................................273 6.3.1 CHECKLIST: Removing the main boom................................................274 Preconditions......................................................................274 Checklist..........................................................................274 6.3.2 CHECKLIST: Mounting the main boom................................................277 Prerequisites......................................................................277 Checklist..........................................................................277 6.3.3 Slinging the main boom...........................................................280 Marking............................................................................280 Installing the lifting gear........................................................280 Removing the lifting gear..........................................................281 6.3.4 Removing/attaching the clamps....................................................282 6.3.5 Switching the pressure relief on/off.............................................283 6.3.6 Connecting/disconnecting the derricking cylinder from the boom...................284 Retracting the derricking cylinder head axle.......................................285 Fitting the derricking cylinder head axle..........................................286 6.3.7 Pulling out/pushing in the boom pivot pin........................................287 Before pulling it out..............................................................287 After pushing it in................................................................287 Pulling out the pivot pin..........................................................288 Pushing the pivot pin in...........................................................289 6.3.8 Disconnecting/making the hydraulic/electrical connection.........................290 Disconnecting......................................................................290 Establishing.......................................................................291 6.3.9 Lifting the main boom off/onto the turntable.....................................292 Lifting from the turntable.........................................................292 Lifting on to the turntable........................................................293 6.3.10 Aligning the connecting points..................................................294 6.3.11 Securing/releasing the derricking cylinder......................................294 6.3.12 Transporting the main boom......................................................295 6.3.13 Inspections after main boom mounting............................................296 6.4 Installing/removing the hose drum......................................................297 installing the hose drum...............................................................297 Removing the hose drum.................................................................298 6.5 Installing/removing outrigger beams....................................................299 6.5.1 CHECKLIST: Removing the outrigger beams..........................................300 6.5.2 CHECKLIST: Installing the outrigger beams........................................302 6.5.3 Preparing the truck crane........................................................304 Prerequisites......................................................................304 For removal........................................................................304 6.5.4 Removing/attaching outrigger pads................................................305 Removing the outrigger pads........................................................305 Attaching the outrigger pads.......................................................306 6.5.5 Disconnecting/establishing the hydraulic connection..............................307 6.5.6 Establishing/disconnecting the electrical connection.............................308 6.5.7 Unscrewing/screwing in the spacers...............................................309 Unscrewing.........................................................................309 Screwing in........................................................................310 6.5.8 Disconnecting/establishing the connections to the outrigger box..................311 6.5.9 Extending/Retracting the outrigger beam..........................................311 Extending the outrigger beam.......................................................311 Inserting the outrigger beam.......................................................313 6.5.10 Transporting the outrigger beams................................................315 6.6 Installing/removing supporting boxes...................................................316 6.6.1 CHECKLIST: Removing the outrigger box............................................317 6.6.2 CHECKLIST: Installing the outrigger box..........................................320 6.6.3 Rig the outrigger span 7.98x8.50/1.00m........................................322 Front outrigger....................................................................323 Auxiliary supports.................................................................323 6.6.4 Establishing/disconnecting the pneumatic connection..............................325 6.6.5 Establishing/disconnecting the electrical connection.............................326 6.6.6 Disconnecting/establishing the hydraulic connection..............................327 6.6.7 Raising/attaching the outrigger box with the truck crane.........................328 Prerequisites......................................................................328 Lifting............................................................................329 Hanging............................................................................330 6.6.8 Installing the reverse camera....................................................331 6.6.9 Crane movements during the installation and removal procedures..................332 Prerequisites......................................................................332 Before the installation............................................................332 After the removal..................................................................332 6.6.10 Slinging points on the outrigger box............................................333 6.6.11 Fixing/releasing the outrigger pins.............................................334 Locking............................................................................334 Releasing the locking pin..........................................................335 6.6.12 Transporting the outrigger box on the separate vehicle..........................336 Lashing eyelets....................................................................336 6.7 Rig the auxiliary hoist................................................................337 6.7.1 CHECKLIST: Installing the auxiliary hoist........................................337 Prerequisites......................................................................337 6.7.2 CHECKLIST: Removing the auxiliary hoist..........................................339 Prerequisites......................................................................339 6.7.3 Slinging the auxiliary hoist.....................................................341 6.7.4 Slinging the rigging frame.......................................................341 6.7.5 Placing the auxiliary hoist on the counterweight combination.....................342 6.7.6 Rig auxiliary hoist with rigging frame...........................................342 Prerequisite.......................................................................342 6.7.7 Establishing/disconnecting the hydraulic connections.............................343 6.7.8 Making/breaking the electrical connection........................................344 6.7.9 Creating the connection to the turntable.........................................345 Establishing aconnection..........................................................345 Disconnecting......................................................................347 6.7.10 Securing the hoist rope.........................................................348 6.7.11 Transporting the auxiliary hoist................................................349 6.7.12 Check that the auxiliary hoist is functioning properly..........................350 Slewing direction..................................................................350 Slewing indicator..................................................................350 7 Malfunctions in driving mode.................................................................353 7.1 Emergency stop switch..................................................................353 7.2 What to do when a malfunction occurs in road traffic...................................355 7.3 Towing the truck crane.................................................................357 7.3.1 Towing in the event of engine or transmission damage.............................358 Compressed-air supply..............................................................358 Electric power supply..............................................................359 On the transmission................................................................359 Axle drives........................................................................359 Transfer case......................................................................360 Parking brake......................................................................360 Towing the truck crane out of the danger area......................................361 7.3.2 Tow starting.....................................................................361 7.4 Other emergency operations.............................................................363 7.4.1 Externally starting the truck crane..............................................363 7.4.2 Battery charger..................................................................363 7.5 Wheels and tyres.......................................................................365 7.5.1 Wheel change.....................................................................365 Removing a damaged wheel...........................................................366 On the spare wheel holder..........................................................366 Mounting a wheel...................................................................367 7.5.2 Filling the tyres yourself.......................................................369 Connecting the filling hose........................................................369 Filling the tyres..................................................................370 Removing the filling hose..........................................................370 7.6 Fuses..................................................................................371 Notes on changing fuses................................................................371 7.6.1 Fuses in the driver's cab........................................................372 Group F1...........................................................................372 Group F2...........................................................................373 Group F3...........................................................................373 Group F4...........................................................................374 Group F5...........................................................................374 Group F6...........................................................................375 Group F7...........................................................................375 Group F8...........................................................................375 Group F9...........................................................................376 Group F10..........................................................................376 7.6.2 Fuses in the battery box.........................................................377 7.7 Troubleshooting........................................................................379 7.7.1 Malfunctions on the engine.......................................................379 7.7.2 Exhaust system malfunctions......................................................381 7.7.3 Malfunctions to the transmission.................................................382 7.7.4 Transfer case malfunctions.......................................................383 7.7.5 Malfunctions of the service brake................................................383 7.7.6 Malfunctions of the steering.....................................................384 7.7.7 Differential lock malfunctions...................................................385 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler........................385 7.7.9 Malfunctions on the suspension...................................................386 7.7.10 Malfunctions of the level adjustment system.....................................386 7.7.11 Malfunctions on the ECOS carrier................................................387 ECOS program version...............................................................387 General malfunctions...............................................................387 Error messages.....................................................................388 Exiting the submenu................................................................389 7.8 Procedure in the event of malfunctions.................................................390 7.8.1 Switching on emergency operation in coolant circuit..............................390 7.8.2 Procedure in the event of engine malfunctions....................................391 7.8.3 Malfunctions to the transmission.................................................392 General malfunctions...............................................................392 Transmission malfunction...........................................................392 Reading out error codes............................................................394 8 Index........................................................................................397 A..........................................................................................399 B..........................................................................................399 C..........................................................................................400 D..........................................................................................401 E..........................................................................................403 F..........................................................................................405 H..........................................................................................405 I..........................................................................................406 K..........................................................................................406 L..........................................................................................406 M..........................................................................................407 O..........................................................................................408 P..........................................................................................409 R..........................................................................................409 S..........................................................................................411 T..........................................................................................412 V..........................................................................................414 W..........................................................................................414 Correction sheets .............................................................................421 Possible reeving methods on the main boom..................................................421 Telescoping emergency program – Telescoping with folded lattice extension..................431 Swinging the swing-away lattice........................................................432 Checks before telescoping..............................................................433 Rope grab modification.....................................................................435 Hoist rope guide.......................................................................435 7 sheave hook block .......................................................................437 9 Operating elements for crane operation.......................................................443 9.1 Overview of the operating elements.....................................................443 9.1.1 On the outside of the truck crane................................................444 9.1.2 Crane cab........................................................................448 9.1.3 Front panel......................................................................450 9.1.4 Side panel.......................................................................451 Bottom.............................................................................451 Top................................................................................452 Console, rear......................................................................454 Standard heating system............................................................455 Auxiliary water heating system.....................................................456 Auxiliary air heater...............................................................457 9.1.5 Control panels...................................................................458 Left...............................................................................458 Right..............................................................................459 9.1.6 Control lever assignment.........................................................460 Version 1..........................................................................460 Version 2..........................................................................461 9.1.7 ECOS control unit................................................................462 9.1.8 ECOS display – main menu.........................................................464 9.1.9 ECOS display – submenus..........................................................466 Counterweight submenu..............................................................466 Slewing gear/ Houselock submenu....................................................467 Outrigger submenu..................................................................468 Telescoping submenu................................................................470 Power unit speeds submenu..........................................................472 Monitoring submenu.................................................................473 Settings submenu...................................................................474 Operating hours submenu............................................................476 Warning submenu....................................................................477 Error submenu......................................................................479 Working range limitation submenu...................................................480 9.1.10 RCL control unit................................................................482 9.1.11 RCL display – main menu.........................................................484 9.1.12 RCL display – submenus..........................................................485 Rigging mode entry submenu.........................................................485 Monitoring submenu.................................................................486 Rigging mode monitoring submenu....................................................488 Lifting capacity table submenu.....................................................489 working range submenu..............................................................490 Error submenu......................................................................491 Settings submenu...................................................................493 9.1.13 Hand-held control...............................................................494 Outriggers control panel...........................................................495 9.1.14 Outriggers control units........................................................496 Button.............................................................................496 Outrigger button...................................................................497 Inclination and outrigger pressure display.........................................498 Raise axle display.................................................................499 9.2 Short description of the controls......................................................501 9.2.1 Definition of information relating to directions of movement.....................501 Basic rule.........................................................................501 Switch.............................................................................501 9.2.2 General rules for buttons and symbols on the display.............................502 9.2.3 Engine for crane operation.......................................................503 Side panel.........................................................................503 Console, rear......................................................................504 ECOS display.......................................................................504 9.2.4 Engine for driving...............................................................504 Side panel.........................................................................504 Main menu..........................................................................504 Outrigger submenu..................................................................505 9.2.5 Seat contact switch and dead man's switch........................................506 9.2.6 ECOS crane control...............................................................507 Control unit.......................................................................507 9.2.7 Outrigger........................................................................510 Hand-held control..................................................................510 In the Outriggers submenu..........................................................511 In the settings submenu............................................................512 On the Outriggers control units....................................................513 9.2.8 Inclination indicators...........................................................515 9.2.9 Raise axle.......................................................................516 Outriggers control units...........................................................516 9.2.10 Outrigger pressure displays.....................................................518 Outrigger submenu..................................................................518 Outriggers control units...........................................................518 9.2.11 Anemometer display..............................................................518 9.2.12 Counterweight submenu...........................................................519 Counterweight submenu..............................................................519 9.2.13 Main hoist......................................................................522 9.2.14 Auxiliary hoist.................................................................524 9.2.15 Slewing gear....................................................................525 Submenu............................................................................526 9.2.16 Derricking gear.................................................................528 9.2.17 Telescoping mechanism...........................................................530 Control panels.....................................................................530 Submenu............................................................................531 In the settings submenu............................................................536 9.2.18 Hydraulic system................................................................537 9.2.19 Houselock.......................................................................538 9.2.20 Rated capacity limiter (RCL)....................................................538 Control unit.......................................................................538 Main menu..........................................................................541 Enter rigging mode submenu.........................................................542 Monitoring submenu.................................................................545 Lifting capacity table submenu.....................................................549 Working range submenu..............................................................550 Other..............................................................................551 9.2.21 Electrical system...............................................................552 9.2.22 Lighting, windscreen wiper/washing system.......................................552 Lighting...........................................................................552 Windscreen wiper/washing system....................................................554 9.2.23 Hand-held control...............................................................555 Sockets for hand- held control.....................................................555 Engine control panel...............................................................556 Horn...............................................................................556 Outriggers control panel...........................................................557 9.2.24 Windows, doors, keys............................................................559 Windows............................................................................559 Crane cab door.....................................................................559 Keys...............................................................................560 9.2.25 Diagnostics.....................................................................561 10 Starting/stopping the engine – for crane operation..........................................565 10.1 Starting the engine – from the crane cab..............................................565 10.1.1 CHECKLIST: Starting the engine..................................................565 10.1.2 CHECKLIST: At low temperatures..................................................568 10.1.3 Refuelling......................................................................568 Fuel...............................................................................568 Carbamide..........................................................................570 10.1.4 Inspections before starting the engine..........................................571 On the hydraulic tank..............................................................571 Battery master switch..............................................................571 Checking the hand-held control.....................................................572 10.1.5 Switch on the ignition..........................................................572 10.1.6 Lamp test/equalisation of the switching states..................................573 Lamp test..........................................................................573 10.1.7 Setting the display brightness..................................................575 10.1.8 Start the engine................................................................576 Without flame start system.........................................................576 With flame start system............................................................577 10.1.9 Inspections after starting the engine...........................................578 10.1.10 Monitoring submenu.............................................................579 10.1.11 Setting the idling speed.......................................................580 10.1.12 Override the torque reduction..................................................581 10.2 Starting the engine – with the hand-held control......................................583 Prerequisites..........................................................................583 Start the engine.......................................................................583 10.3 Turning off the engine................................................................585 10.3.1 During normal operation, with the ignition lock/with the hand- held control....585 After turning off..................................................................585 10.3.2 In emergencies, with the emergency stop switches................................586 Resetting the emergency stop switch................................................586 10.4 Air intake inhibitor..................................................................587 Releasing the air intake inhibitor.....................................................587 11 Crane operation.............................................................................591 11.1 Before crane operation................................................................591 11.1.1 CHECKLIST: Inspections prior to crane operation.................................591 11.1.2 Checking the condition of the truck crane.......................................595 Windscreen washing system – receptacle.............................................595 Visual inspection..................................................................595 Checking the position of the hoist ropes...........................................596 Checking the electrical system.....................................................596 11.1.3 Adjusting the crane cab seat and front panel....................................597 Crane cab seat.....................................................................597 Front panel........................................................................598 11.1.4 Checking the safety devices.....................................................599 Rated capacity limiter.............................................................599 Lifting limit switch...............................................................599 Emergency stop switch..............................................................600 Seat contact switch................................................................601 11.1.5 Load, earthing..................................................................602 11.1.6 Preheating the hydraulic oil....................................................603 11.1.7 Locking/unlocking the turntable.................................................604 Locking points.....................................................................604 11.1.8 Switching the houselock on/off..................................................606 Switching on the houselock.........................................................606 Switching off the houselock........................................................608 11.2 Operation of the rated capacity limiter...............................................609 11.2.1 Switching on the RCL............................................................610 Switching on.......................................................................610 Brightness of the displays.........................................................612 11.2.2 Entering the rigging mode.......................................................613 Entering individual components.....................................................614 Entering the RCLcode..............................................................617 Entering the reeving...............................................................618 Accepting the rigging mode.........................................................618 11.2.3 Inspections prior to crane operation............................................620 Opening the submenu................................................................620 Inspections........................................................................621 11.2.4 Displays during crane operation.................................................623 11.2.5 RCL early warning...............................................................626 11.2.6 RCL shutdown....................................................................626 Shutdown due to overload...........................................................626 11.2.7 Display in the event of errors..................................................628 11.2.8 RCL override....................................................................629 Table – error/ information codes...................................................637 11.2.9 Displaying the lifting capacity tables..........................................638 11.2.10 Entering the time/date.........................................................640 11.3 Crane operation with main boom........................................................641 11.3.1 Checks during crane operation...................................................641 Horizontal alignment...............................................................641 Safe distances.....................................................................641 Checking the wind speed............................................................642 11.3.2 Permissible slewing ranges and working positions................................643 360 slewing range.................................................................643 Working position 0 to the rear....................................................643 180 to the front rigging position.................................................643 11.3.3 Main hoist......................................................................644 Switching on the main hoist........................................................645 Lifting and lowering...............................................................645 Switching off the main hoist.......................................................646 11.3.4 Auxiliary hoist.................................................................647 Switching on the auxiliary hoist...................................................647 Lifting and lowering...............................................................648 Switching off the auxiliary hoist..................................................649 11.3.5 Lifting limit switch and lowering limit switch..................................650 Lifting limit switch...............................................................650 Lowering limit switch..............................................................651 11.3.6 Derricking gear.................................................................652 Switching on the derricking gear...................................................652 Raising and lowering...............................................................653 Re-enable raising function.........................................................654 Switching off the derricking gear..................................................654 Lowering the main boom to ahorizontal position....................................655 11.3.7 Telescoping mechanism...........................................................656 Overview...........................................................................657 Telescoping process................................................................657 Assignment for display.............................................................659 Fixed length, intermediate length, telescoping length..............................661 Telescoping........................................................................662 Telescoping sequence...............................................................662 Inspections prior to starting operations...........................................663 Switching on the telescoping mechanism.............................................664 Function of the control lever......................................................664 Telescoping with lattice extension folded at the side..............................666 Switching off the telescoping mechanism............................................666 Manual telescoping.................................................................667 Checking the initial position......................................................667 Unlock the telescoping cylinder....................................................669 Extending/ retracting the telescoping cylinder.....................................672 Lock telescoping cylinder..........................................................673 Unlocking the telescopic section...................................................674 Telescoping the telescopic section.................................................676 Locking the telescopic section.....................................................677 Locking the telescopic section for on-road driving.................................678 Telescoping with teleautomation....................................................679 Telescoping the main boom in horizontal position...................................683 11.3.8 High-speed mode.................................................................684 Switch on function................................................................684 Derricking gear/ Telescoping mechanism.............................................684 Hoists.............................................................................685 11.3.9 Slewing gear....................................................................686 Switching on the slewing gear......................................................686 Slewing gear brake.................................................................686 Releasing the slewing gear brake...................................................687 Engaging the slewing gear brake....................................................688 Slewing............................................................................688 Braking the slewing movement.......................................................690 Slewing gear freewheel.............................................................690 Switch off the slewing gear........................................................691 11.3.10 Possible movement combinations.................................................691 11.3.11 Hydraulic oil cooling..........................................................692 11.4 Settings and displays for crane operation.............................................693 11.4.1 Inclining the crane cab.........................................................693 11.4.2 Setting the idling speed........................................................693 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.....................694 11.4.4 Limiting the power unit speeds..................................................694 11.4.5 Setting the characteristic curves for the control levers........................696 11.4.6 Critical load control...........................................................697 Function...........................................................................697 Switching on andoff...............................................................697 11.4.7 Operation of the directional spotlights.........................................698 11.4.8 Displaying the operating hours..................................................699 11.4.9 Warning submenu.................................................................700 Meaning of the symbols.............................................................700 Exiting the submenu................................................................703 11.4.10 Error submenu..................................................................703 11.5 Working range limiter.................................................................704 11.5.1 Opening the Working range limiter submenu.......................................705 11.5.2 Viewing current settings........................................................705 11.5.3 Entering limit values...........................................................707 Overall height/ working radius.....................................................707 Slewing angle......................................................................708 Entering objects...................................................................710 11.5.4 Entering limit values/objects manually..........................................713 Limit values.......................................................................713 Objects............................................................................714 11.5.5 Switching monitoring functions on/off...........................................715 11.5.6 Shutdown by working range limiter...............................................716 11.6 Work break............................................................................717 11.6.1 In case of short work breaks....................................................717 11.6.2 In case of work breaks of more than 8 hours.....................................718 To secure the truck crane..........................................................718 11.7 Heating and air-conditioning system...................................................719 11.7.1 Standard heating system.........................................................719 Switching on.......................................................................719 Heating............................................................................719 Air distribution...................................................................720 Switching off......................................................................720 11.7.2 Air-conditioning system.........................................................721 Warnings...........................................................................721 Switching on/off...................................................................721 Cooling............................................................................722 Drying the air.....................................................................722 11.7.3 Auxiliary water heating system..................................................723 Preheating the engine..............................................................723 Preheating the crane cab...........................................................724 Switching on.......................................................................725 Setting the day and time...........................................................726 Storing the heating start..........................................................727 Setting the heating period.........................................................728 Switching heating start on/off.....................................................728 Switching off......................................................................729 Setting the remaining time.........................................................729 11.7.4 Auxiliary air heater............................................................730 Switching on.......................................................................730 Temperature........................................................................731 Switching off......................................................................731 Other functions....................................................................731 11.8 CraneSTAR system......................................................................733 11.8.1 Overview........................................................................733 11.8.2 Position of the components......................................................733 12 Rigging work................................................................................737 12.1 Rigging work checklists for crane operation with the main boom........................737 12.1.1 CHECKLIST: Rigging..............................................................737 12.1.2 CHECKLIST: Unrigging............................................................741 12.2 Choosing a suitable site..............................................................745 12.2.1 Determining the required ground bearing area....................................745 12.2.2 Safe distance from slopes and pits..............................................748 12.2.3 Earthing the truck crane........................................................749 12.2.4 Safe distance from electrical cables............................................750 12.3 Rigging work after driving with a trailer.............................................753 12.3.1 Switching off the boom floating position........................................753 12.3.2 Switching off the slewing gear freewheel........................................754 Before slewing.....................................................................754 12.3.3 Switching off boom pre-tensioning...............................................755 12.4 Connecting/disconnecting the hand-held control........................................757 12.5 Starting the engine for driving for rigging work......................................759 12.5.1 Starting/turning off the engine with the hand-held control......................759 Prerequisites......................................................................759 Start the engine...................................................................760 Turning off the engine.............................................................760 12.5.2 Starting/turning off the engine from the crane cab..............................761 Prerequisites......................................................................761 Start the engine...................................................................761 After starting the engine..........................................................762 Turning off the engine.............................................................762 12.5.3 Starting/turning off the engine from the outrigger control units................763 Prerequisites......................................................................763 Start the engine...................................................................763 Turning off the engine.............................................................763 12.6 Outrigger.............................................................................765 12.6.1 CHECKLIST: Extending the outriggers.............................................765 12.6.2 CHECKLIST: Retracting the outriggers............................................767 12.6.3 Permissible outrigger spans.....................................................768 12.6.4 Preparing the truck crane.......................................................769 In the driver's cab................................................................769 Outrigger control units............................................................769 12.6.5 Setting the spans...............................................................770 For on-road driving................................................................772 12.6.6 Extending/retracting outriggers.................................................773 From the control units.............................................................774 With the hand- held control........................................................775 From the crane cab.................................................................777 12.6.7 Moving the outrigger pads into working/driving position.........................779 12.6.8 Enlarging the ground bearing area...............................................780 12.6.9 Extending/retracting supporting cylinders.......................................781 From the control units.............................................................782 With the hand- held control........................................................783 From the crane cab.................................................................784 12.6.10 Levelling the truck crane on outriggers horizontally...........................786 Inclination indicators.............................................................786 Prerequisites......................................................................787 Manual alignment...................................................................788 Automatic alignment................................................................789 12.6.11 Levelling the free-standing truck crane........................................791 12.6.12 Outrigger pressure display.....................................................793 12.7 Rigging/unrigging the counterweight...................................................794 12.7.1 Counterweight sections..........................................................794 Version A..........................................................................794 Version B..........................................................................795 12.7.2 Identification..................................................................796 12.7.3 Slinging points on the counterweight sections...................................797 12.7.4 CHECKLIST: Rigging the counterweight............................................799 12.7.5 CHECKLIST: Unrigging the counterweight..........................................801 12.7.6 Assembling counterweight combination............................................803 Combinations forthe basic equipment in version A..................................804 Combinations forthe additional equipment in version A.............................807 Combinations forthe basic equipment in version B..................................809 Combinations forthe additional equipment in version B.............................812 12.7.7 Counterweight hoist unit........................................................817 Counterweight submenu..............................................................817 Extending/ retracting the lifting cylinders........................................818 automatic mode, rigging............................................................819 automatic mode, unrigging..........................................................820 Cancel automatic mode..............................................................822 12.7.8 Setting down counterweight for driving the truck crane..........................823 Version A..........................................................................823 Version B..........................................................................823 12.7.9 Slewing with rigged counterweight...............................................825 12.8 Rigging work on the main boom.........................................................827 12.8.1 Hook block on the bumper........................................................827 Picking up the hook block..........................................................827 Attaching the hook block...........................................................828 12.8.2 Hook block on a separate vehicle................................................829 Picking up the hook block..........................................................830 Setting down the hook block........................................................830 12.8.3 Reeving and unreeving the hoist rope............................................832 Rope end fitting...................................................................832 Reeving the hoist rope.............................................................833 Unreeving the hoist rope...........................................................836 12.8.4 Possible reeving methods on the main boom.......................................837 With 9 head sheaves................................................................837 With 10 head sheaves...............................................................841 12.8.5 Installing/removing the lifting limit switch....................................844 Installing the lifting limit switch................................................844 Removing the lifting limit switch..................................................847 12.8.6 Locking/Unlocking the lifting limit switch......................................848 Locking............................................................................848 Removing the lock..................................................................849 12.8.7 Anemometer and air traffic control light........................................850 Installing.........................................................................850 Removing...........................................................................851 12.9 Other rigging work....................................................................853 12.9.1 Railings on the turntable.......................................................853 12.9.2 Mirror for crane operation......................................................854 12.9.3 Access ladder on the counterweight..............................................855 13 Driving with rigged truck crane.............................................................859 13.1 Driving distance......................................................................859 13.2 Permissible rigging modes and axle loads..............................................860 Axle load table........................................................................860 13.3 Before driving........................................................................862 13.3.1 Securing the superstructure against slewing.....................................862 13.3.2 Checking the tyre pressure and the wind speed...................................862 13.3.3 Putting the truck crane on the wheels...........................................863 13.3.4 Transmission/Connections........................................................865 Transmission.......................................................................865 Connections........................................................................865 13.4 While driving.........................................................................865 13.5 After driving.........................................................................867 13.6 Driving in combined operation.........................................................868 13.6.1 Switching combined operation on/off.............................................868 Prerequisites......................................................................868 Switching on.......................................................................869 Switching off......................................................................869 13.6.2 Starting/turning off the engine.................................................870 13.6.3 Preparing to drive..............................................................871 Transmission.......................................................................871 Switching on separate steering.....................................................871 Connections........................................................................871 13.6.4 While driving...................................................................872 14 Malfunctions during crane operation.........................................................875 14.1 Emergency stop switch.................................................................875 14.2 What to do when malfunctions occur during crane operation.............................877 Load can be lowered....................................................................877 Load cannot be lowered.................................................................877 14.3 Fuses.................................................................................879 Notes on changing fuses................................................................879 14.3.1 Fuses on the turntable..........................................................880 Fuse groups F1/F2/F3...............................................................880 Fuses on the circuit board.........................................................881 14.3.2 Fuses in the crane cab..........................................................883 14.3.3 Fuses in the battery box........................................................885 14.3.4 RCL fuses.......................................................................886 14.4 Finding and eliminating malfunctions..................................................887 14.4.1 Malfunctions on the engine......................................................887 14.4.2 Exhaust system malfunctions.....................................................888 14.4.3 Malfunctions on the main hoist/auxiliary hoist..................................889 14.4.4 Malfunctions on the derricking gear.............................................890 14.4.5 Malfunctions in the telescoping mechanism.......................................891 Telescoping mechanism error messages...............................................892 14.4.6 Malfunctions on the slewing gear................................................894 14.4.7 Malfunctions on the counterweight hoist unit....................................895 14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.......................896 14.4.9 Malfunctions when inclining the crane cab.......................................896 14.4.10 Malfunctions when operating with the hand-held control.........................896 14.4.11 Malfunctions of the outriggers.................................................897 14.4.12 Troubleshooting the RCL........................................................898 General malfunctions...............................................................898 Error messages in the monitoring submenu...........................................899 Displays in the Error submenu......................................................901 Table – Error codes................................................................903 Switching off the sensor/ tachogenerator..........................................906 14.4.13 Malfunctions ECOS – superstructure.............................................907 ECOS program version...............................................................907 General malfunctions...............................................................907 Error messages.....................................................................908 Exiting the submenu................................................................909 14.4.14 Malfunctions on the CraneSTAR system...........................................910 14.5 Emergency operations and programs.....................................................915 14.5.1 Mechanical emergency activation for retracting..................................916 Prior to the emergency operation, check............................................916 Procedure..........................................................................916 Mechanical emergency activation....................................................917 14.5.2 Telescoping emergency program...................................................919 Start the emergency program........................................................919 Determining the error type.........................................................920 If there is an error on the length indicator.......................................921 If there is an error at a proximity switch.........................................925 Terminating the emergency program..................................................926 Tables for approaching the locking points..........................................927 14.5.3 Entering the current telescoping................................................929 14.5.4 Emergency operation with the hand-held control..................................931 Preparations.......................................................................931 Operating a power unit.............................................................932 Stopping movements.................................................................934 Stopping movements in emergencies..................................................934 Turning off the engine.............................................................934 14.5.5 Switching on emergency operation in coolant circuit.............................935 14.6 Hydraulic emergency operation.........................................................937 14.6.1 Operating principle.............................................................937 14.6.2 Connecting/disconnecting hoses..................................................938 Establishing connections...........................................................938 Disconnecting......................................................................939 14.6.3 Switching emergency operation on/off............................................940 14.6.4 Establishing the hydraulic circuits required....................................941 Switching over valves..............................................................941 For lifting/ lowering..............................................................943 For slewing........................................................................944 14.6.5 Carrying out emergency operation................................................945 Slewing............................................................................945 Derricking.........................................................................946 Lifting/lowering...................................................................946 14.6.6 After emergency operation.......................................................947 Switch off emergency operation.....................................................947 Switch over to crane operation.....................................................947 Disconnect the hoses...............................................................947 14.6.7 Emergency supply of another crane...............................................948 For emergency supply...............................................................948 After emergency supply.............................................................948 15 Index.......................................................................................951 A..........................................................................................953 B..........................................................................................953 C..........................................................................................954 D..........................................................................................955 E..........................................................................................957 F..........................................................................................959 H..........................................................................................959 I..........................................................................................960 K..........................................................................................960 L..........................................................................................960 M..........................................................................................961 O..........................................................................................962 P..........................................................................................963 R..........................................................................................963 S..........................................................................................965 T..........................................................................................966 V..........................................................................................968 W..........................................................................................968
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