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Grove GMK 6300L Driving & Crane Operation Manual 3112964 PDF Download
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Description
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112964 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112964 – PDF DOWNLOAD
Language : English
Pages : 958
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112964 – PDF DOWNLOAD
Basic safety instructions:
2.1 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.
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 3112964 – PDF DOWNLOAD
Correction sheets ............................................................................. 7 Telescoping emergency program – Telescoping with folded lattice extension.................. 3 Swinging the swing-away lattice........................................................ 4 Checks before telescoping.............................................................. 5 Rope grab modification .................................................................... 7 7 sheave hook block ....................................................................... 9 1 Overview..................................................................................... 15 1.1 Accidents.............................................................................. 15 1.2 Branches............................................................................... 16 1.2.1 Manitowoc Crane Care............................................................. 16 1.2.2 Dealer list...................................................................... 16 1.3 Warranty specifications................................................................ 17 1.4 Terms used............................................................................. 20 1.5 Technical data......................................................................... 23 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................ 23 1.5.2 Maximum lifting capacity (ASME B 30.5)........................................... 23 1.5.3 Dimensions and weights of the truck crane, axle loads............................ 24 Dimensions......................................................................... 25 Weight and axleloads.............................................................. 25 1.5.4 Dimensions and weights of removable parts........................................ 26 Spare wheel........................................................................ 26 Outriggers......................................................................... 26 Hose drum.......................................................................... 26 Main boom.......................................................................... 27 Hook blocks and hook tackle........................................................ 27 Auxiliary hoist.................................................................... 27 Counterweight parts................................................................ 28 1.5.5 Carrier.......................................................................... 29 Engine............................................................................. 29 Transmission....................................................................... 29 Transfer case...................................................................... 29 Axle lines......................................................................... 29 Steering........................................................................... 30 Tyres.............................................................................. 30 Outriggers......................................................................... 30 Auxiliary supports................................................................. 31 Electrical system.................................................................. 31 Tool............................................................................... 31 Towing couplings................................................................... 31 Driving speeds..................................................................... 31 Climbing ability................................................................... 31 Turning circle radiuses............................................................ 32 1.5.6 Superstructure................................................................... 32 Engine............................................................................. 32 Main hoist......................................................................... 33 Auxiliary hoist.................................................................... 33 Slewing gears...................................................................... 33 Derricking gear.................................................................... 34 Main boom.......................................................................... 34 Lattice extension.................................................................. 34 Operating speeds................................................................... 34 1.6 Documentation supplied................................................................. 35 1.6.1 Questions concerning the documentation........................................... 36 1.7 Information about the operating instructions........................................... 37 1.7.1 What do the symbols used mean?................................................... 37 1.7.2 How are the operating instructions structured?................................... 39 Division........................................................................... 39 Structure of the chapters.......................................................... 39 Structure of the pages............................................................. 40 1.7.3 How do I find the information I need?............................................ 41 Cross-references example........................................................... 42 1.7.4 What information is available for operations planning?........................... 44 1.8 Conversion table for US measurements................................................... 45 1.9 Training – Information................................................................. 47 1.10 Identification........................................................................ 48 1.11 EC Declaration of Conformity.......................................................... 50 2 Basic safety instructions.................................................................... 53 2.1 Intended use........................................................................... 53 2.1.1 Improper use..................................................................... 54 2.2 Organisational measures................................................................ 55 2.3 Qualifications of the personnel........................................................ 57 2.4 Safety instructions for driving the truck crane........................................ 58 2.5 Safety instructions for crane operation................................................ 58 2.6 Information on transporting persons.................................................... 60 Equipment for lifting persons......................................................... 60 Personnel.............................................................................. 61 Operation.............................................................................. 61 Truck crane............................................................................ 62 3 Operating elements for driving............................................................... 65 3.1 Overview of the operating elements..................................................... 65 3.1.1 On the outside of the truck crane................................................ 66 3.1.2 Driver's cab..................................................................... 68 Overview........................................................................... 68 Behind the cover................................................................... 70 3.1.3 Instrument panel................................................................. 71 Left/right......................................................................... 71 Middle............................................................................. 72 3.1.4 Display, driving mode............................................................ 75 3.1.5 Steering column/steering wheel................................................... 76 3.1.6 Transmission operating elements.................................................. 77 3.1.7 Tachograph....................................................................... 78 Tachograph Version 1............................................................... 79 3.1.8 ECOS control unit................................................................ 80 3.1.9 ECOS display – main menu......................................................... 82 3.1.10 ECOS display – submenus......................................................... 84 Level adjustment system submenu.................................................... 84 Settings submenu................................................................... 86 Monitoring submenu................................................................. 87 Operating hours submenu............................................................ 88 Warning submenu.................................................................... 88 Error submenu...................................................................... 89 3.1.11 Heating/Air-conditioning system................................................. 90 Standard heating system............................................................ 90 Auxiliary water heating system..................................................... 91 3.1.12 Sockets for hand-held control................................................... 92 3.1.13 Outrigger control units......................................................... 93 3.1.14 Control unit of the rear outrigger box.......................................... 94 3.2 Short description of the controls...................................................... 95 3.2.1 Definition of information relating to directions of movement..................... 95 Basic rule......................................................................... 95 Switches and buttons............................................................... 96 3.2.2 General information on the operating elements.................................... 96 3.2.3 General rules for buttons and symbols on the display............................. 97 3.2.4 Engine........................................................................... 98 Steering column.................................................................... 98 Multipurpose switch................................................................ 98 Instrument panel................................................................... 99 Main menu..........................................................................100 3.2.5 Carbamide system.................................................................101 Instrument panel...................................................................101 Display, driving mode..............................................................102 ECOS display.......................................................................102 3.2.6 Electrical system................................................................103 3.2.7 ECOS crane control...............................................................103 Control unit.......................................................................103 3.2.8 Transmission.....................................................................106 Display, driving mode..............................................................106 Transmission control unit..........................................................106 3.2.9 Reverse camera...................................................................109 3.2.10 Transfer case...................................................................110 3.2.11 Final drive.....................................................................111 3.2.12 Brakes..........................................................................112 Service brake......................................................................112 Additional brakes..................................................................112 Parking brake......................................................................113 3.2.13 Steering/separate steering......................................................114 Instrument panel...................................................................114 ECOS display.......................................................................115 Driver's door......................................................................116 3.2.14 Suspension......................................................................117 3.2.15 Lighting/windscreen wipers/horn.................................................118 Steering column....................................................................118 Instrument panel...................................................................118 Roof...............................................................................121 3.2.16 Level adjustment system.........................................................121 3.2.17 Tachograph/speedometer..........................................................123 Tachograph.........................................................................123 Speedometer........................................................................123 3.2.18 Control unit of the rear outrigger box..........................................124 3.2.19 Diagnostics.....................................................................125 Displays/ submenu..................................................................125 3.2.20 Windows, doors, keys............................................................126 Window winder......................................................................126 Doors..............................................................................127 Keys...............................................................................127 3.2.21 Front flap......................................................................128 4 Starting/turning off the engine for driving..................................................131 4.1 Starting the engine from the driver's cab..............................................131 4.1.1 CHECKLIST: Starting the engine...................................................131 4.1.2 CHECKLIST: At low temperatures...................................................134 4.1.3 Ladders and access ladders.......................................................134 Access ladders.....................................................................134 Ladders............................................................................135 4.1.4 Refuelling.......................................................................138 Fuel...............................................................................138 Carbamide..........................................................................139 4.1.5 Inspections before starting the engine...........................................141 On the hydraulic tank..............................................................141 Battery master switch..............................................................141 Checking the hand-held control.....................................................142 4.1.6 Switch on the ignition...........................................................142 4.1.7 Lamp test/equalisation of the switching states...................................143 Lamp test..........................................................................143 Equalisation of the switching states...............................................144 4.1.8 Display – setting the brightness.................................................145 4.1.9 Start the engine.................................................................146 Without flame start system.........................................................147 With flame start system............................................................147 4.1.10 Inspections after starting the engine...........................................149 Checking in the main menu..........................................................149 Indicator lamps on the instrument panel............................................149 4.1.11 Monitoring elements.............................................................151 Instrument panel...................................................................151 4.1.12 Monitoring submenu..............................................................152 4.1.13 Setting the idling speed........................................................153 4.2 Turning off the engine.................................................................155 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.......155 After turning off..................................................................155 4.2.2 With emergency stop switches.....................................................156 Resetting the emergency stop switch................................................156 4.3 Air intake inhibitor...................................................................157 Releasing the air intake inhibitor.....................................................157 5 Driving......................................................................................161 5.1 Before driving.........................................................................161 5.1.1 CHECKLIST: Checks before on-road driving.........................................161 5.1.2 Checking the condition of the truck crane........................................166 Windscreen washing system..........................................................166 Electrical system..................................................................166 Adjusting the mirrors..............................................................167 Warning plates for vehicle width...................................................168 Displaying the vehicle height......................................................168 Supply pressure....................................................................169 Parking brake......................................................................170 5.1.3 Adjusting the seat and the steering column.......................................171 Driver's seat......................................................................171 Passenger's seat...................................................................172 Adjusting the steering column......................................................173 5.1.4 Switching the suspension on/off..................................................174 Opening the submenu................................................................174 Switching on the suspension........................................................175 Switching off the suspension.......................................................175 5.1.5 Adjusting the tachograph.........................................................176 Preconditions......................................................................176 In the event of malfunctions.......................................................176 Adjusting the tachograph...........................................................177 5.1.6 Displaying the operating hours...................................................181 5.1.7 Settings/indications on the Driving display......................................182 5.2 Operating the transmission.............................................................183 5.2.1 Switching on.....................................................................183 5.2.2 Switching the transmission to neutral position...................................184 While driving......................................................................184 5.2.3 Changing the driving mode........................................................185 5.2.4 Selecting the driving direction..................................................186 5.2.5 Changing highest gear/starting gear..............................................188 5.2.6 Starting.........................................................................188 5.2.7 Driving and changing gears.......................................................189 5.2.8 Changing the driving direction...................................................190 5.2.9 Stopping.........................................................................191 Stopping for a long period of time.................................................191 5.2.10 On the roller type dynamometer..................................................191 5.2.11 Oil level gauge.................................................................192 5.3 Driving and turning off the truck crane................................................195 5.3.1 Checks while driving.............................................................195 Immediately after you start to move................................................195 While driving......................................................................197 5.3.2 Tempomat.........................................................................198 Switching on.......................................................................198 Switching off......................................................................199 5.3.3 Temposet.........................................................................199 Switching on.......................................................................199 Switching off......................................................................199 5.3.4 Driving downhill.................................................................200 Starting...........................................................................200 Inspections when driving downhill..................................................200 Shifting down from the highest gear................................................201 Additional brakes..................................................................202 5.3.5 Driving uphill...................................................................203 Starting...........................................................................203 Driving............................................................................203 5.3.6 Warning submenu..................................................................204 Meaning of the symbols.............................................................204 Exiting the submenu................................................................206 5.3.7 Warning or malfunction messages on the instrument panel..........................207 Meaning of the lamps...............................................................207 5.3.8 Override the torque reduction....................................................209 5.3.9 Error submenu....................................................................210 5.3.10 Turning off the truck crane.....................................................210 Secure against rolling away........................................................210 When stationary for more than 8hours..............................................211 5.3.11 Folding berth...................................................................213 5.4 Off-road driving.......................................................................214 Adjustments to the transmission........................................................214 Connections............................................................................214 Changing the vehicle level.............................................................214 Rocking the vehicle free and towing....................................................214 5.4.1 Transfer case – switching the off-road gear on/off...............................215 Preconditions......................................................................215 Switching on.......................................................................215 Switching off......................................................................216 Neutral position...................................................................216 5.4.2 Longitudinal and transverse differential locks...................................217 5.4.3 Operating the level adjustment system............................................219 Opening the submenu................................................................219 Setting the onroad level..........................................................220 Pre-selecting suspension struts....................................................220 Changing the vehicle level.........................................................221 Viewing the current inclination....................................................221 Exiting the submenu................................................................222 5.4.4 Freeing the truck crane stuck in terrain.........................................223 Rocking the truck crane free.......................................................223 Towing free forwards...............................................................224 Towing free in reverse gear........................................................224 5.5 Separate steering......................................................................225 5.5.1 Switching to separate steering...................................................225 Manually...........................................................................226 Automatically......................................................................227 Switching to normal steering mode..................................................228 5.6 Heating and air-conditioning system....................................................229 5.6.1 Standard heating system..........................................................229 Switching on.......................................................................229 Heating............................................................................229 Air distribution...................................................................230 Examples...........................................................................231 Switching off......................................................................231 5.6.2 Air-conditioning system..........................................................232 Warnings...........................................................................232 Switching on/off...................................................................232 Cooling............................................................................233 Drying.............................................................................233 5.6.3 Auxiliary water heating system...................................................234 Preheating the engine..............................................................234 Preheating the driver's cab........................................................235 Switching on the auxiliary heater..................................................235 Switching off the auxiliary heater.................................................236 Setting time and weekday...........................................................236 Saving automatic heating start.....................................................237 Setting the heating period.........................................................238 Switching the automatic heating start on and off...................................239 Setting the remaining time.........................................................239 5.7 Towing a trailer.......................................................................240 Effects on the axleloads..............................................................240 Coupling the trailer...................................................................241 Connecting the supply lines............................................................242 Removing the supply lines..............................................................243 Uncoupling the trailer.................................................................243 Checking the braking force.............................................................245 6 Driving modes................................................................................249 6.1 Driving modes..........................................................................249 Information about the axle loads.......................................................249 6.1.1 Information on how to use the tables.............................................250 6.1.2 Tables for a maximum axle load of 12 t (26 500 lbs)..............................251 For 385/95 R25 tyres...............................................................251 For 445/95 R25 tyres...............................................................252 For 525/80 R25 tyres...............................................................253 6.1.3 Maximum permitted speeds with an axle load of over 12t (26500 lbs).............255 6.2 Rigging work for driving with a trailer................................................257 6.2.1 Switching on the slewing gear freewheel..........................................258 6.2.2 Switching on boom floating position..............................................259 6.2.3 Switching on boom pre-tensioning.................................................260 6.2.4 Switching the superstructure driving lights on/off...............................261 Switching off......................................................................261 Switching on.......................................................................261 6.3 Removing/installing the main boom......................................................263 Additional equipment required..........................................................263 6.3.1 CHECKLIST: Removing the main boom................................................264 Preconditions......................................................................264 Checklist..........................................................................264 6.3.2 CHECKLIST: Mounting the main boom................................................267 Prerequisites......................................................................267 Checklist..........................................................................267 6.3.3 Slinging the main boom...........................................................270 Marking............................................................................270 Installing the lifting gear........................................................270 Removing the lifting gear..........................................................271 6.3.4 Removing/attaching the clamps....................................................272 6.3.5 Switching the pressure relief on/off.............................................273 6.3.6 Connecting/disconnecting the derricking cylinder from the boom...................274 Retracting the derricking cylinder head axle.......................................275 Fitting the derricking cylinder head axle..........................................276 6.3.7 Pulling out/pushing in the boom pivot pin........................................277 Before pulling it out..............................................................277 After pushing it in................................................................277 Pulling out the pivot pin..........................................................278 Pushing the pivot pin in...........................................................279 6.3.8 Disconnecting/making the hydraulic/electrical connection.........................280 Disconnecting......................................................................280 Establishing.......................................................................281 6.3.9 Lifting the main boom off/onto the turntable.....................................282 Lifting from the turntable.........................................................282 Lifting on to the turntable........................................................283 6.3.10 Aligning the connecting points..................................................284 6.3.11 Securing/releasing the derricking cylinder......................................284 6.3.12 Transporting the main boom......................................................285 6.3.13 Inspections after main boom mounting............................................286 6.4 Installing/removing the hose drum......................................................287 installing the hose drum...............................................................287 Removing the hose drum.................................................................288 6.5 Installing/removing outrigger beams....................................................289 6.5.1 CHECKLIST: Removing the outrigger beams..........................................290 6.5.2 CHECKLIST: Installing the outrigger beams........................................292 6.5.3 Preparing the truck crane........................................................294 Prerequisites......................................................................294 For removal........................................................................294 6.5.4 Removing/attaching outrigger pads................................................295 Removing the outrigger pads........................................................295 Attaching the outrigger pads.......................................................296 6.5.5 Disconnecting/establishing the hydraulic connection..............................297 6.5.6 Establishing/disconnecting the electrical connection.............................298 6.5.7 Unscrewing/screwing in the spacers...............................................299 Unscrewing.........................................................................299 Screwing in........................................................................300 6.5.8 Disconnecting/establishing the connections to the outrigger box..................301 6.5.9 Extending/Retracting the outrigger beam..........................................301 Extending the outrigger beam.......................................................301 Inserting the outrigger beam.......................................................303 6.5.10 Transporting the outrigger beams................................................305 6.6 Installing/removing supporting boxes...................................................307 6.6.1 CHECKLIST: Removing the outrigger box............................................308 6.6.2 CHECKLIST: Installing the outrigger box..........................................311 6.6.3 Rig the outrigger span 7.98x8.50/1.00m (26.1x27.9/3.3ft)...................313 Front outrigger....................................................................314 Auxiliary supports.................................................................314 6.6.4 Establishing/disconnecting the pneumatic connection..............................316 6.6.5 Establishing/disconnecting the electrical connection.............................317 6.6.6 Disconnecting/establishing the hydraulic connection..............................318 6.6.7 Raising/attaching the outrigger box with the truck crane.........................319 Prerequisites......................................................................319 Lifting............................................................................320 Hanging............................................................................321 6.6.8 Installing the reverse camera....................................................322 6.6.9 Crane movements during the installation and removal procedures..................323 Prerequisites......................................................................323 Before the installation............................................................323 After the removal..................................................................323 6.6.10 Slinging points on the outrigger box............................................324 6.6.11 Fixing/releasing the outrigger pins.............................................325 Locking............................................................................325 Releasing the locking pin..........................................................325 6.6.12 Transporting the outrigger box on the separate vehicle..........................326 Lashing eyelets....................................................................326 6.7 Rig the auxiliary hoist................................................................327 6.7.1 CHECKLIST: Installing the auxiliary hoist........................................327 Prerequisites......................................................................327 6.7.2 CHECKLIST: Removing the auxiliary hoist..........................................329 Prerequisites......................................................................329 6.7.3 Slinging the auxiliary hoist.....................................................331 6.7.4 Slinging the rigging frame.......................................................331 6.7.5 Placing the auxiliary hoist on the counterweight combination.....................332 6.7.6 Rig auxiliary hoist with rigging frame...........................................332 Prerequisite.......................................................................332 6.7.7 Establishing/disconnecting the hydraulic connections.............................333 6.7.8 Making/breaking the electrical connection........................................334 6.7.9 Creating the connection to the turntable.........................................335 Establishing aconnection..........................................................335 Disconnecting......................................................................337 6.7.10 Securing the hoist rope.........................................................338 6.7.11 Transporting the auxiliary hoist................................................339 6.7.12 Check that the auxiliary hoist is functioning properly..........................340 Slewing direction..................................................................340 Slewing indicator..................................................................340 7 Malfunctions in driving mode.................................................................343 7.1 Emergency stop switch..................................................................343 7.2 What to do when a malfunction occurs in road traffic...................................345 7.3 Towing the truck crane.................................................................347 7.3.1 Towing in the event of engine or transmission damage.............................348 Compressed-air supply..............................................................348 Electric power supply..............................................................349 On the transmission................................................................349 Axle drives........................................................................349 Transfer case......................................................................350 Parking brake......................................................................350 Towing the truck crane out of the danger area......................................351 7.3.2 Tow starting.....................................................................351 7.4 Other emergency operations.............................................................353 7.4.1 Externally starting the truck crane..............................................353 7.4.2 Battery charger..................................................................353 7.5 Wheels and tyres.......................................................................355 7.5.1 Wheel change.....................................................................355 Removing a damaged wheel...........................................................356 On the spare wheel holder..........................................................356 Mounting a wheel...................................................................357 7.5.2 Filling the tyres yourself.......................................................359 Connecting the filling hose........................................................359 Filling the tyres..................................................................360 Removing the filling hose..........................................................360 7.6 Fuses..................................................................................361 Notes on changing fuses................................................................361 7.6.1 Fuses in the driver's cab........................................................362 Group F1...........................................................................362 Group F2...........................................................................363 Group F3...........................................................................363 Group F4...........................................................................364 Group F5...........................................................................364 Group F6...........................................................................365 Group F7...........................................................................365 Group F8...........................................................................365 Group F9...........................................................................366 Group F10..........................................................................366 7.6.2 Fuses in the battery box.........................................................367 7.7 Troubleshooting........................................................................369 7.7.1 Malfunctions on the engine.......................................................369 7.7.2 Exhaust system malfunctions......................................................371 7.7.3 Malfunctions to the transmission.................................................372 7.7.4 Transfer case malfunctions.......................................................373 7.7.5 Malfunctions of the service brake................................................373 7.7.6 Malfunctions of the steering.....................................................374 7.7.7 Differential lock malfunctions...................................................375 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler........................375 7.7.9 Malfunctions on the suspension...................................................376 7.7.10 Malfunctions of the level adjustment system.....................................376 7.7.11 Malfunctions on the ECOS carrier................................................377 ECOS program version...............................................................377 General malfunctions...............................................................377 Error messages.....................................................................378 Exiting the submenu................................................................379 7.8 Procedure in the event of malfunctions.................................................381 7.8.1 Switching on emergency operation in coolant circuit..............................381 7.8.2 Procedure in the event of engine malfunctions....................................382 7.8.3 Malfunctions to the transmission.................................................383 General malfunctions...............................................................383 Transmission malfunction...........................................................383 Reading out error codes............................................................385 8 Index........................................................................................389 A..........................................................................................391 B..........................................................................................391 C..........................................................................................392 D..........................................................................................393 E..........................................................................................395 F..........................................................................................397 H..........................................................................................397 I..........................................................................................398 K..........................................................................................398 L..........................................................................................399 M..........................................................................................399 O..........................................................................................400 P..........................................................................................401 R..........................................................................................401 S..........................................................................................403 T..........................................................................................405 V..........................................................................................407 W..........................................................................................407 Correction sheets .............................................................................417 Telescoping with folded lattice extension..................................................413 Swinging the swing-away lattice........................................................414 Checks before telescoping..............................................................415 Rope grab modification.....................................................................417 Hoist rope guide.......................................................................417 7 sheave hook block .......................................................................419 9 Operating elements for crane operation.......................................................425 9.1 Overview of the operating elements.....................................................425 9.1.1 On the outside of the truck crane................................................426 9.1.2 Crane cab........................................................................430 9.1.3 Front panel......................................................................432 9.1.4 Side panel.......................................................................433 Bottom.............................................................................433 Top................................................................................434 Console, rear......................................................................436 Standard heating system............................................................437 Auxiliary water heating system.....................................................438 Auxiliary air heater...............................................................439 9.1.5 Control panels...................................................................440 Left...............................................................................440 Right..............................................................................441 9.1.6 Control lever assignment.........................................................442 Version 1..........................................................................442 Version 2..........................................................................443 9.1.7 ECOS control unit................................................................444 9.1.8 ECOS display – main menu.........................................................446 9.1.9 ECOS display – submenus..........................................................448 Counterweight submenu..............................................................448 Slewing gear/ Houselock submenu....................................................449 Outrigger submenu..................................................................450 Telescoping submenu................................................................452 Power unit speeds submenu..........................................................454 Monitoring submenu.................................................................455 Settings submenu...................................................................456 Operating hours submenu............................................................458 Warning submenu....................................................................459 Error submenu......................................................................461 Working range limitation submenu...................................................462 9.1.10 RCL control unit................................................................464 9.1.11 RCL display – main menu.........................................................466 9.1.12 RCL display – submenus..........................................................467 Rigging mode entry submenu.........................................................467 Monitoring submenu.................................................................468 Rigging mode monitoring submenu....................................................470 Lifting capacity table submenu.....................................................471 working range submenu..............................................................472 Error submenu......................................................................473 Settings submenu...................................................................475 9.1.13 Hand-held control...............................................................476 Outriggers control panel...........................................................477 9.1.14 Outriggers control units........................................................478 Button.............................................................................478 Outrigger button...................................................................479 Inclination and outrigger pressure display.........................................480 Raise axle display.................................................................481 9.2 Short description of the controls......................................................483 9.2.1 Definition of information relating to directions of movement.....................483 Basic rule.........................................................................483 Switch.............................................................................483 9.2.2 General rules for buttons and symbols on the display.............................484 9.2.3 Engine for crane operation.......................................................485 Side panel.........................................................................485 Console, rear......................................................................486 ECOS display.......................................................................486 9.2.4 Engine for driving...............................................................486 Side panel.........................................................................486 Main menu..........................................................................486 Outrigger submenu..................................................................487 9.2.5 Seat contact switch and dead man's switch........................................488 9.2.6 ECOS crane control...............................................................489 Control unit.......................................................................489 9.2.7 Outrigger........................................................................492 Hand-held control..................................................................492 In the Outriggers submenu..........................................................493 In the settings submenu............................................................494 On the Outriggers control units....................................................495 9.2.8 Inclination indicators...........................................................497 9.2.9 Raise axle.......................................................................498 Outriggers control units...........................................................498 9.2.10 Outrigger pressure displays.....................................................500 Outrigger submenu..................................................................500 Outriggers control units...........................................................500 9.2.11 Anemometer display..............................................................500 9.2.12 Counterweight submenu...........................................................501 Counterweight submenu..............................................................501 9.2.13 Main hoist......................................................................504 9.2.14 Auxiliary hoist.................................................................506 9.2.15 Slewing gear....................................................................507 Submenu............................................................................508 9.2.16 Derricking gear.................................................................510 9.2.17 Telescoping mechanism...........................................................512 Control panels.....................................................................512 Submenu............................................................................513 In the settings submenu............................................................518 9.2.18 Hydraulic system................................................................519 9.2.19 Houselock.......................................................................520 9.2.20 Rated capacity limiter (RCL)....................................................521 Control unit.......................................................................521 Main menu..........................................................................523 Enter rigging mode submenu.........................................................524 Monitoring submenu.................................................................527 Lifting capacity table submenu.....................................................531 Working range submenu..............................................................532 Other..............................................................................533 9.2.21 Electrical system...............................................................534 9.2.22 Lighting, windscreen wiper/washing system.......................................534 Lighting...........................................................................534 Windscreen wiper/washing system....................................................536 9.2.23 Hand-held control...............................................................537 Sockets for hand- held control.....................................................537 Engine control panel...............................................................538 Horn...............................................................................538 Outriggers control panel...........................................................539 9.2.24 Windows, doors, keys............................................................541 Windows............................................................................541 Crane cab door.....................................................................541 Keys...............................................................................542 9.2.25 Diagnostics.....................................................................543 10 Starting/stopping the engine – for crane operation..........................................547 10.1 Starting the engine – from the crane cab..............................................547 10.1.1 CHECKLIST: Starting the engine..................................................547 10.1.2 CHECKLIST: At low temperatures..................................................550 10.1.3 Refuelling......................................................................550 Fuel...............................................................................550 Carbamide..........................................................................552 10.1.4 Inspections before starting the engine..........................................553 On the hydraulic tank..............................................................553 Battery master switch..............................................................553 Checking the hand-held control.....................................................554 10.1.5 Switch on the ignition..........................................................554 10.1.6 Lamp test/equalisation of the switching states..................................555 Lamp test..........................................................................555 10.1.7 Setting the display brightness..................................................557 10.1.8 Start the engine................................................................558 Without flame start system.........................................................558 With flame start system............................................................559 10.1.9 Inspections after starting the engine...........................................560 10.1.10 Monitoring submenu.............................................................561 10.1.11 Setting the idling speed.......................................................562 10.1.12 Override the torque reduction..................................................563 10.2 Starting the engine – with the hand-held control......................................565 Prerequisites..........................................................................565 Start the engine.......................................................................565 10.3 Turning off the engine................................................................567 10.3.1 During normal operation, with the ignition lock/with the hand- held control....567 After turning off..................................................................567 10.3.2 In emergencies, with the emergency stop switches................................568 Resetting the emergency stop switch................................................568 10.4 Air intake inhibitor..................................................................569 Releasing the air intake inhibitor.....................................................569 11 Crane operation.............................................................................573 11.1 Before crane operation................................................................573 11.1.1 CHECKLIST: Inspections prior to crane operation.................................573 11.1.2 Checking the condition of the truck crane.......................................577 Windscreen washing system – receptacle.............................................577 Visual inspection..................................................................577 Checking the position of the hoist ropes...........................................578 Checking the electrical system.....................................................578 11.1.3 Adjusting the crane cab seat and front panel....................................579 Crane cab seat.....................................................................579 Front panel........................................................................580 11.1.4 Checking the safety devices.....................................................581 Rated capacity limiter.............................................................581 Lifting limit switch...............................................................581 Emergency stop switch..............................................................582 Seat contact switch................................................................583 11.1.5 Load, earthing..................................................................584 11.1.6 Preheating the hydraulic oil....................................................585 11.1.7 Locking/unlocking the turntable.................................................586 Locking points.....................................................................586 11.1.8 Switching the houselock on/off..................................................588 Switching on the houselock.........................................................588 Switching off the houselock........................................................590 11.2 Operation of the rated capacity limiter...............................................591 11.2.1 Switching on the RCL............................................................592 Switching on.......................................................................592 Brightness of the displays.........................................................594 11.2.2 Entering the rigging mode.......................................................595 Entering individual components.....................................................596 Entering the RCLcode..............................................................599 Entering the reeving...............................................................600 Accepting the rigging mode.........................................................600 11.2.3 Inspections prior to crane operation............................................602 Opening the submenu................................................................602 Inspections........................................................................603 11.2.4 Displays during crane operation.................................................605 11.2.5 RCL early warning...............................................................608 11.2.6 RCL shutdown....................................................................608 Shutdown due to overload...........................................................608 11.2.7 Display in the event of errors..................................................610 11.2.8 RCL override....................................................................611 Table – error/ information codes...................................................619 11.2.9 Displaying the lifting capacity tables..........................................620 11.2.10 Entering the time/date.........................................................622 11.3 Crane operation with main boom........................................................623 11.3.1 Checks during crane operation...................................................623 Horizontal alignment...............................................................623 Safe distances.....................................................................623 Checking the wind speed............................................................624 11.3.2 Permissible slewing ranges and working positions................................625 360 slewing range.................................................................625 Working position 0 to the rear....................................................625 180 to the front rigging position.................................................625 11.3.3 Main hoist......................................................................626 Switching on the main hoist........................................................627 Lifting and lowering...............................................................627 Switching off the main hoist.......................................................628 11.3.4 Auxiliary hoist.................................................................629 Switching on the auxiliary hoist...................................................629 Lifting and lowering...............................................................630 Switching off the auxiliary hoist..................................................631 11.3.5 Lifting limit switch and lowering limit switch..................................632 Lifting limit switch...............................................................632 Lowering limit switch..............................................................633 11.3.6 Derricking gear.................................................................634 Switching on the derricking gear...................................................634 Raising and lowering...............................................................635 Re-enable raising function.........................................................636 Switching off the derricking gear..................................................636 Lowering the main boom to ahorizontal position....................................637 11.3.7 Telescoping mechanism...........................................................638 Overview...........................................................................639 Telescoping process................................................................639 Assignment for display.............................................................641 Fixed length, intermediate length, telescoping length..............................643 Telescoping........................................................................644 Telescoping sequence...............................................................644 Inspections prior to starting operations...........................................645 Switching on the telescoping mechanism.............................................646 Function of the control lever......................................................646 Telescoping with lattice extension folded at the side..............................648 Switching off the telescoping mechanism............................................648 Manual telescoping.................................................................649 Checking the initial position......................................................649 Unlock the telescoping cylinder....................................................651 Extending/ retracting the telescoping cylinder.....................................654 Lock telescoping cylinder..........................................................655 Unlocking the telescopic section...................................................656 Telescoping the telescopic section.................................................658 Locking the telescopic section.....................................................659 Locking the telescopic section for on-road driving.................................660 Telescoping with teleautomation....................................................661 Telescoping the main boom in horizontal position...................................665 11.3.8 High-speed mode.................................................................666 Switch on function................................................................666 Derricking gear/ Telescoping mechanism.............................................666 Hoists.............................................................................667 11.3.9 Slewing gear....................................................................668 Switching on the slewing gear......................................................668 Slewing gear brake.................................................................668 Releasing the slewing gear brake...................................................669 Engaging the slewing gear brake....................................................670 Slewing............................................................................670 Braking the slewing movement.......................................................672 Slewing gear freewheel.............................................................672 Switch off the slewing gear........................................................673 11.3.10 Possible movement combinations.................................................673 11.3.11 Hydraulic oil cooling..........................................................674 11.4 Settings and displays for crane operation.............................................675 11.4.1 Inclining the crane cab.........................................................675 11.4.2 Setting the idling speed........................................................675 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.....................676 11.4.4 Limiting the power unit speeds..................................................676 11.4.5 Setting the characteristic curves for the control levers........................678 11.4.6 Critical load control...........................................................679 Function...........................................................................679 Switching on andoff...............................................................679 11.4.7 Operation of the directional spotlights.........................................680 11.4.8 Displaying the operating hours..................................................681 11.4.9 Warning submenu.................................................................682 Meaning of the symbols.............................................................682 Exiting the submenu................................................................685 11.4.10 Error submenu..................................................................685 11.5 Working range limiter.................................................................686 11.5.1 Opening the Working range limiter submenu.......................................687 11.5.2 Viewing current settings........................................................687 11.5.3 Entering limit values...........................................................689 Overall height/ working radius.....................................................689 Slewing angle......................................................................690 Entering objects...................................................................692 11.5.4 Entering limit values/objects manually..........................................695 Limit values.......................................................................695 Objects............................................................................696 11.5.5 Switching monitoring functions on/off...........................................697 11.5.6 Shutdown by working range limiter...............................................698 11.6 Work break............................................................................699 11.6.1 In case of short work breaks....................................................699 11.6.2 In case of work breaks of more than 8 hours.....................................700 To secure the truck crane..........................................................700 11.7 Heating and air-conditioning system...................................................701 11.7.1 Standard heating system.........................................................701 Switching on.......................................................................701 Heating............................................................................701 Air distribution...................................................................702 Switching off......................................................................702 11.7.2 Air-conditioning system.........................................................703 Warnings...........................................................................703 Switching on/off...................................................................703 Cooling............................................................................704 Drying the air.....................................................................704 11.7.3 Auxiliary water heating system..................................................705 Preheating the engine..............................................................705 Preheating the crane cab...........................................................706 Switching on.......................................................................707 Setting the day and time...........................................................708 Storing the heating start..........................................................709 Setting the heating period.........................................................710 Switching heating start on/off.....................................................710 Switching off......................................................................711 Setting the remaining time.........................................................711 11.7.4 Auxiliary air heater............................................................712 Switching on.......................................................................712 Temperature........................................................................713 Switching off......................................................................713 Other functions....................................................................713 11.8 CraneSTAR system......................................................................715 11.8.1 Overview........................................................................715 11.8.2 Position of the components......................................................715 12 Rigging work................................................................................719 12.1 Rigging work checklists for crane operation with the main boom........................719 12.1.1 CHECKLIST: Rigging..............................................................719 12.1.2 CHECKLIST: Unrigging............................................................723 12.2 Choosing a suitable site..............................................................727 12.2.1 Determining the required ground bearing area....................................727 12.2.2 Safe distance from slopes and pits..............................................730 12.2.3 Earthing the truck crane........................................................731 12.2.4 Safe distance from electrical cables............................................732 12.3 Rigging work after driving with a trailer.............................................735 12.3.1 Switching off the boom floating position........................................735 12.3.2 Switching off the slewing gear freewheel........................................736 Before slewing.....................................................................736 12.3.3 Switching off boom pre-tensioning...............................................737 12.4 Connecting/disconnecting the hand-held control........................................739 12.5 Starting the engine for driving for rigging work......................................741 12.5.1 Starting/turning off the engine with the hand-held control......................741 Prerequisites......................................................................741 Start the engine...................................................................742 Turning off the engine.............................................................742 12.5.2 Starting/turning off the engine from the crane cab..............................743 Prerequisites......................................................................743 Start the engine...................................................................743 After starting the engine..........................................................744 Turning off the engine.............................................................744 12.5.3 Starting/turning off the engine from the outrigger control units................745 Prerequisites......................................................................745 Start the engine...................................................................745 Turning off the engine.............................................................745 12.6 Outrigger.............................................................................747 12.6.1 CHECKLIST: Extending the outriggers.............................................747 12.6.2 CHECKLIST: Retracting the outriggers............................................749 12.6.3 Permissible outrigger spans.....................................................750 12.6.4 Preparing the truck crane.......................................................751 In the driver's cab................................................................751 Outrigger control units............................................................751 12.6.5 Setting the spans...............................................................752 For on-road driving................................................................754 12.6.6 Extending/retracting outriggers.................................................755 From the control units.............................................................756 With the hand- held control........................................................757 From the crane cab.................................................................759 12.6.7 Moving the outrigger pads into working/driving position.........................761 12.6.8 Enlarging the ground bearing area...............................................762 12.6.9 Extending/retracting supporting cylinders.......................................763 From the control units.............................................................764 With the hand- held control........................................................765 From the crane cab.................................................................766 12.6.10 Levelling the truck crane on outriggers horizontally...........................768 Inclination indicators.............................................................768 Prerequisites......................................................................769 Manual alignment...................................................................770 Automatic alignment................................................................771 12.6.11 Levelling the free-standing truck crane........................................773 12.6.12 Outrigger pressure display.....................................................775 12.7 Rigging/unrigging the counterweight...................................................776 12.7.1 Counterweight sections..........................................................776 Version A..........................................................................776 Version B..........................................................................777 12.7.2 Identification..................................................................778 12.7.3 Slinging points on the counterweight sections...................................779 12.7.4 CHECKLIST: Rigging the counterweight............................................781 12.7.5 CHECKLIST: Unrigging the counterweight..........................................783 12.7.6 Assembling counterweight combination............................................785 Combinations forthe basic equipment in version A..................................786 Combinations forthe additional equipment in version A.............................789 Combinations forthe basic equipment in version B..................................791 Combinations forthe additional equipment in version B.............................794 12.7.7 Counterweight hoist unit........................................................799 Counterweight submenu..............................................................799 Extending/ retracting the lifting cylinders........................................800 automatic mode, rigging............................................................801 automatic mode, unrigging..........................................................802 Cancel automatic mode..............................................................804 12.7.8 Setting down counterweight for driving the truck crane..........................805 Version A..........................................................................805 Version B..........................................................................805 12.7.9 Slewing with rigged counterweight...............................................807 12.8 Rigging work on the main boom.........................................................809 12.8.1 Hook block on the bumper........................................................809 Picking up the hook block..........................................................809 Attaching the hook block...........................................................810 12.8.2 Hook block on a separate vehicle................................................811 Picking up the hook block..........................................................812 Setting down the hook block........................................................812 12.8.3 Reeving and unreeving the hoist rope............................................814 Rope end fitting...................................................................814 Reeving the hoist rope.............................................................815 Unreeving the hoist rope...........................................................818 12.8.4 Possible reeving methods on the main boom.......................................819 With 9 head sheaves................................................................819 With 10 head sheaves...............................................................823 12.8.5 Installing/removing the lifting limit switch....................................826 Installing the lifting limit switch................................................826 Removing the lifting limit switch..................................................829 12.8.6 Locking/Unlocking the lifting limit switch......................................830 Locking............................................................................830 Removing the lock..................................................................831 12.8.7 Anemometer and air traffic control light........................................832 Installing.........................................................................832 Removing...........................................................................833 12.9 Other rigging work....................................................................835 12.9.1 Railings on the turntable.......................................................835 12.9.2 Mirror for crane operation......................................................836 12.9.3 Access ladder on the counterweight..............................................837 13 Driving with rigged truck crane.............................................................841 13.1 Driving distance......................................................................841 13.2 Permissible rigging modes and axle loads..............................................843 Axle load table........................................................................843 13.3 Before driving........................................................................845 13.3.1 Securing the superstructure against slewing.....................................845 13.3.2 Checking the tyre pressure and the wind speed...................................845 13.3.3 Putting the truck crane on the wheels...........................................846 13.3.4 Transmission/Connections........................................................848 Transmission.......................................................................848 Connections........................................................................848 13.4 While driving.........................................................................849 13.5 After driving.........................................................................851 13.6 Driving in combined operation.........................................................853 13.6.1 Switching combined operation on/off.............................................853 Prerequisites......................................................................853 Switching on.......................................................................854 Switching off......................................................................854 13.6.2 Starting/turning off the engine.................................................855 13.6.3 Preparing to drive..............................................................856 Transmission.......................................................................856 Switching on separate steering.....................................................856 Connections........................................................................856 13.6.4 While driving...................................................................857 14 Malfunctions during crane operation.........................................................861 14.1 Emergency stop switch.................................................................861 14.2 What to do when malfunctions occur during crane operation.............................863 Load can be lowered....................................................................863 Load cannot be lowered.................................................................863 14.3 Fuses.................................................................................865 Notes on changing fuses................................................................865 14.3.1 Fuses on the turntable..........................................................866 Fuse groups F1/F2/F3...............................................................866 Fuses on the circuit board.........................................................867 14.3.2 Fuses in the crane cab..........................................................869 14.3.3 Fuses in the battery box........................................................871 14.3.4 RCL fuses.......................................................................872 14.4 Finding and eliminating malfunctions..................................................873 14.4.1 Malfunctions on the engine......................................................873 14.4.2 Exhaust system malfunctions.....................................................874 14.4.3 Malfunctions on the main hoist/auxiliary hoist..................................875 14.4.4 Malfunctions on the derricking gear.............................................876 14.4.5 Malfunctions in the telescoping mechanism.......................................877 Telescoping mechanism error messages...............................................878 14.4.6 Malfunctions on the slewing gear................................................880 14.4.7 Malfunctions on the counterweight hoist unit....................................881 14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.......................882 14.4.9 Malfunctions when inclining the crane cab.......................................882 14.4.10 Malfunctions when operating with the hand-held control.........................882 14.4.11 Malfunctions of the outriggers.................................................883 14.4.12 Troubleshooting the RCL........................................................884 General malfunctions...............................................................884 Error messages in the monitoring submenu...........................................885 Displays in the Error submenu......................................................887 Table – Error codes................................................................889 Switching off the sensor/ tachogenerator..........................................892 14.4.13 Malfunctions ECOS – superstructure.............................................893 ECOS program version...............................................................893 General malfunctions...............................................................893 Error messages.....................................................................894 Exiting the submenu................................................................895 14.4.14 Malfunctions on the CraneSTAR system...........................................896 14.5 Emergency operations and programs.....................................................901 14.5.1 Mechanical emergency activation for retracting..................................902 Prior to the emergency operation, check............................................902 Procedure..........................................................................902 Mechanical emergency activation....................................................903 14.5.2 Telescoping emergency program...................................................905 Start the emergency program........................................................905 Determining the error type.........................................................906 If there is an error on the length indicator.......................................907 If there is an error at a proximity switch.........................................911 Terminating the emergency program..................................................912 Tables for approaching the locking points..........................................913 14.5.3 Entering the current telescoping................................................915 14.5.4 Emergency operation with the hand-held control..................................917 Preparations.......................................................................917 Operating a power unit.............................................................918 Stopping movements.................................................................920 Stopping movements in emergencies..................................................920 Turning off the engine.............................................................920 14.5.5 Switching on emergency operation in coolant circuit.............................921 14.6 Hydraulic emergency operation.........................................................923 14.6.1 Operating principle.............................................................923 14.6.2 Connecting/disconnecting hoses..................................................924 Establishing connections...........................................................924 Disconnecting......................................................................925 14.6.3 Switching emergency operation on/off............................................926 14.6.4 Establishing the hydraulic circuits required....................................927 Switching over valves..............................................................927 For lifting/ lowering..............................................................929 For slewing........................................................................930 14.6.5 Carrying out emergency operation................................................931 Slewing............................................................................931 Derricking.........................................................................932 Lifting/lowering...................................................................932 14.6.6 After emergency operation.......................................................933 Switch off emergency operation.....................................................933 Switch over to crane operation.....................................................933 Disconnect the hoses...............................................................933 14.6.7 Emergency supply of another crane...............................................934 For emergency supply...............................................................934 After emergency supply.............................................................934 15 Index.......................................................................................937 A..........................................................................................939 B..........................................................................................939 C..........................................................................................940 D..........................................................................................941 E..........................................................................................943 F..........................................................................................945 H..........................................................................................945 I..........................................................................................946 K..........................................................................................946 L..........................................................................................947 M..........................................................................................947 O..........................................................................................948 P..........................................................................................949 R..........................................................................................949 S..........................................................................................951 T..........................................................................................953 V..........................................................................................955 W..........................................................................................955
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