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Grove Crane GMK 6300L Driving & Crane Operation Operating Manual 3112964 – PDF DOWNLOAD
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Grove Crane GMK 6300L Driving & Crane Operation Operating 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 : 950
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:
Intended use:
- The GMK 6300L is a state-of-the-art truck crane, designed in accordance
with approved safety regulations. Nevertheless, the operator or third parties
can still be endangered and the crane or other property put at risk while
using it. - The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK 6300L truck crane may only be used when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 6300L truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
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 unauthorized
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 ............................................................................. 3 Rope grab modification .................................................................... 3 7 sheave hook block ....................................................................... 5 1 Overview..................................................................................... 11 1.1 Accidents.............................................................................. 11 1.2 Branches............................................................................... 12 1.2.1 Manitowoc Crane Care............................................................. 12 1.2.2 Dealer list...................................................................... 12 1.3 Warranty specifications................................................................ 13 1.4 Terms used............................................................................. 16 1.5 Technical data......................................................................... 19 1.5.1 Maximum lifting capacity (DIN/ISO/EN)............................................ 19 1.5.2 Maximum lifting capacity (ASME B 30.5)........................................... 19 1.5.3 Dimensions and weights of the truck crane, axle loads............................ 20 Dimensions......................................................................... 21 Weight and axleloads.............................................................. 21 1.5.4 Dimensions and weights of removable parts........................................ 22 Spare wheel........................................................................ 22 Outriggers......................................................................... 22 Hose drum.......................................................................... 22 Main boom.......................................................................... 23 Hook blocks and hook tackle........................................................ 23 Auxiliary hoist.................................................................... 23 Counterweight parts................................................................ 24 1.5.5 Carrier.......................................................................... 25 Engine............................................................................. 25 Transmission....................................................................... 25 Transfer case...................................................................... 25 Axle lines......................................................................... 25 Steering........................................................................... 26 Tyres.............................................................................. 26 Outriggers......................................................................... 26 Auxiliary supports................................................................. 27 Electrical system.................................................................. 27 Tool............................................................................... 27 Towing couplings................................................................... 27 Driving speeds..................................................................... 27 Climbing ability................................................................... 27 Turning circle radiuses............................................................ 28 1.5.6 Superstructure................................................................... 28 Engine............................................................................. 28 Main hoist......................................................................... 29 Auxiliary hoist.................................................................... 29 Slewing gears...................................................................... 29 Derricking gear.................................................................... 30 Main boom.......................................................................... 30 Lattice extension.................................................................. 30 Operating speeds................................................................... 30 1.6 Documentation supplied................................................................. 31 1.6.1 Questions concerning the documentation........................................... 32 1.7 Information about the operating instructions........................................... 33 1.7.1 What do the symbols used mean?................................................... 33 1.7.2 How are the operating instructions structured?................................... 35 Division........................................................................... 35 Structure of the chapters.......................................................... 35 Structure of the pages............................................................. 36 1.7.3 How do I find the information I need?............................................ 37 Cross-references example........................................................... 38 1.7.4 What information is available for operations planning?........................... 40 1.8 Conversion table for US measurements................................................... 41 1.9 Training – Information................................................................. 43 1.10 Identification........................................................................ 44 1.11 EC Declaration of Conformity.......................................................... 46 2 Basic safety instructions.................................................................... 49 2.1 Intended use........................................................................... 49 2.1.1 Improper use..................................................................... 50 2.2 Organisational measures................................................................ 51 2.3 Qualifications of the personnel........................................................ 53 2.4 Safety instructions for driving the truck crane........................................ 54 2.5 Safety instructions for crane operation................................................ 54 2.6 Information on transporting persons.................................................... 56 Equipment for lifting persons......................................................... 56 Personnel.............................................................................. 57 Operation.............................................................................. 57 Truck crane............................................................................ 58 3 Operating elements for driving............................................................... 61 3.1 Overview of the operating elements..................................................... 61 3.1.1 On the outside of the truck crane................................................ 62 3.1.2 Driver's cab..................................................................... 64 Overview........................................................................... 64 Behind the cover................................................................... 66 3.1.3 Instrument panel................................................................. 67 Left/right......................................................................... 67 Middle............................................................................. 68 3.1.4 Display, driving mode............................................................ 71 3.1.5 Steering column/steering wheel................................................... 72 3.1.6 Transmission operating elements.................................................. 73 3.1.7 Tachograph....................................................................... 74 Tachograph Version 1............................................................... 75 3.1.8 ECOS control unit................................................................ 76 3.1.9 ECOS display – main menu......................................................... 78 3.1.10 ECOS display – submenus......................................................... 80 Level adjustment system submenu.................................................... 80 Settings submenu................................................................... 82 Monitoring submenu................................................................. 83 Operating hours submenu............................................................ 84 Warning submenu.................................................................... 84 Error submenu...................................................................... 85 3.1.11 Heating/Air-conditioning system................................................. 86 Standard heating system............................................................ 86 Auxiliary water heating system..................................................... 87 3.1.12 Sockets for hand-held control................................................... 88 3.1.13 Outrigger control units......................................................... 89 3.1.14 Control unit of the rear outrigger box.......................................... 90 3.2 Short description of the controls...................................................... 91 3.2.1 Definition of information relating to directions of movement..................... 91 Basic rule......................................................................... 91 Switches and buttons............................................................... 92 3.2.2 General information on the operating elements.................................... 92 3.2.3 General rules for buttons and symbols on the display............................. 93 3.2.4 Engine........................................................................... 94 Steering column.................................................................... 94 Multipurpose switch................................................................ 94 Instrument panel................................................................... 95 Main menu.......................................................................... 96 3.2.5 Carbamide system................................................................. 97 Instrument panel................................................................... 97 Display, driving mode.............................................................. 98 ECOS display....................................................................... 98 3.2.6 Electrical system................................................................ 99 3.2.7 ECOS crane control............................................................... 99 Control unit....................................................................... 99 3.2.8 Transmission.....................................................................102 Display, driving mode..............................................................102 Transmission control unit..........................................................102 3.2.9 Reverse camera...................................................................105 3.2.10 Transfer case...................................................................106 3.2.11 Final drive.....................................................................107 3.2.12 Brakes..........................................................................108 Service brake......................................................................108 Additional brakes..................................................................108 Parking brake......................................................................109 3.2.13 Steering/separate steering......................................................110 Instrument panel...................................................................110 ECOS display.......................................................................111 Driver's door......................................................................112 3.2.14 Suspension......................................................................113 3.2.15 Lighting/windscreen wipers/horn.................................................114 Steering column....................................................................114 Instrument panel...................................................................114 Roof...............................................................................117 3.2.16 Level adjustment system.........................................................117 3.2.17 Tachograph/speedometer..........................................................119 Tachograph.........................................................................119 Speedometer........................................................................119 3.2.18 Control unit of the rear outrigger box..........................................120 3.2.19 Diagnostics.....................................................................121 Displays/ submenu..................................................................121 3.2.20 Windows, doors, keys............................................................122 Window winder......................................................................122 Doors..............................................................................123 Keys...............................................................................123 3.2.21 Front flap......................................................................124 4 Starting/turning off the engine for driving..................................................127 4.1 Starting the engine from the driver's cab..............................................127 4.1.1 CHECKLIST: Starting the engine...................................................127 4.1.2 CHECKLIST: At low temperatures...................................................130 4.1.3 Ladders and access ladders.......................................................130 Access ladders.....................................................................130 Ladders............................................................................131 4.1.4 Refuelling.......................................................................134 Fuel...............................................................................134 Carbamide..........................................................................135 4.1.5 Inspections before starting the engine...........................................137 On the hydraulic tank..............................................................137 Battery master switch..............................................................137 Checking the hand-held control.....................................................138 4.1.6 Switch on the ignition...........................................................138 4.1.7 Lamp test/equalisation of the switching states...................................139 Lamp test..........................................................................139 Equalisation of the switching states...............................................140 4.1.8 Display – setting the brightness.................................................141 4.1.9 Start the engine.................................................................142 Without flame start system.........................................................143 With flame start system............................................................143 4.1.10 Inspections after starting the engine...........................................145 Checking in the main menu..........................................................145 Indicator lamps on the instrument panel............................................145 4.1.11 Monitoring elements.............................................................147 Instrument panel...................................................................147 4.1.12 Monitoring submenu..............................................................148 4.1.13 Setting the idling speed........................................................149 4.2 Turning off the engine.................................................................151 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.......151 After turning off..................................................................151 4.2.2 With emergency stop switches.....................................................152 Resetting the emergency stop switch................................................152 4.3 Air intake inhibitor...................................................................153 Releasing the air intake inhibitor.....................................................153 5 Driving......................................................................................157 5.1 Before driving.........................................................................157 5.1.1 CHECKLIST: Checks before on-road driving.........................................157 5.1.2 Checking the condition of the truck crane........................................162 Windscreen washing system..........................................................162 Electrical system..................................................................162 Adjusting the mirrors..............................................................163 Warning plates for vehicle width...................................................164 Displaying the vehicle height......................................................164 Supply pressure....................................................................165 Parking brake......................................................................166 5.1.3 Adjusting the seat and the steering column.......................................167 Driver's seat......................................................................167 Passenger's seat...................................................................168 Adjusting the steering column......................................................169 5.1.4 Switching the suspension on/off..................................................170 Opening the submenu................................................................170 Switching on the suspension........................................................171 Switching off the suspension.......................................................171 5.1.5 Adjusting the tachograph.........................................................172 Preconditions......................................................................172 In the event of malfunctions.......................................................172 Adjusting the tachograph...........................................................173 5.1.6 Displaying the operating hours...................................................177 5.1.7 Settings/indications on the Driving display......................................178 5.2 Operating the transmission.............................................................179 5.2.1 Switching on.....................................................................179 5.2.2 Switching the transmission to neutral position...................................180 While driving......................................................................180 5.2.3 Changing the driving mode........................................................181 5.2.4 Selecting the driving direction..................................................182 5.2.5 Changing highest gear/starting gear..............................................184 5.2.6 Starting.........................................................................184 5.2.7 Driving and changing gears.......................................................185 5.2.8 Changing the driving direction...................................................186 5.2.9 Stopping.........................................................................187 Stopping for a long period of time.................................................187 5.2.10 On the roller type dynamometer..................................................187 5.2.11 Oil level gauge.................................................................188 5.3 Driving and turning off the truck crane................................................191 5.3.1 Checks while driving.............................................................191 Immediately after you start to move................................................191 While driving......................................................................193 5.3.2 Tempomat.........................................................................194 Switching on.......................................................................194 Switching off......................................................................195 5.3.3 Temposet.........................................................................195 Switching on.......................................................................195 Switching off......................................................................195 5.3.4 Driving downhill.................................................................196 Starting...........................................................................196 Inspections when driving downhill..................................................196 Shifting down from the highest gear................................................197 Additional brakes..................................................................198 5.3.5 Driving uphill...................................................................199 Starting...........................................................................199 Driving............................................................................199 5.3.6 Warning submenu..................................................................200 Meaning of the symbols.............................................................200 Exiting the submenu................................................................202 5.3.7 Warning or malfunction messages on the instrument panel..........................203 Meaning of the lamps...............................................................203 5.3.8 Override the torque reduction....................................................205 5.3.9 Error submenu....................................................................206 5.3.10 Turning off the truck crane.....................................................206 Secure against rolling away........................................................206 When stationary for more than 8hours..............................................207 5.3.11 Folding berth...................................................................209 5.4 Off-road driving.......................................................................210 Adjustments to the transmission........................................................210 Connections............................................................................210 Changing the vehicle level.............................................................210 Rocking the vehicle free and towing....................................................210 5.4.1 Transfer case – switching the off-road gear on/off...............................211 Preconditions......................................................................211 Switching on.......................................................................211 Switching off......................................................................212 Neutral position...................................................................212 5.4.2 Longitudinal and transverse differential locks...................................213 5.4.3 Operating the level adjustment system............................................215 Opening the submenu................................................................215 Setting the onroad level..........................................................216 Pre-selecting suspension struts....................................................216 Changing the vehicle level.........................................................217 Viewing the current inclination....................................................217 Exiting the submenu................................................................218 5.4.4 Freeing the truck crane stuck in terrain.........................................219 Rocking the truck crane free.......................................................219 Towing free forwards...............................................................220 Towing free in reverse gear........................................................220 5.5 Separate steering......................................................................221 5.5.1 Switching to separate steering...................................................221 Manually...........................................................................222 Automatically......................................................................223 Switching to normal steering mode..................................................224 5.6 Heating and air-conditioning system....................................................225 5.6.1 Standard heating system..........................................................225 Switching on.......................................................................225 Heating............................................................................225 Air distribution...................................................................226 Examples...........................................................................227 Switching off......................................................................227 5.6.2 Air-conditioning system..........................................................228 Warnings...........................................................................228 Switching on/off...................................................................228 Cooling............................................................................229 Drying.............................................................................229 5.6.3 Auxiliary water heating system...................................................230 Preheating the engine..............................................................230 Preheating the driver's cab........................................................231 Switching on the auxiliary heater..................................................231 Switching off the auxiliary heater.................................................232 Setting time and weekday...........................................................232 Saving automatic heating start.....................................................233 Setting the heating period.........................................................234 Switching the automatic heating start on and off...................................235 Setting the remaining time.........................................................235 5.7 Towing a trailer.......................................................................236 Effects on the axleloads..............................................................236 Coupling the trailer...................................................................237 Connecting the supply lines............................................................238 Removing the supply lines..............................................................239 Uncoupling the trailer.................................................................239 Checking the braking force.............................................................241 6 Driving modes................................................................................245 6.1 Driving modes..........................................................................245 Information about the axle loads.......................................................245 6.1.1 Information on how to use the tables.............................................246 6.1.2 Tables for a maximum axle load of 12 t (26 500 lbs)..............................247 For 385/95 R25 tyres...............................................................247 For 445/95 R25 tyres...............................................................248 For 525/80 R25 tyres...............................................................249 6.1.3 Maximum permitted speeds with an axle load of over 12t (26500 lbs).............251 6.2 Rigging work for driving with a trailer................................................253 6.2.1 Switching on the slewing gear freewheel..........................................254 6.2.2 Switching on boom floating position..............................................255 6.2.3 Switching on boom pre-tensioning.................................................256 6.2.4 Switching the superstructure driving lights on/off...............................257 Switching off......................................................................257 Switching on.......................................................................257 6.3 Removing/installing the main boom......................................................259 Additional equipment required..........................................................259 6.3.1 CHECKLIST: Removing the main boom................................................260 Preconditions......................................................................260 Checklist..........................................................................260 6.3.2 CHECKLIST: Mounting the main boom................................................263 Prerequisites......................................................................263 Checklist..........................................................................263 6.3.3 Slinging the main boom...........................................................266 Marking............................................................................266 Installing the lifting gear........................................................266 Removing the lifting gear..........................................................267 6.3.4 Removing/attaching the clamps....................................................268 6.3.5 Switching the pressure relief on/off.............................................269 6.3.6 Connecting/disconnecting the derricking cylinder from the boom...................270 Retracting the derricking cylinder head axle.......................................271 Fitting the derricking cylinder head axle..........................................272 6.3.7 Pulling out/pushing in the boom pivot pin........................................273 Before pulling it out..............................................................273 After pushing it in................................................................273 Pulling out the pivot pin..........................................................274 Pushing the pivot pin in...........................................................275 6.3.8 Disconnecting/making the hydraulic/electrical connection.........................276 Disconnecting......................................................................276 Establishing.......................................................................277 6.3.9 Lifting the main boom off/onto the turntable.....................................278 Lifting from the turntable.........................................................278 Lifting on to the turntable........................................................279 6.3.10 Aligning the connecting points..................................................280 6.3.11 Securing/releasing the derricking cylinder......................................280 6.3.12 Transporting the main boom......................................................281 6.3.13 Inspections after main boom mounting............................................282 6.4 Installing/removing the hose drum......................................................283 installing the hose drum...............................................................283 Removing the hose drum.................................................................284 6.5 Installing/removing outrigger beams....................................................285 6.5.1 CHECKLIST: Removing the outrigger beams..........................................286 6.5.2 CHECKLIST: Installing the outrigger beams........................................288 6.5.3 Preparing the truck crane........................................................290 Prerequisites......................................................................290 For removal........................................................................290 6.5.4 Removing/attaching outrigger pads................................................291 Removing the outrigger pads........................................................291 Attaching the outrigger pads.......................................................292 6.5.5 Disconnecting/establishing the hydraulic connection..............................293 6.5.6 Establishing/disconnecting the electrical connection.............................294 6.5.7 Unscrewing/screwing in the spacers...............................................295 Unscrewing.........................................................................295 Screwing in........................................................................296 6.5.8 Disconnecting/establishing the connections to the outrigger box..................297 6.5.9 Extending/Retracting the outrigger beam..........................................297 Extending the outrigger beam.......................................................297 Inserting the outrigger beam.......................................................299 6.5.10 Transporting the outrigger beams................................................301 6.6 Installing/removing supporting boxes...................................................303 6.6.1 CHECKLIST: Removing the outrigger box............................................304 6.6.2 CHECKLIST: Installing the outrigger box..........................................307 6.6.3 Rig the outrigger span 7.98x8.50/1.00m (26.1x27.9/3.3ft)...................309 Front outrigger....................................................................310 Auxiliary supports.................................................................310 6.6.4 Establishing/disconnecting the pneumatic connection..............................312 6.6.5 Establishing/disconnecting the electrical connection.............................313 6.6.6 Disconnecting/establishing the hydraulic connection..............................314 6.6.7 Raising/attaching the outrigger box with the truck crane.........................315 Prerequisites......................................................................315 Lifting............................................................................316 Hanging............................................................................317 6.6.8 Installing the reverse camera....................................................318 6.6.9 Crane movements during the installation and removal procedures..................319 Prerequisites......................................................................319 Before the installation............................................................319 After the removal..................................................................319 6.6.10 Slinging points on the outrigger box............................................320 6.6.11 Fixing/releasing the outrigger pins.............................................321 Locking............................................................................321 Releasing the locking pin..........................................................321 6.6.12 Transporting the outrigger box on the separate vehicle..........................322 Lashing eyelets....................................................................322 6.7 Rig the auxiliary hoist................................................................323 6.7.1 CHECKLIST: Installing the auxiliary hoist........................................323 Prerequisites......................................................................323 6.7.2 CHECKLIST: Removing the auxiliary hoist..........................................325 Prerequisites......................................................................325 6.7.3 Slinging the auxiliary hoist.....................................................327 6.7.4 Slinging the rigging frame.......................................................327 6.7.5 Placing the auxiliary hoist on the counterweight combination.....................328 6.7.6 Rig auxiliary hoist with rigging frame...........................................328 Prerequisite.......................................................................328 6.7.7 Establishing/disconnecting the hydraulic connections.............................329 6.7.8 Making/breaking the electrical connection........................................330 6.7.9 Creating the connection to the turntable.........................................331 Establishing aconnection..........................................................331 Disconnecting......................................................................333 6.7.10 Securing the hoist rope.........................................................334 6.7.11 Transporting the auxiliary hoist................................................335 6.7.12 Check that the auxiliary hoist is functioning properly..........................336 Slewing direction..................................................................336 Slewing indicator..................................................................336 7 Malfunctions in driving mode.................................................................339 7.1 Emergency stop switch..................................................................339 7.2 What to do when a malfunction occurs in road traffic...................................341 7.3 Towing the truck crane.................................................................343 7.3.1 Towing in the event of engine or transmission damage.............................344 Compressed-air supply..............................................................344 Electric power supply..............................................................345 On the transmission................................................................345 Axle drives........................................................................345 Transfer case......................................................................346 Parking brake......................................................................346 Towing the truck crane out of the danger area......................................347 7.3.2 Tow starting.....................................................................347 7.4 Other emergency operations.............................................................349 7.4.1 Externally starting the truck crane..............................................349 7.4.2 Battery charger..................................................................349 7.5 Wheels and tyres.......................................................................351 7.5.1 Wheel change.....................................................................351 Removing a damaged wheel...........................................................352 On the spare wheel holder..........................................................352 Mounting a wheel...................................................................353 7.5.2 Filling the tyres yourself.......................................................355 Connecting the filling hose........................................................355 Filling the tyres..................................................................356 Removing the filling hose..........................................................356 7.6 Fuses..................................................................................357 Notes on changing fuses................................................................357 7.6.1 Fuses in the driver's cab........................................................358 Group F1...........................................................................358 Group F2...........................................................................359 Group F3...........................................................................359 Group F4...........................................................................360 Group F5...........................................................................360 Group F6...........................................................................361 Group F7...........................................................................361 Group F8...........................................................................361 Group F9...........................................................................362 Group F10..........................................................................362 7.6.2 Fuses in the battery box.........................................................363 7.7 Troubleshooting........................................................................365 7.7.1 Malfunctions on the engine.......................................................365 7.7.2 Exhaust system malfunctions......................................................367 7.7.3 Malfunctions to the transmission.................................................368 7.7.4 Transfer case malfunctions.......................................................369 7.7.5 Malfunctions of the service brake................................................369 7.7.6 Malfunctions of the steering.....................................................370 7.7.7 Differential lock malfunctions...................................................371 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler........................371 7.7.9 Malfunctions on the suspension...................................................372 7.7.10 Malfunctions of the level adjustment system.....................................372 7.7.11 Malfunctions on the ECOS carrier................................................373 ECOS program version...............................................................373 General malfunctions...............................................................373 Error messages.....................................................................374 Exiting the submenu................................................................375 7.8 Procedure in the event of malfunctions.................................................377 7.8.1 Switching on emergency operation in coolant circuit..............................377 7.8.2 Procedure in the event of engine malfunctions....................................378 7.8.3 Malfunctions to the transmission.................................................379 General malfunctions...............................................................379 Transmission malfunction...........................................................379 Reading out error codes............................................................381 8 Index........................................................................................385 A..........................................................................................387 B..........................................................................................387 C..........................................................................................388 D..........................................................................................389 E..........................................................................................391 F..........................................................................................393 H..........................................................................................393 I..........................................................................................394 K..........................................................................................394 L..........................................................................................395 M..........................................................................................395 O..........................................................................................396 P..........................................................................................397 R..........................................................................................397 S..........................................................................................399 T..........................................................................................401 V..........................................................................................403 W..........................................................................................403 Correction sheets .............................................................................409 Rope grab modification.....................................................................409 Hoist rope guide.......................................................................409 7 sheave hook block .......................................................................411 9 Operating elements for crane operation.......................................................417 9.1 Overview of the operating elements.....................................................417 9.1.1 On the outside of the truck crane................................................418 9.1.2 Crane cab........................................................................422 9.1.3 Front panel......................................................................424 9.1.4 Side panel.......................................................................425 Bottom.............................................................................425 Top................................................................................426 Console, rear......................................................................428 Standard heating system............................................................429 Auxiliary water heating system.....................................................430 Auxiliary air heater...............................................................431 9.1.5 Control panels...................................................................432 Left...............................................................................432 Right..............................................................................433 9.1.6 Control lever assignment.........................................................434 Version 1..........................................................................434 Version 2..........................................................................435 9.1.7 ECOS control unit................................................................436 9.1.8 ECOS display – main menu.........................................................438 9.1.9 ECOS display – submenus..........................................................440 Counterweight submenu..............................................................440 Slewing gear/ Houselock submenu....................................................441 Outrigger submenu..................................................................442 Telescoping submenu................................................................444 Power unit speeds submenu..........................................................446 Monitoring submenu.................................................................447 Settings submenu...................................................................448 Operating hours submenu............................................................450 Warning submenu....................................................................451 Error submenu......................................................................453 Working range limitation submenu...................................................454 9.1.10 RCL control unit................................................................456 9.1.11 RCL display – main menu.........................................................458 9.1.12 RCL display – submenus..........................................................459 Rigging mode entry submenu.........................................................459 Monitoring submenu.................................................................460 Rigging mode monitoring submenu....................................................462 Lifting capacity table submenu.....................................................463 working range submenu..............................................................464 Error submenu......................................................................465 Settings submenu...................................................................467 9.1.13 Hand-held control...............................................................468 Outriggers control panel...........................................................469 9.1.14 Outriggers control units........................................................470 Button.............................................................................470 Outrigger button...................................................................471 Inclination and outrigger pressure display.........................................472 Raise axle display.................................................................473 9.2 Short description of the controls......................................................475 9.2.1 Definition of information relating to directions of movement.....................475 Basic rule.........................................................................475 Switch.............................................................................475 9.2.2 General rules for buttons and symbols on the display.............................476 9.2.3 Engine for crane operation.......................................................477 Side panel.........................................................................477 Console, rear......................................................................478 ECOS display.......................................................................478 9.2.4 Engine for driving...............................................................478 Side panel.........................................................................478 Main menu..........................................................................478 Outrigger submenu..................................................................479 9.2.5 Seat contact switch and dead man's switch........................................480 9.2.6 ECOS crane control...............................................................481 Control unit.......................................................................481 9.2.7 Outrigger........................................................................484 Hand-held control..................................................................484 In the Outriggers submenu..........................................................485 In the settings submenu............................................................486 On the Outriggers control units....................................................487 9.2.8 Inclination indicators...........................................................489 9.2.9 Raise axle.......................................................................490 Outriggers control units...........................................................490 9.2.10 Outrigger pressure displays.....................................................492 Outrigger submenu..................................................................492 Outriggers control units...........................................................492 9.2.11 Anemometer display..............................................................492 9.2.12 Counterweight submenu...........................................................493 Counterweight submenu..............................................................493 9.2.13 Main hoist......................................................................496 9.2.14 Auxiliary hoist.................................................................498 9.2.15 Slewing gear....................................................................499 Submenu............................................................................500 9.2.16 Derricking gear.................................................................502 9.2.17 Telescoping mechanism...........................................................504 Control panels.....................................................................504 Submenu............................................................................505 In the settings submenu............................................................510 9.2.18 Hydraulic system................................................................511 9.2.19 Houselock.......................................................................512 9.2.20 Rated capacity limiter (RCL)....................................................513 Control unit.......................................................................513 Main menu..........................................................................515 Enter rigging mode submenu.........................................................516 Monitoring submenu.................................................................519 Lifting capacity table submenu.....................................................523 Working range submenu..............................................................524 Other..............................................................................525 9.2.21 Electrical system...............................................................526 9.2.22 Lighting, windscreen wiper/washing system.......................................526 Lighting...........................................................................526 Windscreen wiper/washing system....................................................528 9.2.23 Hand-held control...............................................................529 Sockets for hand- held control.....................................................529 Engine control panel...............................................................530 Horn...............................................................................530 Outriggers control panel...........................................................531 9.2.24 Windows, doors, keys............................................................533 Windows............................................................................533 Crane cab door.....................................................................533 Keys...............................................................................534 9.2.25 Diagnostics.....................................................................535 10 Starting/stopping the engine – for crane operation..........................................539 10.1 Starting the engine – from the crane cab..............................................539 10.1.1 CHECKLIST: Starting the engine..................................................539 10.1.2 CHECKLIST: At low temperatures..................................................542 10.1.3 Refuelling......................................................................542 Fuel...............................................................................542 Carbamide..........................................................................544 10.1.4 Inspections before starting the engine..........................................545 On the hydraulic tank..............................................................545 Battery master switch..............................................................545 Checking the hand-held control.....................................................546 10.1.5 Switch on the ignition..........................................................546 10.1.6 Lamp test/equalisation of the switching states..................................547 Lamp test..........................................................................547 10.1.7 Setting the display brightness..................................................549 10.1.8 Start the engine................................................................550 Without flame start system.........................................................550 With flame start system............................................................551 10.1.9 Inspections after starting the engine...........................................552 10.1.10 Monitoring submenu.............................................................553 10.1.11 Setting the idling speed.......................................................554 10.1.12 Override the torque reduction..................................................555 10.2 Starting the engine – with the hand-held control......................................557 Prerequisites..........................................................................557 Start the engine.......................................................................557 10.3 Turning off the engine................................................................559 10.3.1 During normal operation, with the ignition lock/with the hand- held control....559 After turning off..................................................................559 10.3.2 In emergencies, with the emergency stop switches................................560 Resetting the emergency stop switch................................................560 10.4 Air intake inhibitor..................................................................561 Releasing the air intake inhibitor.....................................................561 11 Crane operation.............................................................................565 11.1 Before crane operation................................................................565 11.1.1 CHECKLIST: Inspections prior to crane operation.................................565 11.1.2 Checking the condition of the truck crane.......................................569 Windscreen washing system – receptacle.............................................569 Visual inspection..................................................................569 Checking the position of the hoist ropes...........................................570 Checking the electrical system.....................................................570 11.1.3 Adjusting the crane cab seat and front panel....................................571 Crane cab seat.....................................................................571 Front panel........................................................................572 11.1.4 Checking the safety devices.....................................................573 Rated capacity limiter.............................................................573 Lifting limit switch...............................................................573 Emergency stop switch..............................................................574 Seat contact switch................................................................575 11.1.5 Load, earthing..................................................................576 11.1.6 Preheating the hydraulic oil....................................................577 11.1.7 Locking/unlocking the turntable.................................................578 Locking points.....................................................................578 11.1.8 Switching the houselock on/off..................................................580 Switching on the houselock.........................................................580 Switching off the houselock........................................................582 11.2 Operation of the rated capacity limiter...............................................583 11.2.1 Switching on the RCL............................................................584 Switching on.......................................................................584 Brightness of the displays.........................................................586 11.2.2 Entering the rigging mode.......................................................587 Entering individual components.....................................................588 Entering the RCLcode..............................................................591 Entering the reeving...............................................................592 Accepting the rigging mode.........................................................592 11.2.3 Inspections prior to crane operation............................................594 Opening the submenu................................................................594 Inspections........................................................................595 11.2.4 Displays during crane operation.................................................597 11.2.5 RCL early warning...............................................................600 11.2.6 RCL shutdown....................................................................600 Shutdown due to overload...........................................................600 11.2.7 Display in the event of errors..................................................602 11.2.8 RCL override....................................................................603 Table – error/ information codes...................................................611 11.2.9 Displaying the lifting capacity tables..........................................612 11.2.10 Entering the time/date.........................................................614 11.3 Crane operation with main boom........................................................615 11.3.1 Checks during crane operation...................................................615 Horizontal alignment...............................................................615 Safe distances.....................................................................615 Checking the wind speed............................................................616 11.3.2 Permissible slewing ranges and working positions................................617 360 slewing range.................................................................617 Working position 0 to the rear....................................................617 180 to the front rigging position.................................................617 11.3.3 Main hoist......................................................................618 Switching on the main hoist........................................................619 Lifting and lowering...............................................................619 Switching off the main hoist.......................................................620 11.3.4 Auxiliary hoist.................................................................621 Switching on the auxiliary hoist...................................................621 Lifting and lowering...............................................................622 Switching off the auxiliary hoist..................................................623 11.3.5 Lifting limit switch and lowering limit switch..................................624 Lifting limit switch...............................................................624 Lowering limit switch..............................................................625 11.3.6 Derricking gear.................................................................626 Switching on the derricking gear...................................................626 Raising and lowering...............................................................627 Re-enable raising function.........................................................628 Switching off the derricking gear..................................................628 Lowering the main boom to ahorizontal position....................................629 11.3.7 Telescoping mechanism...........................................................630 Overview...........................................................................631 Telescoping process................................................................631 Assignment for display.............................................................633 Fixed length, intermediate length, telescoping length..............................635 Telescoping........................................................................636 Telescoping sequence...............................................................636 Inspections prior to starting operations...........................................637 Switching on the telescoping mechanism.............................................638 Function of the control lever......................................................638 Telescoping with lattice extension folded at the side..............................640 Switching off the telescoping mechanism............................................640 Manual telescoping.................................................................641 Checking the initial position......................................................641 Unlock the telescoping cylinder....................................................643 Extending/ retracting the telescoping cylinder.....................................646 Lock telescoping cylinder..........................................................647 Unlocking the telescopic section...................................................648 Telescoping the telescopic section.................................................650 Locking the telescopic section.....................................................651 Locking the telescopic section for on-road driving.................................652 Telescoping with teleautomation....................................................653 Telescoping the main boom in horizontal position...................................657 11.3.8 High-speed mode.................................................................658 Switch on function................................................................658 Derricking gear/ Telescoping mechanism.............................................658 Hoists.............................................................................659 11.3.9 Slewing gear....................................................................660 Switching on the slewing gear......................................................660 Slewing gear brake.................................................................660 Releasing the slewing gear brake...................................................661 Engaging the slewing gear brake....................................................662 Slewing............................................................................662 Braking the slewing movement.......................................................664 Slewing gear freewheel.............................................................664 Switch off the slewing gear........................................................665 11.3.10 Possible movement combinations.................................................665 11.3.11 Hydraulic oil cooling..........................................................666 11.4 Settings and displays for crane operation.............................................667 11.4.1 Inclining the crane cab.........................................................667 11.4.2 Setting the idling speed........................................................667 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.....................668 11.4.4 Limiting the power unit speeds..................................................668 11.4.5 Setting the characteristic curves for the control levers........................670 11.4.6 Critical load control...........................................................671 Function...........................................................................671 Switching on andoff...............................................................671 11.4.7 Operation of the directional spotlights.........................................672 11.4.8 Displaying the operating hours..................................................673 11.4.9 Warning submenu.................................................................674 Meaning of the symbols.............................................................674 Exiting the submenu................................................................677 11.4.10 Error submenu..................................................................677 11.5 Working range limiter.................................................................678 11.5.1 Opening the Working range limiter submenu.......................................679 11.5.2 Viewing current settings........................................................679 11.5.3 Entering limit values...........................................................681 Overall height/ working radius.....................................................681 Slewing angle......................................................................682 Entering objects...................................................................684 11.5.4 Entering limit values/objects manually..........................................687 Limit values.......................................................................687 Objects............................................................................688 11.5.5 Switching monitoring functions on/off...........................................689 11.5.6 Shutdown by working range limiter...............................................690 11.6 Work break............................................................................691 11.6.1 In case of short work breaks....................................................691 11.6.2 In case of work breaks of more than 8 hours.....................................692 To secure the truck crane..........................................................692 11.7 Heating and air-conditioning system...................................................693 11.7.1 Standard heating system.........................................................693 Switching on.......................................................................693 Heating............................................................................693 Air distribution...................................................................694 Switching off......................................................................694 11.7.2 Air-conditioning system.........................................................695 Warnings...........................................................................695 Switching on/off...................................................................695 Cooling............................................................................696 Drying the air.....................................................................696 11.7.3 Auxiliary water heating system..................................................697 Preheating the engine..............................................................697 Preheating the crane cab...........................................................698 Switching on.......................................................................699 Setting the day and time...........................................................700 Storing the heating start..........................................................701 Setting the heating period.........................................................702 Switching heating start on/off.....................................................702 Switching off......................................................................703 Setting the remaining time.........................................................703 11.7.4 Auxiliary air heater............................................................704 Switching on.......................................................................704 Temperature........................................................................705 Switching off......................................................................705 Other functions....................................................................705 11.8 CraneSTAR system......................................................................707 11.8.1 Overview........................................................................707 11.8.2 Position of the components......................................................707 12 Rigging work................................................................................711 12.1 Rigging work checklists for crane operation with the main boom........................711 12.1.1 CHECKLIST: Rigging..............................................................711 12.1.2 CHECKLIST: Unrigging............................................................715 12.2 Choosing a suitable site..............................................................719 12.2.1 Determining the required ground bearing area....................................719 12.2.2 Safe distance from slopes and pits..............................................722 12.2.3 Earthing the truck crane........................................................723 12.2.4 Safe distance from electrical cables............................................724 12.3 Rigging work after driving with a trailer.............................................727 12.3.1 Switching off the boom floating position........................................727 12.3.2 Switching off the slewing gear freewheel........................................728 Before slewing.....................................................................728 12.3.3 Switching off boom pre-tensioning...............................................729 12.4 Connecting/disconnecting the hand-held control........................................731 12.5 Starting the engine for driving for rigging work......................................733 12.5.1 Starting/turning off the engine with the hand-held control......................733 Prerequisites......................................................................733 Start the engine...................................................................734 Turning off the engine.............................................................734 12.5.2 Starting/turning off the engine from the crane cab..............................735 Prerequisites......................................................................735 Start the engine...................................................................735 After starting the engine..........................................................736 Turning off the engine.............................................................736 12.5.3 Starting/turning off the engine from the outrigger control units................737 Prerequisites......................................................................737 Start the engine...................................................................737 Turning off the engine.............................................................737 12.6 Outrigger.............................................................................739 12.6.1 CHECKLIST: Extending the outriggers.............................................739 12.6.2 CHECKLIST: Retracting the outriggers............................................741 12.6.3 Permissible outrigger spans.....................................................742 12.6.4 Preparing the truck crane.......................................................743 In the driver's cab................................................................743 Outrigger control units............................................................743 12.6.5 Setting the spans...............................................................744 For on-road driving................................................................746 12.6.6 Extending/retracting outriggers.................................................747 From the control units.............................................................748 With the hand- held control........................................................749 From the crane cab.................................................................751 12.6.7 Moving the outrigger pads into working/driving position.........................753 12.6.8 Enlarging the ground bearing area...............................................754 12.6.9 Extending/retracting supporting cylinders.......................................755 From the control units.............................................................756 With the hand- held control........................................................757 From the crane cab.................................................................758 12.6.10 Levelling the truck crane on outriggers horizontally...........................760 Inclination indicators.............................................................760 Prerequisites......................................................................761 Manual alignment...................................................................762 Automatic alignment................................................................763 12.6.11 Levelling the free-standing truck crane........................................765 12.6.12 Outrigger pressure display.....................................................767 12.7 Rigging/unrigging the counterweight...................................................768 12.7.1 Counterweight sections..........................................................768 Version A..........................................................................768 Version B..........................................................................769 12.7.2 Identification..................................................................770 12.7.3 Slinging points on the counterweight sections...................................771 12.7.4 CHECKLIST: Rigging the counterweight............................................773 12.7.5 CHECKLIST: Unrigging the counterweight..........................................775 12.7.6 Assembling counterweight combination............................................777 Combinations forthe basic equipment in version A..................................778 Combinations forthe additional equipment in version A.............................781 Combinations forthe basic equipment in version B..................................783 Combinations forthe additional equipment in version B.............................786 12.7.7 Counterweight hoist unit........................................................791 Counterweight submenu..............................................................791 Extending/ retracting the lifting cylinders........................................792 automatic mode, rigging............................................................793 automatic mode, unrigging..........................................................794 Cancel automatic mode..............................................................796 12.7.8 Setting down counterweight for driving the truck crane..........................797 Version A..........................................................................797 Version B..........................................................................797 12.7.9 Slewing with rigged counterweight...............................................799 12.8 Rigging work on the main boom.........................................................801 12.8.1 Hook block on the bumper........................................................801 Picking up the hook block..........................................................801 Attaching the hook block...........................................................802 12.8.2 Hook block on a separate vehicle................................................803 Picking up the hook block..........................................................804 Setting down the hook block........................................................804 12.8.3 Reeving and unreeving the hoist rope............................................806 Rope end fitting...................................................................806 Reeving the hoist rope.............................................................807 Unreeving the hoist rope...........................................................810 12.8.4 Possible reeving methods on the main boom.......................................811 With 9 head sheaves................................................................811 With 10 head sheaves...............................................................815 12.8.5 Installing/removing the lifting limit switch....................................818 Installing the lifting limit switch................................................818 Removing the lifting limit switch..................................................821 12.8.6 Locking/Unlocking the lifting limit switch......................................822 Locking............................................................................822 Removing the lock..................................................................823 12.8.7 Anemometer and air traffic control light........................................824 Installing.........................................................................824 Removing...........................................................................825 12.9 Other rigging work....................................................................827 12.9.1 Railings on the turntable.......................................................827 12.9.2 Mirror for crane operation......................................................828 12.9.3 Access ladder on the counterweight..............................................829 13 Driving with rigged truck crane.............................................................833 13.1 Driving distance......................................................................833 13.2 Permissible rigging modes and axle loads..............................................835 Axle load table........................................................................835 13.3 Before driving........................................................................837 13.3.1 Securing the superstructure against slewing.....................................837 13.3.2 Checking the tyre pressure and the wind speed...................................837 13.3.3 Putting the truck crane on the wheels...........................................838 13.3.4 Transmission/Connections........................................................840 Transmission.......................................................................840 Connections........................................................................840 13.4 While driving.........................................................................841 13.5 After driving.........................................................................843 13.6 Driving in combined operation.........................................................845 13.6.1 Switching combined operation on/off.............................................845 Prerequisites......................................................................845 Switching on.......................................................................846 Switching off......................................................................846 13.6.2 Starting/turning off the engine.................................................847 13.6.3 Preparing to drive..............................................................848 Transmission.......................................................................848 Switching on separate steering.....................................................848 Connections........................................................................848 13.6.4 While driving...................................................................849 14 Malfunctions during crane operation.........................................................853 14.1 Emergency stop switch.................................................................853 14.2 What to do when malfunctions occur during crane operation.............................855 Load can be lowered....................................................................855 Load cannot be lowered.................................................................855 14.3 Fuses.................................................................................857 Notes on changing fuses................................................................857 14.3.1 Fuses on the turntable..........................................................858 Fuse groups F1/F2/F3...............................................................858 Fuses on the circuit board.........................................................859 14.3.2 Fuses in the crane cab..........................................................861 14.3.3 Fuses in the battery box........................................................863 14.3.4 RCL fuses.......................................................................864 14.4 Finding and eliminating malfunctions..................................................865 14.4.1 Malfunctions on the engine......................................................865 14.4.2 Exhaust system malfunctions.....................................................866 14.4.3 Malfunctions on the main hoist/auxiliary hoist..................................867 14.4.4 Malfunctions on the derricking gear.............................................868 14.4.5 Malfunctions in the telescoping mechanism.......................................869 Telescoping mechanism error messages...............................................870 14.4.6 Malfunctions on the slewing gear................................................872 14.4.7 Malfunctions on the counterweight hoist unit....................................873 14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.......................874 14.4.9 Malfunctions when inclining the crane cab.......................................874 14.4.10 Malfunctions when operating with the hand-held control.........................874 14.4.11 Malfunctions of the outriggers.................................................875 14.4.12 Troubleshooting the RCL........................................................876 General malfunctions...............................................................876 Error messages in the monitoring submenu...........................................877 Displays in the Error submenu......................................................879 Table – Error codes................................................................881 Switching off the sensor/ tachogenerator..........................................884 14.4.13 Malfunctions ECOS – superstructure.............................................885 ECOS program version...............................................................885 General malfunctions...............................................................885 Error messages.....................................................................886 Exiting the submenu................................................................887 14.4.14 Malfunctions on the CraneSTAR system...........................................888 14.5 Emergency operations and programs.....................................................893 14.5.1 Mechanical emergency activation for retracting..................................894 Prior to the emergency operation, check............................................894 Procedure..........................................................................894 Mechanical emergency activation....................................................895 14.5.2 Telescoping emergency program...................................................897 Start the emergency program........................................................897 Determining the error type.........................................................898 If there is an error on the length indicator.......................................899 If there is an error at a proximity switch.........................................903 Terminating the emergency program..................................................904 Tables for approaching the locking points..........................................905 14.5.3 Entering the current telescoping................................................907 14.5.4 Emergency operation with the hand-held control..................................909 Preparations.......................................................................909 Operating a power unit.............................................................910 Stopping movements.................................................................912 Stopping movements in emergencies..................................................912 Turning off the engine.............................................................912 14.5.5 Switching on emergency operation in coolant circuit.............................913 14.6 Hydraulic emergency operation.........................................................915 14.6.1 Operating principle.............................................................915 14.6.2 Connecting/disconnecting hoses..................................................916 Establishing connections...........................................................916 Disconnecting......................................................................917 14.6.3 Switching emergency operation on/off............................................918 14.6.4 Establishing the hydraulic circuits required....................................919 Switching over valves..............................................................919 For lifting/ lowering..............................................................921 For slewing........................................................................922 14.6.5 Carrying out emergency operation................................................923 Slewing............................................................................923 Derricking.........................................................................924 Lifting/lowering...................................................................924 14.6.6 After emergency operation.......................................................925 Switch off emergency operation.....................................................925 Switch over to crane operation.....................................................925 Disconnect the hoses...............................................................925 14.6.7 Emergency supply of another crane...............................................926 For emergency supply...............................................................926 After emergency supply.............................................................926 15 Index.......................................................................................929 A..........................................................................................931 B..........................................................................................931 C..........................................................................................932 D..........................................................................................933 E..........................................................................................935 F..........................................................................................937 H..........................................................................................937 I..........................................................................................938 K..........................................................................................938 L..........................................................................................939 M..........................................................................................939 O..........................................................................................940 P..........................................................................................941 R..........................................................................................941 S..........................................................................................943 T..........................................................................................945 V..........................................................................................947 W..........................................................................................947
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