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Grove Crane GMK 6300L Driving Operating Manual 3302596 – PDF DOWNLOAD
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Description
Grove Crane GMK 6300L Driving Operating Manual 3302596 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L Driving Operating Manual 3302596 – PDF DOWNLOAD
Language : English
Pages : 976
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L Driving Operating Manual 3302596 – PDF DOWNLOAD
Intended use:
- The GMK6300L 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 GMK6300L 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 GMK6300L truck crane may only be operated without the correspond- ing special equipment within
the permitted temperature range;
à Technical data, p. 1 – 7. - The GMK6300L truck crane is designed solely for lifting loads that are within the permitted
GMK6300L 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 manual(s), 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 GMK6300L 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 GMK6300L.
The manufacturer is not liable for any damage caused by improper or unau- thorized use of the
GMK6300L truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 6300L Driving Operating Manual 3302596 – PDF DOWNLOAD
1 Overview................................................................................... 7 1.1 Accidents............................................................................ 7 1.2 Branch offices....................................................................... 9 1.2.1 Manitowoc Crane Care........................................................... 9 1.2.2 Dealer list.................................................................... 9 1.3 Warranty specifications.............................................................. 9 1.4 Terms used........................................................................... 10 1.5 Technical data....................................................................... 13 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 13 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 14 Dimensions....................................................................... 15 Weight and axleloads............................................................ 15 1.5.3 Dimensions and weights of removable parts...................................... 16 Spare wheel...................................................................... 16 Outriggers....................................................................... 16 Driver's safety guard............................................................ 17 Hose drum........................................................................ 17 Hook blocks and hook tackle...................................................... 17 Auxiliary hoist.................................................................. 18 Main boom........................................................................ 18 Counterweight parts............................................................. 18 1.5.4 Carrier........................................................................ 19 Engine........................................................................... 19 Transmission..................................................................... 19 Transfer case.................................................................... 19 Axle lines....................................................................... 19 Steering......................................................................... 20 Tyres............................................................................ 20 Outriggers....................................................................... 20 Auxiliary supports............................................................... 21 Electrical system................................................................ 21 Tool............................................................................. 21 Towing coupling................................................................. 21 Driving speeds................................................................... 21 Climbing ability................................................................. 21 Turning radii.................................................................... 22 1.5.5 Superstructure................................................................. 23 Engine........................................................................... 23 Main hoist....................................................................... 23 Auxiliary hoist.................................................................. 23 Slewing gears.................................................................... 24 Derricking gear.................................................................. 24 Main boom........................................................................ 24 Lattice extension................................................................ 24 Operating speeds................................................................. 25 1.6 Documentation supplied............................................................... 27 1.6.1 Questions on documentation..................................................... 28 1.7 Notes on the operating manual........................................................ 29 1.7.1 What do the symbols used mean?................................................. 29 1.7.2 How is the operating manual structured?........................................ 31 Division......................................................................... 31 Structure of thechapters........................................................ 31 Structure of thepages........................................................... 32 1.7.3 How do I find the information I need?.......................................... 33 Cross-references example......................................................... 34 1.7.4 What information is available for operations planning?......................... 36 1.8 Conversion table for US measuring units.............................................. 37 1.9 Training – Information............................................................... 39 1.10 Identification...................................................................... 40 1.11 EC Declaration of Conformity........................................................ 42 2 Basic safety instructions.................................................................. 45 2.1 Intended use......................................................................... 45 2.1.1 Improper use................................................................... 46 2.2 Organisational measures.............................................................. 47 2.3 Personnel qualifications............................................................. 49 2.4 Safety instructions for driving the truck crane...................................... 51 2.5 Safety instructions for crane operation.............................................. 53 2.6 Instructions on transporting persons................................................. 57 Equipment for lifting persons........................................................ 57 Personnel............................................................................ 58 Operation............................................................................ 58 Truck crane.......................................................................... 59 3 Operating elements for driving............................................................. 63 3.1 Overview of the operating elements................................................... 63 3.1.1 On the outside of the truck crane.............................................. 64 3.1.2 Driver's cab................................................................... 68 Front overview................................................................... 68 Behind the cover................................................................ 72 Rear overview.................................................................... 73 3.1.3 Instrument panel............................................................... 74 Left/right....................................................................... 74 Middle........................................................................... 75 3.1.4 Display, driving mode.......................................................... 78 3.1.5 Steering column/steering wheel................................................. 79 3.1.6 Transmission operating elements................................................ 80 3.1.7 Tachograph, time correction.................................................... 81 3.1.8 ECOS control unit.............................................................. 82 3.1.9 ECOS display – main menu....................................................... 84 3.1.10 ECOS display – submenus....................................................... 86 Level adjustment system submenu................................................. 86 Settings submenu................................................................. 88 Monitoring submenu............................................................... 89 Operating hours submenu......................................................... 90 Warning submenu.................................................................. 90 Error submenu.................................................................... 91 3.1.11 Heating/Air-conditioning system............................................... 92 Standard heating system.......................................................... 92 Auxiliary water heating system.................................................. 93 3.1.12 Outrigger control units....................................................... 94 3.1.13 Rear supporting box control unit.............................................. 95 3.2 Short description of the operating elements.......................................... 97 3.2.1 Definition of direction information............................................ 97 Basic rule....................................................................... 97 Switches and buttons............................................................ 98 3.2.2 General notes on the operating elements........................................ 98 3.2.3 General rules for buttons and symbols on the display........................... 99 3.2.4 Engine.........................................................................100 Steering column..................................................................100 Multipurpose switch..............................................................100 Instrument panel.................................................................101 Main menu........................................................................102 3.2.5 Carbamide system...............................................................103 Instrument panel.................................................................103 Display, driving mode............................................................104 ECOS display.....................................................................104 3.2.6 Electrical system..............................................................105 3.2.7 ECOS crane control.............................................................106 Control unit.....................................................................106 3.2.8 Transmission...................................................................109 Instrument panel, middle.........................................................109 Display, driving mode............................................................109 Transmission control unit........................................................109 3.2.9 Reverse camera.................................................................113 Reverse camera on/off............................................................113 3.2.10 Transfer case.................................................................114 3.2.11 Final drive...................................................................115 3.2.12 Brakes........................................................................116 Service brake....................................................................116 Additional brakes................................................................116 Parking brake....................................................................117 3.2.13 Steering/separate steering....................................................118 Instrument panel.................................................................118 ECOS display.....................................................................119 Driver's door....................................................................120 3.2.14 Suspension....................................................................121 3.2.15 Lighting/windscreen wipers/horn...............................................122 Steering column..................................................................122 Instrument panel.................................................................122 Roof.............................................................................125 3.2.16 Level adjustment system.......................................................126 3.2.17 Tachograph/speedometer........................................................129 Tachograph.......................................................................129 Speedometer......................................................................129 3.2.18 Rear supporting box control unit..............................................130 3.2.19 Diagnostics...................................................................131 Displays/ submenu................................................................131 3.2.20 Windows, doors, keys..........................................................132 Window winder....................................................................132 Doors............................................................................133 Keys.............................................................................133 3.2.21 Front flap....................................................................134 4 Starting the engine for driving / switching it off.........................................137 4.1 Starting the engine from the driver's cab............................................137 4.1.1 CHECKLIST: Starting the engine.................................................137 4.1.2 CHECKLIST: At low temperatures.................................................140 4.1.3 Ladders and access ladders.....................................................140 Fixed ladders....................................................................140 Ladders..........................................................................141 4.1.4 Refuel.........................................................................143 Fuel.............................................................................143 Carbamide........................................................................144 4.1.5 Checks before starting the engine..............................................146 At the hydraulic tank............................................................146 Battery master switch............................................................146 Checking the hand-held control...................................................147 4.1.6 Switch on the ignition.........................................................147 4.1.7 Lamp test/equalisation of the switching states.................................148 Lamp test........................................................................148 Switching state alignment........................................................149 4.1.8 Display – setting the brightness...............................................150 4.1.9 Starting the engine............................................................151 Without flame start system.......................................................152 With flame start system.........................................................152 4.1.10 Checks after starting the engine..............................................154 Checking in the main menu........................................................154 Indicator lamps on the instrument panel..........................................154 4.1.11 Monitoring elements...........................................................156 Instrument panel.................................................................156 4.1.12 Monitoring submenu............................................................157 4.1.13 Setting idling speed..........................................................158 4.2 Switch the engine off................................................................159 4.2.1 At the ignition lock and with the outrigger control units......................159 After switching off.............................................................159 4.2.2 Using the emergency stop switches..............................................160 Resetting the emergency stop switch..............................................160 4.3 Air intake inhibitor.................................................................161 Releasing the air intake inhibitor...................................................161 5 Driving....................................................................................165 5.1 Before driving.......................................................................165 5.1.1 CHECKLIST: Checks before on-road driving.......................................165 5.1.2 Checking the condition of the truck crane......................................171 Windscreen washing system........................................................171 Electrical system................................................................171 Adjusting themirrors............................................................172 Warning plates for vehicle width.................................................173 Displaying vehicle height........................................................173 Supply pressure..................................................................174 Parking brake....................................................................175 5.1.3 Adjusting the seats and steering column........................................177 Driver's seat....................................................................177 Passenger's seat.................................................................179 Adjusting the steering column...................................................180 5.1.4 Switching the suspension on/off................................................181 Opening the submenu..............................................................181 Switching the suspension on.....................................................182 Switching the suspension off....................................................182 5.1.5 Setting the tachograph.........................................................183 Prerequisites....................................................................183 In the event of malfunctions.....................................................183 Setting the tachograph..........................................................184 5.1.6 Displaying the operating hours.................................................189 5.1.7 Settings/indications on the driving display....................................190 5.2 Operating the transmission...........................................................191 5.2.1 Switching on...................................................................191 5.2.2 Switching the transmission to the neutral position.............................192 While driving....................................................................192 5.2.3 Changing the driving mode......................................................193 5.2.4 Selecting the driving direction................................................194 5.2.5 Changing highest gear/starting gear............................................196 5.2.6 Starting.......................................................................196 5.2.7 Driving and changing gears.....................................................197 5.2.8 Changing the driving direction.................................................198 5.2.9 Stopping.......................................................................199 Stopping for longer periods.....................................................199 5.2.10 On the roller type dynamometer................................................199 5.2.11 Oil level gauge...............................................................200 5.3 Driving the truck crane and switching it off.........................................203 5.3.1 Checks whilst driving..........................................................203 Immediately after you start to move..............................................203 While driving....................................................................205 5.3.2 Cruise control.................................................................206 Switching on.....................................................................206 Switching off....................................................................207 5.3.3 Temposet.......................................................................207 Switching on.....................................................................207 Switching off....................................................................207 5.3.4 Driving downhill...............................................................208 Starting.........................................................................208 Checks when driving downhill....................................................208 Shifting down from the highest gear..............................................209 Additional brakes................................................................210 5.3.5 Driving uphill.................................................................211 Starting.........................................................................211 Driving..........................................................................211 5.3.6 Warning submenu................................................................212 Meaning of thesymbols...........................................................212 Exiting the submenu.............................................................214 5.3.7 Warning or malfunction messages on the instrument panel........................215 Meaning of the lamps.............................................................215 5.3.8 Override torque reduction......................................................217 5.3.9 Error submenu..................................................................218 5.3.10 Switching the truck crane off.................................................218 Secure it against rolling away...................................................218 When stationary for more than 8hours............................................219 5.3.11 Folding berth.................................................................221 5.4 Off-road driving.....................................................................223 Adjustments to the transmission......................................................223 Connections..........................................................................223 Changing the vehicle level...........................................................223 Rocking the vehicle free andtowing..................................................223 5.4.1 Transfer case – switching the off-road gear on/off.............................224 Prerequisites....................................................................224 Switching on.....................................................................225 Switching off....................................................................225 Neutral position.................................................................225 5.4.2 Longitudinal and transverse differential locks.................................226 5.4.3 Operating the level adjustment system..........................................228 Opening the submenu..............................................................228 Setting the on-road level.......................................................229 Pre-selecting suspension struts.................................................229 Changing the vehicle level.......................................................230 Viewing the current inclination..................................................230 Exiting the submenu.............................................................231 5.4.4 Freeing truck crane stuck in terrain...........................................232 Rocking the truck crane free....................................................232 Towing free to thefront........................................................233 Towing free to therear.........................................................233 5.5 Separate steering....................................................................235 5.5.1 Switching to separate steering.................................................235 Manual...........................................................................236 Automatic........................................................................237 switching to normal steering mode................................................238 5.6 Heating and air-conditioning system..................................................239 5.6.1 Standard heating system........................................................239 Switching on.....................................................................239 Heating..........................................................................239 Air distribution.................................................................240 Examples.........................................................................241 Switching off....................................................................241 5.6.2 Air-conditioning system........................................................242 Information......................................................................242 Switching on/off.................................................................242 Cooling..........................................................................243 Drying...........................................................................243 5.6.3 Auxiliary water heater.........................................................244 Preheating theengine............................................................244 Preheating the driver's cab.....................................................245 Switching on the auxiliary heater................................................245 Switching off the auxiliary heater...............................................246 Setting time andweekday.........................................................246 Saving automatic heating start..................................................247 Setting the heating period......................................................248 Switching the automatic heating start on and off.................................249 Setting the remaining run time..................................................249 5.7 Towing a trailer.....................................................................251 Effects on the axleloads............................................................251 Coupling the trailer................................................................252 Connecting the supply lines.........................................................253 Removing supply lines..............................................................254 Uncoupling thetrailer..............................................................254 Checking the braking force...........................................................256 6 Driving modes..............................................................................259 6.1 Driving modes........................................................................259 Information about the axle loads.....................................................259 6.1.1 Information on how to use the tables...........................................260 6.1.2 Tables for a maximum axle load of 12 t.........................................261 For tyres 385/95 R25.............................................................261 For tyres 445/95 R25.............................................................262 For tyres 525/80 R25.............................................................263 6.1.3 Maximum permitted speeds with an axle load of over 12 t........................264 6.2 Weighing the truck crane.............................................................265 Determining..........................................................................265 Axle groups..........................................................................266 Weighing procedure...................................................................267 Evaluation...........................................................................268 6.3 Rigging work for driving with a trailer..............................................269 6.3.1 Switching on the slewing gear freewheel........................................270 6.3.2 Switching on the boom floating position........................................271 6.3.3 Switching on boom pre-tensioning...............................................272 6.3.4 Adjusting axle pressure........................................................273 Preselecting the axle pair.......................................................273 Adjusting axle pressure..........................................................274 Driving with changed axle pressures..............................................274 Adjusting axle pressure for on-road driving......................................274 6.3.5 Switching the superstructure driving lights on/off.............................275 Switching off....................................................................275 Switching on.....................................................................275 6.4 Main boom, removing/installing.......................................................277 Additional equipment required........................................................277 6.4.1 CHECKLIST: Removing the main boom..............................................278 Prerequisites....................................................................278 Checklist........................................................................278 6.4.2 CHECKLIST: Mounting the main boom..............................................281 Prerequisites....................................................................281 Checklist........................................................................281 6.4.3 Slinging the main boom.........................................................284 Marking..........................................................................284 Installing the lifting gear......................................................284 Removing the lifting gear........................................................285 6.4.4 Removing/attaching the clamps..................................................286 6.4.5 Switching the pressure relief on/off...........................................287 6.4.6 Connecting/disconnecting the derricking cylinder from the boom.................288 Retracting the derricking cylinder head axle.....................................289 Fitting the derricking cylinder head axle........................................290 6.4.7 Extending/retracting the boom pivot pin........................................291 Before pulling itout............................................................291 After pushing it in..............................................................291 Pulling out the pivot pin........................................................292 Pushing the pivot pin in.........................................................293 6.4.8 Disconnecting/connecting hydraulics/electrical.................................294 Disconnecting....................................................................294 Connecting.......................................................................295 6.4.9 Lifting the main boom off/on the turntable.....................................296 Lifting from the turntable.......................................................296 Lifting on to the turntable......................................................297 6.4.10 Aligning the connecting points................................................298 6.4.11 Securing/releasing the derricking cylinder....................................298 6.4.12 Transporting the main boom....................................................299 6.4.13 Inspections after main boom mounting..........................................300 6.4.14 Installing/removing the hose drum.............................................301 Installing.......................................................................301 Removing.........................................................................302 6.5 Installing/removing outrigger beams..................................................305 6.5.1 CHECKLIST: Removing the outrigger beams........................................306 6.5.2 CHECKLIST: Installing the outrigger beams......................................308 6.5.3 Preparing the truck crane......................................................310 Prerequisites....................................................................310 For removal......................................................................310 6.5.4 Removing/attaching outrigger pads..............................................311 Removing outrigger pads.........................................................311 Attaching outrigger pads........................................................312 6.5.5 Disconnecting/establishing the hydraulic connection............................313 6.5.6 Disconnecting/establishing the electrical connection...........................314 6.5.7 Unscrewing/screwing in the spacers.............................................315 Unscrewing.......................................................................315 Screwing in......................................................................316 6.5.8 Disconnecting/establishing the connections to the supporting box...............317 6.5.9 Extending/retracting the outrigger beam........................................317 Extending the outrigger beam....................................................317 Inserting the outrigger beam.....................................................319 6.5.10 Transporting the outrigger beams..............................................321 6.6 Installing/removing the supporting box...............................................323 6.6.1 CHECKLIST: Removing the supporting box.........................................324 6.6.2 CHECKLIST: Installing the supporting box.......................................327 6.6.3 Rig the outrigger span 7.98x8.50/1.00m......................................329 Front outrigger..................................................................330 Auxiliary supports...............................................................330 6.6.4 Establishing/disconnecting the pneumatic connection............................332 6.6.5 Disconnecting/establishing the electrical connection...........................333 6.6.6 Disconnecting/establishing the hydraulic connection............................334 6.6.7 Attaching/raising the supporting box with the truck crane......................335 Prerequisites:...................................................................335 Lifting..........................................................................336 Hanging..........................................................................337 6.6.8 Installing the reverse camera..................................................338 6.6.9 Crane movements during installation and removal................................339 Prerequisites....................................................................339 Before installation..............................................................339 After the removal...............................................................339 6.6.10 Slinging points on the supporting box.........................................340 6.6.11 Locking/unlocking the supporting box..........................................341 Locking..........................................................................341 Unlocking........................................................................342 6.6.12 Transporting the supporting box on the separate vehicle.......................343 Lashing eyelets..................................................................343 6.6.13 Installing / removing the rear bumper.........................................344 Prerequisites:...................................................................344 Installing.......................................................................345 Removing.........................................................................345 6.7 Rigging the auxiliary hoist..........................................................347 6.7.1 CHECKLIST: Auxiliary hoist, installing.........................................347 Prerequisites....................................................................347 6.7.2 CHECKLIST: Auxiliary hoist, removing...........................................349 Prerequisites....................................................................349 6.7.3 Slinging the auxiliary hoist...................................................351 6.7.4 Installing/removing the rigging frame..........................................352 Prerequisite.....................................................................352 6.7.5 Setting down the auxiliary hoist...............................................353 6.7.6 Making/breaking the hydraulic connection.......................................354 6.7.7 Establishing/disconnecting the electrical connection...........................355 6.7.8 Creating the connection to the turntable.......................................356 Establishing the connection......................................................356 Separating the connection........................................................358 6.7.9 Securing the hoist rope........................................................359 6.7.10 Transporting the auxiliary hoist..............................................360 6.7.11 Check that the auxiliary hoist is functioning properly........................361 Slewing direction................................................................361 Slewing indicator................................................................361 7 Malfunctions in driving mode...............................................................365 7.1 Emergency stop switch................................................................365 7.2 What to do when a malfunction occurs in road traffic.................................367 7.3 Towing the truck crane...............................................................369 7.3.1 Towing after engine/transmission damage........................................370 Compressed-air supply............................................................370 Electric power supply............................................................371 On the transmission..............................................................371 Axle drives......................................................................371 Transfer case....................................................................372 Parking brake....................................................................372 Towing the truck crane out of the danger area....................................373 7.3.2 Tow starting...................................................................373 7.3.3 External starting socket.......................................................374 Performing a jump start..........................................................374 7.3.4 Battery charger................................................................375 Prerequisites....................................................................375 7.4 Wheels and tyres.....................................................................377 7.4.1 Wheel change...................................................................377 Removing adamaged wheel.........................................................378 On the spare wheel holder........................................................378 Mounting a wheel.................................................................379 7.4.2 Inflating the tyres yourself...................................................381 Connecting the filling hose......................................................381 Inflating the tyres..............................................................382 Removing the filling hose........................................................382 7.5 Fuses................................................................................383 Information on replacing fuses.....................................................383 7.5.1 Fuses in the driver's cab......................................................384 Group F1.........................................................................384 Group F2.........................................................................385 Group F3.........................................................................385 Group F4.........................................................................386 Group F5.........................................................................386 Group F6.........................................................................387 Group F7.........................................................................387 Group F8.........................................................................387 Group F9.........................................................................388 Group F10........................................................................388 7.5.2 Fuses in the battery box.......................................................389 7.6 Troubleshooting......................................................................391 7.6.1 Malfunctions on the engine.....................................................391 7.6.2 Malfunctions in the exhaust system.............................................393 7.6.3 Malfunctions in the transmission...............................................394 7.6.4 Transfer case malfunctions.....................................................395 7.6.5 Malfunctions of the service brake..............................................395 7.6.6 Malfunctions of the steering...................................................396 7.6.7 Differential lock malfunctions.................................................397 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................397 7.6.9 Malfunctions on the suspension.................................................398 7.6.10 Malfunctions of the level adjustment system...................................398 7.6.11 Malfunctions on the ECOS carrier..............................................399 ECOS programme version...........................................................399 General malfunctions............................................................399 Error messages...................................................................400 Exiting the submenu.............................................................401 7.7 Procedure in the event of malfunctions...............................................402 7.7.1 Switching on emergency operation in coolant circuit............................402 7.7.2 Procedure during engine malfunctions...........................................403 7.7.3 Malfunctions in the transmission...............................................404 General malfunctions.............................................................404 Transmission malfunction.........................................................404 Reading out error codes.........................................................406 8 Index......................................................................................409 A........................................................................................411 B........................................................................................411 C........................................................................................412 D........................................................................................413 E........................................................................................415 F........................................................................................417 H........................................................................................417 I........................................................................................418 K........................................................................................418 L........................................................................................419 M........................................................................................419 O........................................................................................420 P........................................................................................422 R........................................................................................422 S........................................................................................423 T........................................................................................425 V........................................................................................427 W........................................................................................427 9 Operating elements for crane operation.....................................................437 9.1 Overview of the operating elements...................................................437 9.1.1 Exterior of the truck crane....................................................438 9.1.2 Crane cab......................................................................442 9.1.3 Front panel....................................................................444 9.1.4 Side panel.....................................................................445 Bottom...........................................................................445 Top..............................................................................446 Console, rear....................................................................448 Standard heating system..........................................................449 Auxiliary water heating system..................................................450 Auxiliary air heater............................................................451 9.1.5 Control panels.................................................................452 Left.............................................................................452 Right............................................................................453 9.1.6 Control lever configuration....................................................454 Version 1........................................................................454 Version 2........................................................................455 9.1.7 ECOS control unit..............................................................456 9.1.8 ECOS display – main menu.......................................................458 9.1.9 ECOS display – submenus........................................................460 Counterweight submenu...........................................................460 Slewing gear/ houselock submenu..................................................461 Outriggers submenu..............................................................462 Telescoping submenu.............................................................464 Power unit speeds submenu.....................................................466 Monitoring submenu..............................................................467 Settings submenu................................................................468 Operating hours submenu.........................................................469 Submenu Warning.................................................................470 Error submenu....................................................................473 Working range limiter submenu..................................................474 9.1.10 RCL control unit..............................................................476 9.1.11 RCL display – main menu.......................................................477 9.1.12 Display RCL – submenus........................................................479 Enter rigging mode submenu....................................................479 Monitoring submenu..............................................................480 Rigging mode monitoring submenu................................................482 Lifting capacity table submenu.................................................483 Working range submenu...........................................................484 Error submenu....................................................................485 Settings submenu.................................................................486 9.1.13 Hand-held control.............................................................487 9.1.14 Outrigger control units.......................................................488 Button...........................................................................488 Outrigger button.................................................................489 Inclination and outrigger pressure display.......................................490 Raise axle display...............................................................491 9.2 Short description of the operating elements..........................................493 9.2.1 Definition of direction information............................................493 Basic rule.......................................................................493 Switches.........................................................................494 9.2.2 General rules for buttons and symbols on the display...........................494 9.2.3 Engine for crane operation.....................................................495 Side panel......................................................................495 Console, rear....................................................................496 ECOS display.....................................................................496 9.2.4 Engine for driving.............................................................496 Side panel.......................................................................496 Main menu........................................................................496 Outriggers submenu..............................................................497 9.2.5 Seat contact switch and dead man's switch......................................498 9.2.6 ECOS crane control.............................................................499 Control unit.....................................................................499 9.2.7 Outriggers.....................................................................502 In the Outriggers submenu.......................................................502 In the Settings submenu..........................................................503 On the outrigger control units...................................................504 9.2.8 Inclination indicators.........................................................506 9.2.9 Raise axle.....................................................................507 Outrigger control units..........................................................507 9.2.10 Outrigger pressure displays...................................................509 Outriggers submenu..............................................................509 Outriggers controlunits........................................................509 9.2.11 Anemometer display............................................................509 9.2.12 Counterweight submenu.........................................................510 Counterweight submenu...........................................................510 9.2.13 Main hoist....................................................................514 9.2.14 Auxiliary hoist...............................................................516 9.2.15 Slewing gear..................................................................517 Submenu..........................................................................518 9.2.16 Derricking gear...............................................................520 9.2.17 Telescoping mechanism.........................................................522 Control panels...................................................................522 Submenu..........................................................................523 In the Settings submenu..........................................................528 9.2.18 Hydraulic system..............................................................529 9.2.19 House lock....................................................................530 9.2.20 Rated capacity limiter (RCL)..................................................531 Control unit.....................................................................531 Main menu........................................................................533 Submenu Rigging mode entry.......................................................534 Monitoring submenu...............................................................538 Submenu Lifting capacity table...................................................542 Working range submenu...........................................................543 RCL override.....................................................................544 External displays................................................................545 9.2.21 Electrical system.............................................................546 9.2.22 Lighting, windscreen wiper/washing system.....................................547 Lighting.........................................................................547 Windscreen wiper/washing system.................................................549 9.2.23 Hand-held control.............................................................550 Sockets for hand-held control....................................................550 Engine control panel.............................................................551 Horn.............................................................................551 9.2.24 Windows, doors, keys..........................................................554 Windscreen.......................................................................554 Rear window......................................................................554 Crane cab door...................................................................555 Keys.............................................................................556 9.2.25 Diagnostics...................................................................556 10 Starting/switching off the engine – for crane operation...................................559 10.1 Starting the engine – from the crane cab............................................559 10.1.1 CHECKLIST: Starting the engine................................................559 10.1.2 CHECKLIST: At low temperatures................................................562 10.1.3 Refuel........................................................................562 Fuel.............................................................................562 Carbamide........................................................................564 10.1.4 Checks before starting the engine.............................................565 At the hydraulic tank............................................................565 Battery master switch............................................................565 Checking the hand-held control...................................................566 10.1.5 Switch on the ignition........................................................566 10.1.6 Lamp test / switching state alignment.........................................567 Lamp test........................................................................567 10.1.7 Adjusting display brightness..................................................569 10.1.8 Starting the engine...........................................................570 Without flame start system.......................................................570 With flame start system..........................................................571 10.1.9 Checks after starting the engine..............................................572 10.1.10 Monitoring submenu...........................................................573 10.1.11 Setting idling speed.........................................................574 10.1.12 Override torque reduction....................................................575 10.2 Starting the engine – with the hand-held control....................................577 Prerequisites........................................................................577 Starting the engine..................................................................577 10.3 Switching off the engine............................................................579 10.3.1 During normal operation, with the ignition lock/with the hand-held control....579 After switching off.............................................................579 10.3.2 In emergencies, with the emergency stop switches..............................580 Resetting the emergency stop switch..............................................580 10.4 Air intake inhibitor................................................................581 Releasing the air intake inhibitor...................................................581 11 Crane operation...........................................................................585 11.1 Before operating the crane..........................................................585 11.1.1 CHECKLIST: Checks before operating the crane..................................585 11.1.2 Checking the condition of the truck crane.....................................589 Windscreen washing system – Tank.................................................589 Visual inspection................................................................589 Checking the position of the hoist ropes.........................................590 Checking the electrical system...................................................590 11.1.3 Adjusting the crane cab seat and front control panel..........................591 Crane cab seat...................................................................591 Front control panel..............................................................592 11.1.4 Checking the safety equipment.................................................593 Rated capacity limiter...........................................................593 Lifting limit switch............................................................593 Emergency stop switch............................................................594 Seat contact switch..............................................................595 11.1.5 Earthing the load.............................................................596 11.1.6 Preheating the hydraulic oil..................................................597 11.1.7 Locking/unlocking the turntable...............................................598 Locking points...................................................................598 11.1.8 Switching the houselock on/off................................................599 Switching on the houselock......................................................599 Switching off the houselock.....................................................601 11.2 Operation of the rated capacity limiter.............................................603 11.2.1 Switch on the RCL.............................................................604 Switching on.....................................................................604 Brightness of the displays.......................................................606 11.2.2 Enter rigging mode............................................................607 Entering individual components...................................................608 Entering the RCL code...........................................................612 Entering the reeving............................................................613 Accepting the rigging mode.......................................................613 11.2.3 Checks before operating the crane.............................................615 Opening the submenu..............................................................615 Checks...........................................................................616 11.2.4 Displays during crane operation...............................................618 11.2.5 RCL early warning.............................................................621 11.2.6 RCL shutdown..................................................................621 Shutdown due to overload.........................................................621 11.2.7 Display in the event of errors................................................623 11.2.8 RCL override..................................................................624 Table – error/ information codes.................................................630 11.2.9 Displaying the lifting capacity tables........................................631 11.2.10 Entering the time/date.......................................................633 11.3 Crane operation with main boom......................................................635 11.3.1 Checks during crane operation.................................................635 Horizontal alignment.............................................................635 Safe distances..................................................................635 Checking the windspeed..........................................................636 11.3.2 Permissible slewing ranges and working positions..............................637 360 slewing range...............................................................637 Working position 0 to the rear..................................................637 180 to the front rigging position...............................................637 11.3.3 Main hoist....................................................................638 Maximum permissible hoistrope speed.............................................638 Switching on the main hoist......................................................639 Lifting and lowering............................................................639 Switching off the main hoist....................................................640 11.3.4 Auxiliary hoist...............................................................641 Maximum permissible hoist rope speed.............................................641 Switching on the auxiliary hoist................................................642 Lifting and lowering............................................................643 Switching off the auxiliary hoist...............................................643 11.3.5 Lifting limit switch and lowering limit switch................................644 Lifting limit switch.............................................................644 Lowering limit switch............................................................645 11.3.6 Derricking gear...............................................................646 Switching on the derricking gear................................................646 Maximum permissible derricking speed.............................................646 raising and lowering.............................................................647 Re-enable raising function.......................................................648 Switching off the derricking gear................................................648 Lowering the main boom to ahorizontal position..................................649 11.3.7 Telescoping mechanism.........................................................650 Overview.........................................................................651 Telescoping process..............................................................651 Assignment for display...........................................................653 Fixed length, intermediate length, telescoping length...........................655 Telescoping......................................................................656 Telescoping sequence............................................................656 Checks before starting work.....................................................657 Switching on the telescoping mechanism...........................................658 Function of the control lever....................................................658 Telescoping with lattice extension folded at the side............................660 Switching off the telescoping mechanism..........................................660 Manual telescoping..............................................................661 Checking the initial position....................................................661 Unlocking the telescoping cylinder...............................................663 Extending/retracting the telescoping cylinder....................................666 Lock telescoping cylinder........................................................667 Unlocking the telescopic section................................................668 Telescoping the telescopic section..............................................670 Locking the telescopic section..................................................671 Locking the telescopic section for on-road driving..............................672 Telescoping with teleautomation..................................................673 Telescoping the main boom when horizontal........................................677 11.3.8 High-speed mode...............................................................678 Switch on function...............................................................678 Derricking gear/ telescoping mechanism...........................................678 Hoists...........................................................................679 11.3.9 Slewing gear..................................................................680 Maximum permissible slewing speed................................................680 Switching on the slewing gear...................................................680 Releasing the slewing gear brake.................................................681 Engaging the slewing gear brake..................................................681 Turning..........................................................................681 Braking the slewing movement.....................................................683 Slewing gear freewheel...........................................................684 Switching off the slewing gear..................................................684 11.3.10 Possible movement combinations...............................................685 11.3.11 Hydraulic oil cooling........................................................685 11.4 Settings and displays for crane operation...........................................687 11.4.1 Inclining the crane cab.......................................................687 11.4.2 Setting idling speed..........................................................687 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................688 11.4.4 Limiting the power unit speeds................................................689 11.4.5 Setting the characteristic curves for the control levers......................690 11.4.6 Critical load control.........................................................691 Function.........................................................................691 Switching on andoff............................................................691 11.4.7 Using the pivoting spotlights.................................................692 11.4.8 Displaying the operating hours................................................693 11.4.9 Warning submenu...............................................................694 Meaning of thesymbols...........................................................694 Exiting the submenu.............................................................698 11.4.10 Error submenu................................................................698 11.5 Working range limiter...............................................................699 11.5.1 Opening the working range limiter submenu.....................................700 11.5.2 Viewing current settings......................................................700 11.5.3 Entering limit values.........................................................702 Overall height/ working radius..................................................702 Slewing angle....................................................................703 Entering objects.................................................................705 11.5.4 Entering limit values/objects manually........................................708 Limit values.....................................................................708 Objects..........................................................................709 11.5.5 Switching monitoring functions on/off.........................................710 11.5.6 Shutdown by working range limiter.............................................711 11.6 Work break..........................................................................713 11.6.1 In case of short work breaks..................................................713 11.6.2 In case of work breaks of more than 8 hours...................................714 To secure the truck crane........................................................714 11.7 Heating and air-conditioning system.................................................715 11.7.1 Standard heating system.......................................................715 Switching on.....................................................................715 Heating..........................................................................715 Air distribution.................................................................716 Switching off....................................................................716 11.7.2 Air-conditioning system.......................................................717 Information......................................................................717 Switching on/off.................................................................717 Cooling..........................................................................718 Drying the air...................................................................718 11.7.3 Auxiliary water heater........................................................719 Preheating theengine...........................................................719 Preheating the crane cab........................................................720 Switching on.....................................................................721 Setting the day and time.........................................................722 Storing the heating start.......................................................722 Setting the heating period......................................................723 Switching heating start on/off...................................................724 Switching off....................................................................725 Setting the remaining run time..................................................725 11.7.4 Auxiliary air heater..........................................................726 Switching on.....................................................................726 Temperature......................................................................727 Switching off....................................................................727 Other functions..................................................................727 11.8 CraneSTAR system....................................................................728 11.8.1 Overview......................................................................728 11.8.2 Position of the components....................................................728 12 Rigging work..............................................................................731 12.1 Rigging work checklists for crane operation with the main boom......................731 12.1.1 CHECKLIST: Rigging............................................................731 12.1.2 CHECKLIST: Unrigging..........................................................736 12.2 Choice of a suitable positioning site...............................................739 12.2.1 Determining the required load-bearing area....................................739 12.2.2 Safe distance from slopes and pits............................................742 12.2.3 Earthing the truck crane......................................................743 12.2.4 Safe distance from overhead power lines.......................................744 12.3 Rigging work after driving with a trailer...........................................747 12.3.1 Switching off the boom floating position......................................747 12.3.2 Switching off the slewing gear freewheel......................................748 Before slewing...................................................................748 12.3.3 Switching off boom pre-tensioning.............................................749 12.4 Connecting/disconnecting the hand-held control......................................751 12.5 Starting the engine for driving for rigging work....................................753 12.5.1 Starting/turning off the engine from the crane cab............................753 Prerequisites....................................................................753 Starting the engine..............................................................753 After starting theengine........................................................754 Switching off theengine.........................................................754 12.5.2 Starting/switching off the engine from the outrigger control units............756 Prerequisites....................................................................756 Starting the engine..............................................................756 Switch the engine off............................................................756 12.6 Outriggers..........................................................................757 12.6.1 CHECKLIST: Extending the outriggers...........................................757 12.6.2 CHECKLIST: Retracting the outriggers..........................................759 12.6.3 Permissible outrigger spans...................................................760 12.6.4 Preparing the truck crane.....................................................761 In the driver's cab..............................................................761 Outriggers control units........................................................761 12.6.5 Setting the outrigger spans...................................................762 For on-road driving..............................................................764 12.6.6 Extending/retracting outrigger beams..........................................765 From the control units...........................................................766 From the cranecab...............................................................767 12.6.7 Moving the outrigger pads into working/driving position.......................769 12.6.8 Enlarging the load-bearing area...............................................770 12.6.9 Extending/retracting supporting cylinders.....................................771 From the control units...........................................................772 From the crane cab...............................................................773 12.6.10 Levelling the truck crane on outriggers......................................776 Inclination indicators...........................................................776 Prerequisites....................................................................777 Manual alignment................................................................778 Automatic alignment..............................................................779 12.6.11 Levelling the free-on-wheels truck crane.....................................780 12.6.12 Outrigger pressure display...................................................782 12.7 Rigging/unrigging the counterweight.................................................783 12.7.1 Counterweight sections........................................................783 Version A........................................................................783 Version B........................................................................784 12.7.2 Identification................................................................785 12.7.3 Slinging points on the counterweight sections.................................786 12.7.4 CHECKLIST: Rigging the counterweight..........................................788 12.7.5 CHECKLIST: Unrigging the counterweight........................................790 12.7.6 Assembling counterweight combination..........................................792 Combinations for the basic equipment in version A................................793 Combinations for the additional equipment in version A...........................796 Combinations for the basic equipment in version B................................798 Combinations for the additional equipment in version B...........................801 12.7.7 Counterweight hoist unit......................................................805 Counterweight submenu...........................................................805 Extending/retracting the lifting cylinders.......................................806 Automatic mode rigging..........................................................807 Automatic mode unrigging........................................................808 Cancel automatic mode...........................................................810 12.7.8 Setting down counterweight for driving the truck crane........................811 Version A........................................................................811 Version B........................................................................811 12.7.9 Slewing with rigged counterweight.............................................813 12.8 Rigging work on the main boom.......................................................815 12.8.1 Hook block on the bumper......................................................815 Picking up the hook block........................................................815 Attaching the hook block.........................................................816 12.8.2 Hook block on a separate vehicle..............................................817 Picking up the hook block.......................................................818 Setting down the hook block.....................................................818 12.8.3 Hook block, separable.........................................................820 Rigging for on-road driving......................................................820 Rigging for crane operation......................................................821 12.8.4 Reeving and unreeving the hoist rope..........................................822 Rope end fitting.................................................................822 Reeving the hoist rope...........................................................823 Unreeving hoist rope............................................................826 12.8.5 Possible reeving methods on the main boom.....................................827 With 9 head sheaves..............................................................828 With 10 head sheaves.............................................................831 12.8.6 Installing/removing the lifting limit switch..................................836 Installing the lifting limit switch..............................................836 Removing the lifting limit switch................................................839 12.8.7 Locking/unlocking the lifting limit switch....................................840 Locking..........................................................................840 Removing the lock...............................................................841 12.8.8 Anemometer and air traffic control light......................................842 Installing.......................................................................842 Removing.........................................................................843 12.9 Other rigging work..................................................................845 12.9.1 Railings on the turntable.....................................................845 12.9.2 Cameras for crane operation...................................................847 Cameras on the hoists............................................................847 Camera on main boom..............................................................847 Turning the monitor on/off and switching.........................................850 12.9.3 Ladder on the counterweight...................................................851 12.9.4 Extendable step...............................................................852 12.9.5 Folding the mirrors in and out, and adjusting them............................853 13 Driving with a rigged truck crane.........................................................857 13.1 Driving path........................................................................857 13.2 Permissible rigging modes and axle loads............................................858 Axle load table.....................................................................858 13.3 Before driving......................................................................860 13.3.1 Securing the superstructure against slewing...................................860 13.3.2 Check the tyre pressure and the wind speed....................................860 13.3.3 Putting the truck crane on the wheels.........................................861 13.3.4 Gears/connections.............................................................863 Transmission.....................................................................863 Connections......................................................................863 13.4 Whilst driving......................................................................863 13.5 After driving.......................................................................865 13.6 Driving in combined operation.......................................................866 13.6.1 Switching combined operation on/off...........................................866 Prerequisites....................................................................866 Switching on.....................................................................867 Switching off....................................................................867 13.6.2 Starting/turning off the engine...............................................868 13.6.3 Preparing to drive............................................................869 Transmission.....................................................................869 Switching on separate steering...................................................869 Connections......................................................................869 13.6.4 While driving.................................................................870 14 Malfunctions during crane operation.......................................................873 14.1 Emergency stop switch...............................................................873 14.2 What to do when malfunctions occur during crane operation...........................875 The load can be set down.............................................................875 Load cannot be setdown..............................................................875 14.3 Fuses...............................................................................877 Information on replacing fuses.....................................................877 14.3.1 Fuses on the turntable........................................................878 Fuse groups F1/F2/F3............................................................878 Fuses on the circuit board.......................................................879 14.3.2 Fuses in the crane cab........................................................881 14.3.3 Fuses in the battery box......................................................883 14.3.4 RCL fuses.....................................................................884 14.4 Finding and eliminating malfunctions................................................885 14.4.1 Malfunctions on the engine....................................................885 14.4.2 Malfunctions in the exhaust system............................................886 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................887 14.4.4 Malfunctions in the hoist cameras.............................................888 14.4.5 Malfunctions in the main boom camera..........................................888 14.4.6 Malfunctions on the derricking gear...........................................889 14.4.7 Malfunctions in the telescoping mechanism.....................................890 Telescoping mechanism error messages.............................................891 14.4.8 Malfunctions in the slewing gear..............................................893 14.4.9 Malfunctions in the counterweight hoist unit..................................895 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................896 14.4.11 Malfunctions when inclining the crane cab....................................896 14.4.12 Malfunctions when operating with the hand-held control.......................896 14.4.13 Malfunctions of the outriggers...............................................897 14.4.14 Troubleshooting the RCL......................................................898 General malfunctions............................................................898 Error messages in the Monitoring submenu.........................................899 Displays in the Error submenu....................................................901 Table of error codes.............................................................903 Switch off the sensor/ tachogenerator...........................................906 14.4.15 Malfunctions ECOS – superstructure...........................................907 ECOS programme version...........................................................907 General malfunctions............................................................907 Error messages...................................................................908 Exiting the submenu.............................................................909 14.4.16 Malfunctions on CraneSTAR system.............................................910 14.5 Emergency operations and programs...................................................913 14.5.1 Mechanical emergency activation for retracting................................914 Prior to the emergency activation, check.........................................914 Procedure........................................................................914 Mechanical emergency activation.................................................915 14.5.2 Telescoping emergency program.................................................917 Swinging the swing-away lattice..................................................918 Checks...........................................................................919 Starting the emergency program..................................................919 Determining the type of error...................................................920 Error at the length indicator....................................................921 If there is an error at a proximity switch.......................................925 Terminating emergency programme.................................................926 Tables for approaching the locking points........................................927 14.5.3 Entering the current telescoping..............................................929 14.5.4 Emergency operation with the hand-held control................................931 Preparations.....................................................................931 Operating a power unit...........................................................932 Stopping movements..............................................................934 Stopping movements in emergencies................................................934 Switch the engineoff............................................................934 14.5.5 Switching on emergency operation in coolant circuit...........................935 14.6 Hydraulic emergency operation.......................................................937 14.6.1 Operating principle...........................................................937 14.6.2 Connecting/disconnecting hoses................................................938 Establishing connections.........................................................938 Disconnecting connections.......................................................939 14.6.3 Switching emergency operation on/off..........................................940 14.6.4 Establishing the hydraulic circuits required..................................941 Switching over valves............................................................941 For lifting/ lowering............................................................943 For slewing......................................................................944 14.6.5 Performing emergency operation................................................945 Turning..........................................................................945 Derricking.......................................................................946 Lifting/lowering.................................................................946 14.6.6 After emergency operation.....................................................947 Switching off emergency operation................................................947 Switching over to crane operation................................................947 Disconnecting thehoses..........................................................947 14.6.7 Emergency supply of another crane.............................................948 For emergency supply.............................................................948 After emergency supply...........................................................948 14.7 Other emergency operations..........................................................949 14.7.1 External starting socket......................................................949 Performing a jump start..........................................................950 14.7.2 Battery charger...............................................................951 Prerequisites....................................................................951 15 Index.....................................................................................955 A........................................................................................957 B........................................................................................957 C........................................................................................958 D........................................................................................959 E........................................................................................961 F........................................................................................963 H........................................................................................963 I........................................................................................964 K........................................................................................964 L........................................................................................965 M........................................................................................965 O........................................................................................966 P........................................................................................968 R........................................................................................968 S........................................................................................969 T........................................................................................971 V........................................................................................973 W........................................................................................973
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