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Grove Crane GMK 6300L Driving Operating Manual 3302597 – PDF DOWNLOAD
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Description
Grove Crane GMK 6300L Driving Operating Manual 3302597 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6300L Driving Operating Manual 3302597 – PDF DOWNLOAD
Language : English
Pages : 1000
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6300L Driving Operating Manual 3302597 – 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 3302597 – PDF DOWNLOAD
Correction sheet............................................................................. 3 Possible reeving methods on the main boom................................................ 3 Counterweight version B.................................................................. 13 Information on weight specifications................................................. 13 1 Overview................................................................................... 19 1.1 Accidents............................................................................ 19 1.2 Branch offices....................................................................... 21 1.2.1 Manitowoc Crane Care........................................................... 21 1.2.2 Dealer list.................................................................... 21 1.3 Warranty specifications.............................................................. 21 1.4 Terms used........................................................................... 22 1.5 Technical data....................................................................... 0 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 0 1.5.2 Maximum lifting capacity (ASME B 30.5)......................................... 0 1.5.3 Dimensions and weights of the truck crane, axle loads.......................... 26 Dimensions....................................................................... 27 Weight and axleloads............................................................ 27 1.5.4 Dimensions and weights of removable parts...................................... 28 Spare wheel...................................................................... 28 Outriggers....................................................................... 28 Driver's safety guard............................................................ 29 Hose drum........................................................................ 29 Hook blocks and hook tackle...................................................... 29 Auxiliary hoist.................................................................. 30 Main boom........................................................................ 30 Counterweight parts............................................................. 30 1.5.5 Carrier........................................................................ 31 Engine........................................................................... 31 Transmission..................................................................... 31 Transfer case.................................................................... 31 Axle lines....................................................................... 31 Steering......................................................................... 32 Tyres............................................................................ 32 Outriggers....................................................................... 32 Auxiliary supports............................................................... 33 Electrical system................................................................ 33 Tool............................................................................. 33 Towing coupling................................................................. 33 Driving speeds................................................................... 33 Climbing ability................................................................. 33 Turning radii.................................................................... 34 1.5.6 Superstructure................................................................. 35 Engine........................................................................... 35 Main hoist....................................................................... 35 Auxiliary hoist.................................................................. 35 Slewing gears.................................................................... 36 Derricking gear.................................................................. 36 Main boom........................................................................ 36 Lattice extension................................................................ 36 Operating speeds................................................................. 37 1.6 Documentation supplied............................................................... 39 1.6.1 Questions on documentation..................................................... 40 1.7 Notes on the operating manual........................................................ 41 1.7.1 What do the symbols used mean?................................................. 41 1.7.2 How is the operating manual structured?........................................ 43 Division......................................................................... 43 Structure of thechapters........................................................ 43 Structure of thepages........................................................... 44 1.7.3 How do I find the information I need?.......................................... 45 Cross-references example......................................................... 46 1.7.4 What information is available for operations planning?......................... 48 1.8 Conversion table for US measuring units.............................................. 49 1.9 Training – Information............................................................... 51 1.10 Identification...................................................................... 52 1.11 EC Declaration of Conformity........................................................ 54 2 Basic safety instructions.................................................................. 57 2.1 Intended use......................................................................... 57 2.1.1 Improper use................................................................... 58 2.2 Organisational measures.............................................................. 59 2.3 Personnel qualifications............................................................. 62 2.4 Safety instructions for driving the truck crane...................................... 63 2.5 Safety instructions for crane operation.............................................. 65 2.6 Instructions on transporting persons................................................. 69 Equipment for lifting persons........................................................ 69 Personnel............................................................................ 70 Operation............................................................................ 70 Truck crane.......................................................................... 71 3 Operating elements for driving............................................................. 75 3.1 Overview of the operating elements................................................... 75 3.1.1 On the outside of the truck crane.............................................. 76 3.1.2 Driver's cab................................................................... 80 Front overview................................................................... 80 Behind the cover................................................................ 84 Rear overview.................................................................... 85 3.1.3 Instrument panel............................................................... 86 Left/right....................................................................... 86 Middle........................................................................... 87 3.1.4 Display, driving mode.......................................................... 90 3.1.5 Steering column/steering wheel................................................. 91 3.1.6 Transmission operating elements................................................ 92 3.1.7 Tachograph, time correction.................................................... 93 3.1.8 ECOS control unit.............................................................. 94 3.1.9 ECOS display – main menu....................................................... 96 3.1.10 ECOS display – submenus....................................................... 98 Level adjustment system submenu................................................. 98 Settings submenu.................................................................100 Monitoring submenu...............................................................101 Operating hours submenu.........................................................102 Warning submenu..................................................................102 Error submenu....................................................................103 3.1.11 Heating/Air-conditioning system...............................................104 Standard heating system..........................................................104 Auxiliary water heating system..................................................105 3.1.12 Outrigger control units.......................................................106 3.1.13 Rear supporting box control unit..............................................107 3.2 Short description of the operating elements..........................................109 3.2.1 Definition of direction information............................................109 Basic rule.......................................................................109 Switches and buttons............................................................110 3.2.2 General notes on the operating elements........................................110 3.2.3 General rules for buttons and symbols on the display...........................111 3.2.4 Engine.........................................................................112 Steering column..................................................................112 Multipurpose switch..............................................................112 Instrument panel.................................................................113 Main menu........................................................................114 3.2.5 Carbamide system...............................................................115 Instrument panel.................................................................115 Display, driving mode............................................................116 ECOS display.....................................................................116 3.2.6 Electrical system..............................................................117 3.2.7 ECOS crane control.............................................................118 Control unit.....................................................................118 3.2.8 Transmission...................................................................121 Instrument panel, middle.........................................................121 Display, driving mode............................................................121 Transmission control unit........................................................121 3.2.9 Reverse camera.................................................................125 Reverse camera on/off............................................................125 3.2.10 Transfer case.................................................................126 3.2.11 Final drive...................................................................127 3.2.12 Brakes........................................................................128 Service brake....................................................................128 Additional brakes................................................................128 Parking brake....................................................................129 3.2.13 Steering/separate steering....................................................130 Instrument panel.................................................................130 ECOS display.....................................................................131 Driver's door....................................................................132 3.2.14 Suspension....................................................................133 3.2.15 Lighting/windscreen wipers/horn...............................................134 Steering column..................................................................134 Instrument panel.................................................................134 Roof.............................................................................137 3.2.16 Level adjustment system.......................................................138 3.2.17 Tachograph/speedometer........................................................141 Tachograph.......................................................................141 Speedometer......................................................................141 3.2.18 Rear supporting box control unit..............................................142 3.2.19 Diagnostics...................................................................143 Displays/ submenu................................................................143 3.2.20 Windows, doors, keys..........................................................144 Window winder....................................................................144 Doors............................................................................145 Keys.............................................................................145 3.2.21 Front flap....................................................................146 4 Starting the engine for driving / switching it off.........................................149 4.1 Starting the engine from the driver's cab............................................149 4.1.1 CHECKLIST: Starting the engine.................................................149 4.1.2 CHECKLIST: At low temperatures.................................................152 4.1.3 Ladders and access ladders.....................................................152 Fixed ladders....................................................................152 Ladders..........................................................................153 4.1.4 Refuel.........................................................................155 Fuel.............................................................................155 Carbamide........................................................................156 4.1.5 Checks before starting the engine..............................................158 At the hydraulic tank............................................................158 Battery master switch............................................................158 Checking the hand-held control...................................................159 4.1.6 Switch on the ignition.........................................................159 4.1.7 Lamp test/equalisation of the switching states.................................160 Lamp test........................................................................160 Switching state alignment........................................................161 4.1.8 Display – setting the brightness...............................................162 4.1.9 Starting the engine............................................................163 Without flame start system.......................................................164 With flame start system.........................................................164 4.1.10 Checks after starting the engine..............................................166 Checking in the main menu........................................................166 Indicator lamps on the instrument panel..........................................166 4.1.11 Monitoring elements...........................................................168 Instrument panel.................................................................168 4.1.12 Monitoring submenu............................................................169 4.1.13 Setting idling speed..........................................................170 4.2 Switch the engine off................................................................171 4.2.1 At the ignition lock and with the outrigger control units......................171 After switching off.............................................................171 4.2.2 Using the emergency stop switches..............................................172 Resetting the emergency stop switch..............................................172 4.3 Air intake inhibitor.................................................................173 Releasing the air intake inhibitor...................................................173 5 Driving....................................................................................177 5.1 Before driving.......................................................................177 5.1.1 CHECKLIST: Checks before on-road driving.......................................177 5.1.2 Checking the condition of the truck crane......................................183 Windscreen washing system........................................................183 Electrical system................................................................183 Adjusting themirrors............................................................184 Warning plates for vehicle width.................................................185 Displaying vehicle height........................................................185 Supply pressure..................................................................186 Parking brake....................................................................187 5.1.3 Adjusting the seats and steering column........................................189 Driver's seat....................................................................189 Passenger's seat.................................................................191 Adjusting the steering column...................................................192 5.1.4 Switching the suspension on/off................................................193 Opening the submenu..............................................................193 Switching the suspension on.....................................................194 Switching the suspension off....................................................194 5.1.5 Setting the tachograph.........................................................195 Prerequisites....................................................................195 In the event of malfunctions.....................................................195 Setting the tachograph..........................................................196 5.1.6 Displaying the operating hours.................................................201 5.1.7 Settings/indications on the driving display....................................202 5.2 Operating the transmission...........................................................203 5.2.1 Switching on...................................................................203 5.2.2 Switching the transmission to the neutral position.............................204 While driving....................................................................204 5.2.3 Changing the driving mode......................................................205 5.2.4 Selecting the driving direction................................................206 5.2.5 Changing highest gear/starting gear............................................208 5.2.6 Starting.......................................................................208 5.2.7 Driving and changing gears.....................................................209 5.2.8 Changing the driving direction.................................................210 5.2.9 Stopping.......................................................................211 Stopping for longer periods.....................................................211 5.2.10 On the roller type dynamometer................................................211 5.2.11 Oil level gauge...............................................................212 5.3 Driving the truck crane and switching it off.........................................215 5.3.1 Checks whilst driving..........................................................215 Immediately after you start to move..............................................215 While driving....................................................................217 5.3.2 Cruise control.................................................................218 Switching on.....................................................................218 Switching off....................................................................218 5.3.3 Temposet.......................................................................219 Switching on.....................................................................219 Switching off....................................................................219 5.3.4 Driving downhill...............................................................220 Starting.........................................................................220 Checks when driving downhill....................................................220 Shifting down from the highest gear..............................................221 Additional brakes................................................................222 5.3.5 Driving uphill.................................................................223 Starting.........................................................................223 Driving..........................................................................223 5.3.6 Warning submenu................................................................224 Meaning of thesymbols...........................................................224 Exiting the submenu.............................................................226 5.3.7 Warning or malfunction messages on the instrument panel........................227 Meaning of the lamps.............................................................227 5.3.8 Override torque reduction......................................................229 5.3.9 Error submenu..................................................................230 5.3.10 Switching the truck crane off.................................................230 Secure it against rolling away...................................................230 When stationary for more than 8hours............................................231 5.3.11 Folding berth.................................................................233 5.4 Off-road driving.....................................................................235 Adjustments to the transmission......................................................235 Connections..........................................................................235 Changing the vehicle level...........................................................235 Rocking the vehicle free andtowing..................................................235 5.4.1 Transfer case – switching the off-road gear on/off.............................236 Prerequisites....................................................................236 Switching on.....................................................................237 Switching off....................................................................237 Neutral position.................................................................237 5.4.2 Longitudinal and transverse differential locks.................................238 5.4.3 Operating the level adjustment system..........................................240 Opening the submenu..............................................................240 Setting the on-road level.......................................................241 Pre-selecting suspension struts.................................................241 Changing the vehicle level.......................................................242 Viewing the current inclination..................................................242 Exiting the submenu.............................................................243 5.4.4 Freeing truck crane stuck in terrain...........................................244 Rocking the truck crane free....................................................244 Towing free to thefront........................................................245 Towing free to therear.........................................................245 5.5 Separate steering....................................................................247 5.5.1 Switching to separate steering.................................................247 Manual...........................................................................248 Automatic........................................................................249 switching to normal steering mode................................................250 5.6 Heating and air-conditioning system..................................................251 5.6.1 Standard heating system........................................................251 Switching on.....................................................................251 Heating..........................................................................251 Air distribution.................................................................252 Examples.........................................................................253 Switching off....................................................................253 5.6.2 Air-conditioning system........................................................254 Information......................................................................254 Switching on/off.................................................................254 Cooling..........................................................................255 Drying...........................................................................255 5.6.3 Auxiliary water heater.........................................................256 Preheating theengine............................................................256 Preheating the driver's cab.....................................................257 Switching on the auxiliary heater................................................257 Switching off the auxiliary heater...............................................258 Setting time andweekday.........................................................258 Saving automatic heating start..................................................259 Setting the heating period......................................................260 Switching the automatic heating start on and off.................................261 Setting the remaining run time..................................................261 5.7 Towing a trailer.....................................................................263 Effects on the axleloads............................................................263 Coupling the trailer................................................................264 Connecting the supply lines.........................................................265 Removing supply lines..............................................................266 Uncoupling thetrailer..............................................................266 Checking the braking force...........................................................268 6 Driving modes..............................................................................271 6.1 Driving modes........................................................................271 Information about the axle loads.....................................................271 6.1.1 Information on how to use the tables...........................................272 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs)............................273 For tyres 385/95 R25.............................................................273 For tyres 445/95 R25.............................................................274 For tyres 525/80 R25.............................................................275 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)...........276 6.2 Weighing the truck crane.............................................................277 Determining..........................................................................277 Axle groups..........................................................................278 Weighing procedure...................................................................279 Evaluation...........................................................................280 6.3 Rigging work for driving with a trailer..............................................281 6.3.1 Switching on the slewing gear freewheel........................................282 6.3.2 Switching on the boom floating position........................................283 6.3.3 Switching on boom pre-tensioning...............................................284 6.3.4 Adjusting axle pressure........................................................285 Preselecting the axle pair.......................................................285 Adjusting axle pressure..........................................................286 Driving with changed axle pressures..............................................286 Adjusting axle pressure for on-road driving......................................286 6.3.5 Switching the superstructure driving lights on/off.............................287 Switching off....................................................................287 Switching on.....................................................................287 6.4 Main boom, removing/installing.......................................................289 Additional equipment required........................................................289 6.4.1 CHECKLIST: Removing the main boom..............................................290 Prerequisites....................................................................290 Checklist........................................................................290 6.4.2 CHECKLIST: Mounting the main boom..............................................293 Prerequisites....................................................................293 Checklist........................................................................293 6.4.3 Slinging the main boom.........................................................296 Marking..........................................................................296 Installing the lifting gear......................................................296 Removing the lifting gear........................................................297 6.4.4 Removing/attaching the clamps..................................................298 6.4.5 Switching the pressure relief on/off...........................................299 6.4.6 Connecting/disconnecting the derricking cylinder from the boom.................300 Retracting the derricking cylinder head axle.....................................301 Fitting the derricking cylinder head axle........................................302 6.4.7 Extending/retracting the boom pivot pin........................................303 Before pulling itout............................................................303 After pushing it in..............................................................303 Pulling out the pivot pin........................................................304 Pushing the pivot pin in.........................................................305 6.4.8 Disconnecting/connecting hydraulics/electrical.................................306 Disconnecting....................................................................306 Connecting.......................................................................307 6.4.9 Lifting the main boom off/on the turntable.....................................308 Lifting from the turntable.......................................................308 Lifting on to the turntable......................................................309 6.4.10 Aligning the connecting points................................................310 6.4.11 Securing/releasing the derricking cylinder....................................310 6.4.12 Transporting the main boom....................................................311 6.4.13 Inspections after main boom mounting..........................................312 6.4.14 Installing/removing the hose drum.............................................313 Installing.......................................................................313 Removing.........................................................................314 6.5 Installing/removing outrigger beams..................................................317 6.5.1 CHECKLIST: Removing the outrigger beams........................................318 6.5.2 CHECKLIST: Installing the outrigger beams......................................320 6.5.3 Preparing the truck crane......................................................322 Prerequisites....................................................................322 For removal......................................................................322 6.5.4 Removing/attaching outrigger pads..............................................323 Removing outrigger pads.........................................................323 Attaching outrigger pads........................................................324 6.5.5 Disconnecting/establishing the hydraulic connection............................325 6.5.6 Disconnecting/establishing the electrical connection...........................326 6.5.7 Unscrewing/screwing in the spacers.............................................327 Unscrewing.......................................................................327 Screwing in......................................................................328 6.5.8 Disconnecting/establishing the connections to the supporting box...............329 6.5.9 Extending/retracting the outrigger beam........................................329 Extending the outrigger beam....................................................329 Inserting the outrigger beam.....................................................331 6.5.10 Transporting the outrigger beams..............................................333 6.6 Installing/removing the supporting box...............................................335 6.6.1 CHECKLIST: Removing the supporting box.........................................336 6.6.2 CHECKLIST: Installing the supporting box.......................................339 6.6.3 Rig the outrigger span 7.98x8.50/1.00m (26.1x27.9/3.3ft).................341 Front outrigger..................................................................342 Auxiliary supports...............................................................342 6.6.4 Establishing/disconnecting the pneumatic connection............................344 6.6.5 Disconnecting/establishing the electrical connection...........................345 6.6.6 Disconnecting/establishing the hydraulic connection............................346 6.6.7 Attaching/raising the supporting box with the truck crane......................347 Prerequisites:...................................................................347 Lifting..........................................................................348 Hanging..........................................................................349 6.6.8 Installing the reverse camera..................................................350 6.6.9 Crane movements during installation and removal................................351 Prerequisites....................................................................351 Before installation..............................................................351 After the removal...............................................................351 6.6.10 Slinging points on the supporting box.........................................352 6.6.11 Locking/unlocking the supporting box..........................................353 Locking..........................................................................353 Unlocking........................................................................354 6.6.12 Transporting the supporting box on the separate vehicle.......................355 Lashing eyelets..................................................................355 6.6.13 Installing / removing the rear bumper.........................................356 Prerequisites:...................................................................356 Installing.......................................................................357 Removing.........................................................................357 6.7 Rigging the auxiliary hoist..........................................................359 6.7.1 CHECKLIST: Auxiliary hoist, installing.........................................359 Prerequisites....................................................................359 6.7.2 CHECKLIST: Auxiliary hoist, removing...........................................361 Prerequisites....................................................................361 6.7.3 Slinging the auxiliary hoist...................................................363 6.7.4 Installing/removing the rigging frame..........................................364 Prerequisite.....................................................................364 6.7.5 Setting down the auxiliary hoist...............................................365 6.7.6 Making/breaking the hydraulic connection.......................................366 6.7.7 Establishing/disconnecting the electrical connection...........................367 6.7.8 Creating the connection to the turntable.......................................368 Establishing the connection......................................................368 Separating the connection........................................................370 6.7.9 Securing the hoist rope........................................................371 6.7.10 Transporting the auxiliary hoist..............................................372 6.7.11 Check that the auxiliary hoist is functioning properly........................373 Slewing direction................................................................373 Slewing indicator................................................................373 7 Malfunctions in driving mode...............................................................377 7.1 Emergency stop switch................................................................377 7.2 What to do when a malfunction occurs in road traffic.................................379 7.3 Towing the truck crane...............................................................381 7.3.1 Towing after engine/transmission damage........................................382 Compressed-air supply............................................................382 Electric power supply............................................................383 On the transmission..............................................................383 Axle drives......................................................................383 Transfer case....................................................................384 Parking brake....................................................................384 Towing the truck crane out of the danger area....................................385 7.3.2 Tow starting...................................................................385 7.3.3 External starting socket.......................................................386 Performing a jump start..........................................................386 7.3.4 Battery charger................................................................387 Prerequisites....................................................................387 7.4 Wheels and tyres.....................................................................389 7.4.1 Wheel change...................................................................389 Removing adamaged wheel.........................................................390 On the spare wheel holder........................................................390 Mounting a wheel.................................................................391 7.4.2 Inflating the tyres yourself...................................................393 Connecting the filling hose......................................................393 Inflating the tyres..............................................................394 Removing the filling hose........................................................394 7.5 Fuses................................................................................395 Information on replacing fuses.....................................................395 7.5.1 Fuses in the driver's cab......................................................396 Group F1.........................................................................396 Group F2.........................................................................397 Group F3.........................................................................397 Group F4.........................................................................398 Group F5.........................................................................398 Group F6.........................................................................399 Group F7.........................................................................399 Group F8.........................................................................399 Group F9.........................................................................400 Group F10........................................................................400 7.5.2 Fuses in the battery box.......................................................401 7.6 Troubleshooting......................................................................403 7.6.1 Malfunctions on the engine.....................................................403 7.6.2 Malfunctions in the exhaust system.............................................405 7.6.3 Malfunctions in the transmission...............................................406 7.6.4 Transfer case malfunctions.....................................................407 7.6.5 Malfunctions of the service brake..............................................407 7.6.6 Malfunctions of the steering...................................................408 7.6.7 Differential lock malfunctions.................................................409 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................409 7.6.9 Malfunctions on the suspension.................................................410 7.6.10 Malfunctions of the level adjustment system...................................410 7.6.11 Malfunctions on the ECOS carrier..............................................411 ECOS programme version...........................................................411 General malfunctions............................................................411 Error messages...................................................................412 Exiting the submenu.............................................................413 7.7 Procedure in the event of malfunctions...............................................414 7.7.1 Switching on emergency operation in coolant circuit............................414 7.7.2 Procedure during engine malfunctions...........................................415 7.7.3 Malfunctions in the transmission...............................................416 General malfunctions.............................................................416 Transmission malfunction.........................................................416 Reading out error codes.........................................................418 8 Index......................................................................................421 A........................................................................................423 B........................................................................................423 C........................................................................................424 D........................................................................................425 E........................................................................................427 F........................................................................................429 H........................................................................................429 I........................................................................................430 K........................................................................................430 L........................................................................................431 M........................................................................................431 O........................................................................................432 P........................................................................................434 R........................................................................................434 S........................................................................................435 T........................................................................................437 V........................................................................................439 W........................................................................................439 Correction sheet.............................................................................445 Possible reeving methods on the main boom................................................445 Counterweight version B..................................................................455 Information on weight specifications.................................................455 9 Operating elements for crane operation.....................................................461 9.1 Overview of the operating elements...................................................461 9.1.1 Exterior of the truck crane....................................................462 9.1.2 Crane cab......................................................................466 9.1.3 Front panel....................................................................468 9.1.4 Side panel.....................................................................469 Bottom...........................................................................469 Top..............................................................................470 Console, rear....................................................................472 Standard heating system..........................................................473 Auxiliary water heating system..................................................474 Auxiliary air heater............................................................475 9.1.5 Control panels.................................................................476 Left.............................................................................476 Right............................................................................477 9.1.6 Control lever configuration....................................................478 Version 1........................................................................478 Version 2........................................................................479 9.1.7 ECOS control unit..............................................................480 9.1.8 ECOS display – main menu.......................................................482 9.1.9 ECOS display – submenus........................................................484 Counterweight submenu...........................................................484 Slewing gear/ houselock submenu..................................................485 Outriggers submenu..............................................................486 Telescoping submenu.............................................................488 Power unit speeds submenu.....................................................490 Monitoring submenu..............................................................491 Settings submenu................................................................492 Operating hours submenu.........................................................493 Submenu Warning.................................................................494 Error submenu....................................................................497 Working range limiter submenu..................................................498 9.1.10 RCL control unit..............................................................500 9.1.11 RCL display – main menu.......................................................501 9.1.12 Display RCL – submenus........................................................503 Enter rigging mode submenu....................................................503 Monitoring submenu..............................................................504 Rigging mode monitoring submenu................................................506 Lifting capacity table submenu.................................................507 Working range submenu...........................................................508 Error submenu....................................................................509 Settings submenu.................................................................510 9.1.13 Hand-held control.............................................................511 9.1.14 Outrigger control units.......................................................512 Button...........................................................................512 Outrigger button.................................................................513 Inclination and outrigger pressure display.......................................514 Raise axle display...............................................................515 9.2 Short description of the operating elements..........................................517 9.2.1 Definition of direction information............................................517 Basic rule.......................................................................517 Switches.........................................................................517 9.2.2 General rules for buttons and symbols on the display...........................518 9.2.3 Engine for crane operation.....................................................519 Side panel......................................................................519 Console, rear....................................................................520 ECOS display.....................................................................520 9.2.4 Engine for driving.............................................................520 Side panel.......................................................................520 Main menu........................................................................520 Outriggers submenu..............................................................521 9.2.5 Seat contact switch and dead man's switch......................................522 9.2.6 ECOS crane control.............................................................523 Control unit.....................................................................523 9.2.7 Outriggers.....................................................................526 In the Outriggers submenu.......................................................526 In the Settings submenu..........................................................527 On the outrigger control units...................................................528 9.2.8 Inclination indicators.........................................................530 9.2.9 Raise axle.....................................................................531 Outrigger control units..........................................................531 9.2.10 Outrigger pressure displays...................................................533 Outriggers submenu..............................................................533 Outriggers controlunits........................................................533 9.2.11 Anemometer display............................................................533 9.2.12 Counterweight submenu.........................................................534 Counterweight submenu...........................................................534 9.2.13 Main hoist....................................................................538 9.2.14 Auxiliary hoist...............................................................540 9.2.15 Slewing gear..................................................................541 Submenu..........................................................................542 9.2.16 Derricking gear...............................................................544 9.2.17 Telescoping mechanism.........................................................546 Control panels...................................................................546 Submenu..........................................................................547 In the Settings submenu..........................................................552 9.2.18 Hydraulic system..............................................................553 9.2.19 House lock....................................................................554 9.2.20 Rated capacity limiter (RCL)..................................................555 Control unit.....................................................................555 Main menu........................................................................557 Submenu Rigging mode entry.......................................................558 Monitoring submenu...............................................................562 Submenu Lifting capacity table...................................................566 Working range submenu...........................................................567 RCL override.....................................................................568 External displays................................................................569 9.2.21 Electrical system.............................................................570 9.2.22 Lighting, windscreen wiper/washing system.....................................571 Lighting.........................................................................571 Windscreen wiper/washing system.................................................573 9.2.23 Hand-held control.............................................................574 Sockets for hand-held control....................................................574 Engine control panel.............................................................575 Horn.............................................................................575 9.2.24 Windows, doors, keys..........................................................578 Windscreen.......................................................................578 Rear window......................................................................578 Crane cab door...................................................................579 Keys.............................................................................580 9.2.25 Diagnostics...................................................................580 10 Starting/switching off the engine – for crane operation...................................583 10.1 Starting the engine – from the crane cab............................................583 10.1.1 CHECKLIST: Starting the engine................................................583 10.1.2 CHECKLIST: At low temperatures................................................586 10.1.3 Refuel........................................................................586 Fuel.............................................................................586 Carbamide........................................................................588 10.1.4 Checks before starting the engine.............................................589 At the hydraulic tank............................................................589 Battery master switch............................................................589 Checking the hand-held control...................................................590 10.1.5 Switch on the ignition........................................................590 10.1.6 Lamp test / switching state alignment.........................................591 Lamp test........................................................................591 10.1.7 Adjusting display brightness..................................................593 10.1.8 Starting the engine...........................................................594 Without flame start system.......................................................594 With flame start system..........................................................595 10.1.9 Checks after starting the engine..............................................596 10.1.10 Monitoring submenu...........................................................597 10.1.11 Setting idling speed.........................................................598 10.1.12 Override torque reduction....................................................599 10.2 Starting the engine – with the hand-held control....................................601 Prerequisites........................................................................601 Starting the engine..................................................................601 10.3 Switching off the engine............................................................603 10.3.1 During normal operation, with the ignition lock/with the hand-held control....603 After switching off.............................................................603 10.3.2 In emergencies, with the emergency stop switches..............................604 Resetting the emergency stop switch..............................................604 10.4 Air intake inhibitor................................................................605 Releasing the air intake inhibitor...................................................605 11 Crane operation...........................................................................609 11.1 Before operating the crane..........................................................609 11.1.1 CHECKLIST: Checks before operating the crane..................................609 11.1.2 Checking the condition of the truck crane.....................................613 Windscreen washing system – Tank.................................................613 Visual inspection................................................................613 Checking the position of the hoist ropes.........................................614 Checking the electrical system...................................................614 11.1.3 Adjusting the crane cab seat and front control panel..........................615 Crane cab seat...................................................................615 Front control panel..............................................................616 11.1.4 Checking the safety equipment.................................................617 Rated capacity limiter...........................................................617 Lifting limit switch............................................................617 Emergency stop switch............................................................618 Seat contact switch..............................................................619 11.1.5 Earthing the load.............................................................620 11.1.6 Preheating the hydraulic oil..................................................621 11.1.7 Locking/unlocking the turntable...............................................622 Locking points...................................................................622 11.1.8 Switching the houselock on/off................................................623 Switching on the houselock......................................................623 Switching off the houselock.....................................................625 11.2 Operation of the rated capacity limiter.............................................627 11.2.1 Switch on the RCL.............................................................628 Switching on.....................................................................628 Brightness of the displays.......................................................630 11.2.2 Enter rigging mode............................................................631 Entering individual components...................................................632 Entering the RCL code...........................................................636 Entering the reeving............................................................637 Accepting the rigging mode.......................................................637 11.2.3 Checks before operating the crane.............................................639 Opening the submenu..............................................................639 Checks...........................................................................640 11.2.4 Displays during crane operation...............................................642 11.2.5 RCL early warning.............................................................645 11.2.6 RCL shutdown..................................................................645 Shutdown due to overload.........................................................645 11.2.7 Display in the event of errors................................................647 11.2.8 RCL override..................................................................648 Table – error/ information codes.................................................654 11.2.9 Displaying the lifting capacity tables........................................655 11.2.10 Entering the time/date.......................................................657 11.3 Crane operation with main boom......................................................659 11.3.1 Checks during crane operation.................................................659 Horizontal alignment.............................................................659 Safe distances..................................................................659 Checking the windspeed..........................................................660 11.3.2 Permissible slewing ranges and working positions..............................661 360 slewing range...............................................................661 Working position 0 to the rear..................................................661 180 to the front rigging position...............................................661 11.3.3 Main hoist....................................................................662 Maximum permissible hoistrope speed.............................................662 Switching on the main hoist......................................................663 Lifting and lowering............................................................663 Switching off the main hoist....................................................664 11.3.4 Auxiliary hoist...............................................................665 Maximum permissible hoist rope speed.............................................665 Switching on the auxiliary hoist................................................666 Lifting and lowering............................................................667 Switching off the auxiliary hoist...............................................667 11.3.5 Lifting limit switch and lowering limit switch................................668 Lifting limit switch.............................................................668 Lowering limit switch............................................................669 11.3.6 Derricking gear...............................................................670 Switching on the derricking gear................................................670 Maximum permissible derricking speed.............................................670 raising and lowering.............................................................671 Re-enable raising function.......................................................672 Switching off the derricking gear................................................672 Lowering the main boom to ahorizontal position..................................673 11.3.7 Telescoping mechanism.........................................................674 Overview.........................................................................675 Telescoping process..............................................................675 Assignment for display...........................................................677 Fixed length, intermediate length, telescoping length...........................679 Telescoping......................................................................680 Telescoping sequence............................................................680 Checks before starting work.....................................................681 Switching on the telescoping mechanism...........................................682 Function of the control lever....................................................682 Telescoping with lattice extension folded at the side............................684 Switching off the telescoping mechanism..........................................684 Manual telescoping..............................................................685 Checking the initial position....................................................685 Unlocking the telescoping cylinder...............................................687 Extending/retracting the telescoping cylinder....................................690 Lock telescoping cylinder........................................................691 Unlocking the telescopic section................................................692 Telescoping the telescopic section..............................................694 Locking the telescopic section..................................................695 Locking the telescopic section for on-road driving..............................696 Telescoping with teleautomation..................................................697 Telescoping the main boom when horizontal........................................701 11.3.8 High-speed mode...............................................................702 Switch on function...............................................................702 Derricking gear/ telescoping mechanism...........................................702 Hoists...........................................................................703 11.3.9 Slewing gear..................................................................704 Maximum permissible slewing speed................................................704 Switching on the slewing gear...................................................704 Releasing the slewing gear brake.................................................705 Engaging the slewing gear brake..................................................705 Turning..........................................................................705 Braking the slewing movement.....................................................707 Slewing gear freewheel...........................................................708 Switching off the slewing gear..................................................708 11.3.10 Possible movement combinations...............................................709 11.3.11 Hydraulic oil cooling........................................................709 11.4 Settings and displays for crane operation...........................................711 11.4.1 Inclining the crane cab.......................................................711 11.4.2 Setting idling speed..........................................................711 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................712 11.4.4 Limiting the power unit speeds................................................713 11.4.5 Setting the characteristic curves for the control levers......................714 11.4.6 Critical load control.........................................................715 Function.........................................................................715 Switching on andoff............................................................715 11.4.7 Using the pivoting spotlights.................................................716 11.4.8 Displaying the operating hours................................................717 11.4.9 Warning submenu...............................................................718 Meaning of thesymbols...........................................................718 Exiting the submenu.............................................................722 11.4.10 Error submenu................................................................722 11.5 Working range limiter...............................................................723 11.5.1 Opening the working range limiter submenu.....................................724 11.5.2 Viewing current settings......................................................724 11.5.3 Entering limit values.........................................................726 Overall height/ working radius..................................................726 Slewing angle....................................................................727 Entering objects.................................................................729 11.5.4 Entering limit values/objects manually........................................732 Limit values.....................................................................732 Objects..........................................................................733 11.5.5 Switching monitoring functions on/off.........................................734 11.5.6 Shutdown by working range limiter.............................................735 11.6 Work break..........................................................................737 11.6.1 In case of short work breaks..................................................737 11.6.2 In case of work breaks of more than 8 hours...................................738 To secure the truck crane........................................................738 11.7 Heating and air-conditioning system.................................................739 11.7.1 Standard heating system.......................................................739 Switching on.....................................................................739 Heating..........................................................................739 Air distribution.................................................................740 Switching off....................................................................740 11.7.2 Air-conditioning system.......................................................741 Information......................................................................741 Switching on/off.................................................................741 Cooling..........................................................................742 Drying the air...................................................................742 11.7.3 Auxiliary water heater........................................................743 Preheating theengine...........................................................743 Preheating the crane cab........................................................744 Switching on.....................................................................745 Setting the day and time.........................................................746 Storing the heating start.......................................................746 Setting the heating period......................................................747 Switching heating start on/off...................................................748 Switching off....................................................................749 Setting the remaining run time..................................................749 11.7.4 Auxiliary air heater..........................................................750 Switching on.....................................................................750 Temperature......................................................................751 Switching off....................................................................751 Other functions..................................................................751 11.8 CraneSTAR system....................................................................752 11.8.1 Overview......................................................................752 11.8.2 Position of the components....................................................752 12 Rigging work..............................................................................755 12.1 Rigging work checklists for crane operation with the main boom......................755 12.1.1 CHECKLIST: Rigging............................................................755 12.1.2 CHECKLIST: Unrigging..........................................................760 12.2 Choice of a suitable positioning site...............................................763 12.2.1 Determining the required load-bearing area....................................763 12.2.2 Safe distance from slopes and pits............................................766 12.2.3 Earthing the truck crane......................................................767 12.2.4 Safe distance from overhead power lines.......................................768 12.3 Rigging work after driving with a trailer...........................................771 12.3.1 Switching off the boom floating position......................................771 12.3.2 Switching off the slewing gear freewheel......................................772 Before slewing...................................................................772 12.3.3 Switching off boom pre-tensioning.............................................773 12.4 Connecting/disconnecting the hand-held control......................................775 12.5 Starting the engine for driving for rigging work....................................777 12.5.1 Starting/turning off the engine from the crane cab............................777 Prerequisites....................................................................777 Starting the engine..............................................................777 After starting theengine........................................................778 Switching off theengine.........................................................778 12.5.2 Starting/switching off the engine from the outrigger control units............780 Prerequisites....................................................................780 Starting the engine..............................................................780 Switch the engine off............................................................780 12.6 Outriggers..........................................................................781 12.6.1 CHECKLIST: Extending the outriggers...........................................781 12.6.2 CHECKLIST: Retracting the outriggers..........................................783 12.6.3 Permissible outrigger spans...................................................784 12.6.4 Preparing the truck crane.....................................................785 In the driver's cab..............................................................785 Outriggers control units........................................................785 12.6.5 Setting the outrigger spans...................................................786 For on-road driving..............................................................788 12.6.6 Extending/retracting outrigger beams..........................................789 From the control units...........................................................790 From the cranecab...............................................................791 12.6.7 Moving the outrigger pads into working/driving position.......................793 12.6.8 Enlarging the load-bearing area...............................................794 12.6.9 Extending/retracting supporting cylinders.....................................795 From the control units...........................................................796 From the crane cab...............................................................797 12.6.10 Levelling the truck crane on outriggers......................................800 Inclination indicators...........................................................800 Prerequisites....................................................................801 Manual alignment................................................................802 Automatic alignment..............................................................803 12.6.11 Levelling the free-on-wheels truck crane.....................................804 12.6.12 Outrigger pressure display...................................................806 12.7 Rigging/unrigging the counterweight.................................................807 12.7.1 Counterweight sections........................................................807 Version A........................................................................807 Version B........................................................................808 12.7.2 Identification................................................................809 12.7.3 Slinging points on the counterweight sections.................................810 12.7.4 CHECKLIST: Rigging the counterweight..........................................812 12.7.5 CHECKLIST: Unrigging the counterweight........................................814 12.7.6 Assembling counterweight combination..........................................816 Combinations for the basic equipment in version A................................817 Combinations for the additional equipment in version A...........................820 Combinations for the basic equipment in version B................................822 Combinations for the additional equipment in version B...........................825 12.7.7 Counterweight hoist unit......................................................829 Counterweight submenu...........................................................829 Extending/retracting the lifting cylinders.......................................830 Automatic mode rigging..........................................................831 Automatic mode unrigging........................................................832 Cancel automatic mode...........................................................834 12.7.8 Setting down counterweight for driving the truck crane........................835 Version A........................................................................835 Version B........................................................................835 12.7.9 Slewing with rigged counterweight.............................................837 12.8 Rigging work on the main boom.......................................................839 12.8.1 Hook block on the bumper......................................................839 Picking up the hook block........................................................839 Attaching the hook block.........................................................840 12.8.2 Hook block on a separate vehicle..............................................841 Picking up the hook block.......................................................842 Setting down the hook block.....................................................842 12.8.3 Hook block, separable.........................................................844 Rigging for on-road driving......................................................844 Rigging for crane operation......................................................845 12.8.4 Reeving and unreeving the hoist rope..........................................846 Rope end fitting.................................................................846 Reeving the hoist rope...........................................................847 Unreeving hoist rope............................................................850 12.8.5 Possible reeving methods on the main boom.....................................851 With 9 head sheaves..............................................................852 With 10 head sheaves.............................................................855 12.8.6 Installing/removing the lifting limit switch..................................860 Installing the lifting limit switch..............................................860 Removing the lifting limit switch................................................863 12.8.7 Locking/unlocking the lifting limit switch....................................864 Locking..........................................................................864 Removing the lock...............................................................865 12.8.8 Anemometer and air traffic control light......................................866 Installing.......................................................................866 Removing.........................................................................867 12.9 Other rigging work..................................................................869 12.9.1 Railings on the turntable.....................................................869 12.9.2 Cameras for crane operation...................................................871 Cameras on the hoists............................................................871 Camera on main boom..............................................................871 Turning the monitor on/off and switching.........................................874 12.9.3 Ladder on the counterweight...................................................875 12.9.4 Extendable step...............................................................876 12.9.5 Folding the mirrors in and out, and adjusting them............................877 13 Driving with a rigged truck crane.........................................................881 13.1 Driving path........................................................................881 13.2 Permissible rigging modes and axle loads............................................882 Axle load table.....................................................................882 13.3 Before driving......................................................................884 13.3.1 Securing the superstructure against slewing...................................884 13.3.2 Check the tyre pressure and the wind speed....................................884 13.3.3 Putting the truck crane on the wheels.........................................885 13.3.4 Gears/connections.............................................................887 Transmission.....................................................................887 Connections......................................................................887 13.4 Whilst driving......................................................................887 13.5 After driving.......................................................................889 13.6 Driving in combined operation.......................................................890 13.6.1 Switching combined operation on/off...........................................890 Prerequisites....................................................................890 Switching on.....................................................................891 Switching off....................................................................891 13.6.2 Starting/turning off the engine...............................................892 13.6.3 Preparing to drive............................................................893 Transmission.....................................................................893 Switching on separate steering...................................................893 Connections......................................................................893 13.6.4 While driving.................................................................894 14 Malfunctions during crane operation.......................................................897 14.1 Emergency stop switch...............................................................897 14.2 What to do when malfunctions occur during crane operation...........................899 The load can be set down.............................................................899 Load cannot be setdown..............................................................899 14.3 Fuses...............................................................................901 Information on replacing fuses.....................................................901 14.3.1 Fuses on the turntable........................................................902 Fuse groups F1/F2/F3............................................................902 Fuses on the circuit board.......................................................903 14.3.2 Fuses in the crane cab........................................................905 14.3.3 Fuses in the battery box......................................................907 14.3.4 RCL fuses.....................................................................908 14.4 Finding and eliminating malfunctions................................................909 14.4.1 Malfunctions on the engine....................................................909 14.4.2 Malfunctions in the exhaust system............................................910 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................911 14.4.4 Malfunctions in the hoist cameras.............................................912 14.4.5 Malfunctions in the main boom camera..........................................912 14.4.6 Malfunctions on the derricking gear...........................................913 14.4.7 Malfunctions in the telescoping mechanism.....................................914 Telescoping mechanism error messages.............................................915 14.4.8 Malfunctions in the slewing gear..............................................917 14.4.9 Malfunctions in the counterweight hoist unit..................................919 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................920 14.4.11 Malfunctions when inclining the crane cab....................................920 14.4.12 Malfunctions when operating with the hand-held control.......................920 14.4.13 Malfunctions of the outriggers...............................................921 14.4.14 Troubleshooting the RCL......................................................922 General malfunctions............................................................922 Error messages in the Monitoring submenu.........................................923 Displays in the Error submenu....................................................925 Table of error codes.............................................................927 Switch off the sensor/ tachogenerator...........................................930 14.4.15 Malfunctions ECOS – superstructure...........................................931 ECOS programme version...........................................................931 General malfunctions............................................................931 Error messages...................................................................932 Exiting the submenu.............................................................933 14.4.16 Malfunctions on CraneSTAR system.............................................934 14.5 Emergency operations and programs...................................................937 14.5.1 Mechanical emergency activation for retracting................................938 Prior to the emergency activation, check.........................................938 Procedure........................................................................938 Mechanical emergency activation.................................................939 14.5.2 Telescoping emergency program.................................................941 Swinging the swing-away lattice..................................................942 Checks...........................................................................943 Starting the emergency program..................................................943 Determining the type of error...................................................944 Error at the length indicator....................................................945 If there is an error at a proximity switch.......................................949 Terminating emergency programme.................................................950 Tables for approaching the locking points........................................951 14.5.3 Entering the current telescoping..............................................953 14.5.4 Emergency operation with the hand-held control................................955 Preparations.....................................................................955 Operating a power unit...........................................................956 Stopping movements..............................................................958 Stopping movements in emergencies................................................958 Switch the engineoff............................................................958 14.5.5 Switching on emergency operation in coolant circuit...........................959 14.6 Hydraulic emergency operation.......................................................961 14.6.1 Operating principle...........................................................961 14.6.2 Connecting/disconnecting hoses................................................962 Establishing connections.........................................................962 Disconnecting connections.......................................................963 14.6.3 Switching emergency operation on/off..........................................964 14.6.4 Establishing the hydraulic circuits required..................................965 Switching over valves............................................................965 For lifting/ lowering............................................................967 For slewing......................................................................968 14.6.5 Performing emergency operation................................................969 Turning..........................................................................969 Derricking.......................................................................970 Lifting/lowering.................................................................970 14.6.6 After emergency operation.....................................................971 Switching off emergency operation................................................971 Switching over to crane operation................................................971 Disconnecting thehoses..........................................................971 14.6.7 Emergency supply of another crane.............................................972 For emergency supply.............................................................972 After emergency supply...........................................................972 14.7 Other emergency operations..........................................................973 14.7.1 External starting socket......................................................973 Performing a jump start..........................................................974 14.7.2 Battery charger...............................................................975 Prerequisites....................................................................975 15 Index.....................................................................................979 A........................................................................................981 B........................................................................................981 C........................................................................................982 D........................................................................................983 E........................................................................................985 F........................................................................................987 H........................................................................................987 I........................................................................................988 K........................................................................................988 L........................................................................................989 M........................................................................................989 O........................................................................................990 P........................................................................................992 R........................................................................................992 S........................................................................................993 T........................................................................................995 V........................................................................................997 W........................................................................................997
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