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Grove Crane GMK 6400 Driving & Crane Operating Manual 3112992 – PDF DOWNLOAD
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Description
Grove Crane GMK 6400 Driving & Crane Operating Manual 3112992 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6400 Driving & Crane Operating Manual 3112992 – PDF DOWNLOAD
Language : English
Pages : 960
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6400 Driving & Crane Operating Manual 3112992 – PDF DOWNLOAD
Intended use:
- The GMK 6400 is a state-of-the-art truck crane, designed in accordance with
approved safety regulations. Nevertheless, the operator or third parties can
still be endangered and the crane or other property put at risk while using it.
The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK 6400 truck crane may only be used when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards. - Any malfunctions that could impair safety must be eliminated immediately.
The GMK 6400 truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
data, p. 1 – 7. - The GMK 6400 truck crane is designed solely for lifting loads which are
within the permitted GMK 6400 lifting capacities. The load must be slung as
prescribed to a hook block which is positioned vertically over the load prior
to lifting.
Intended use also includes
– Observing the entire crane documentation, consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual.
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual.
- The GMK 6400 may only be operated with parts of equipment which are
permitted by Manitowoc Crane Group Germany GmbH and which are
labelled with the serial number of the GMK 6400. - The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK 6400 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 6400 Driving & Crane Operating Manual 3112992 – PDF DOWNLOAD
Operating manual Part 1 – Driving.................................................................... 1 Additional pages ................................................................................ 11 Possible reeving methods on the main boom.................................................... 3 Technical Data............................................................................... 11 Safety harness on the main boom.............................................................. 13 Anemometer and air traffic control light..................................................... 19 Use of additional head sheaves............................................................... 21 Mega Wing Lift (MWL)......................................................................... 23 Rigging with double-hook block........................................................... 23 1 Overview....................................................................................... 29 1.1 Accidents................................................................................ 29 1.2 Branch offices........................................................................... 30 1.2.1 Manitowoc Crane Care............................................................... 30 1.2.2 Dealer list........................................................................ 30 1.3 Warranty specifications.................................................................. 30 1.4 Terms used............................................................................... 32 1.5 Technical data........................................................................... 35 1.5.1 Maximum lifting capacity........................................................... 35 1.5.2 Dimensions and weights of the truck crane, axle loads.............................. 36 Dimensions........................................................................... 37 Weight and axle loads................................................................ 37 1.5.3 Dimensions and weights of removable parts.......................................... 38 Spare wheel.......................................................................... 38 Outriggers........................................................................... 38 Main boom............................................................................ 39 Hook blocks and hook tackle.......................................................... 39 Auxiliary hoist...................................................................... 39 Counterweightsections version A...................................................... 40 Counterweightsections version B...................................................... 40 1.5.4 Carrier............................................................................ 41 Engine............................................................................... 41 Transmission......................................................................... 41 Transfer case........................................................................ 41 Axle lines........................................................................... 41 Steering............................................................................. 41 Tyres................................................................................ 42 Electrical system.................................................................... 42 Tool................................................................................. 42 Towing coupling...................................................................... 42 Driving speeds....................................................................... 42 Climbing ability..................................................................... 42 Outriggers........................................................................... 43 Turning radii........................................................................ 44 1.5.5 Superstructure..................................................................... 45 Main hoist........................................................................... 45 Auxiliary hoist...................................................................... 45 Slewing gears........................................................................ 45 Derricking gear...................................................................... 46 Main boom............................................................................ 46 Lattice extension.................................................................... 46 Operating speeds..................................................................... 46 1.6 Documentation supplied................................................................... 47 1.6.1 Questions on documentation......................................................... 48 1.7 Notes on the operating instructions...................................................... 49 1.7.1 What do the symbols used mean?..................................................... 49 1.7.2 How are the operating instructions structured?..................................... 51 Division............................................................................. 51 Structure of the chapters............................................................ 51 Structure of the pages............................................................... 52 1.7.3 How do I find the information I need?.............................................. 53 Cross-references example............................................................. 54 1.7.4 What information is available for operations planning?............................. 56 1.8 Conversion table for US measuring units.................................................. 57 1.9 Training – Information................................................................... 59 1.10 Identification.......................................................................... 60 1.11 EC Declaration of Conformity............................................................ 62 2 Basic safety instructions...................................................................... 65 2.1 Intended use............................................................................. 65 2.1.1 Improper use....................................................................... 66 2.2 Organisational measures.................................................................. 67 2.3 Qualifications of the staff.............................................................. 69 2.4 Safety instructions for driving the truck crane.......................................... 70 2.5 Safety instructions for crane operation.................................................. 70 2.6 Notes on transporting persons............................................................ 72 Equipment for lifting persons............................................................ 72 Personnel................................................................................ 72 Operation................................................................................ 73 Truck crane.............................................................................. 74 3 Operating elements for driving................................................................. 77 3.1 Overview of the operating elements....................................................... 77 3.1.1 On the outside of the truck crane.................................................. 78 3.1.2 Driver's cab....................................................................... 80 Overview............................................................................. 80 Behind the cover..................................................................... 82 In the rear of the driver's cab...................................................... 82 3.1.3 Instrument panel................................................................... 83 Left/right........................................................................... 83 Middle............................................................................... 84 Middle............................................................................... 86 3.1.4 Display, driving mode.............................................................. 88 3.1.5 Steering column/steering wheel..................................................... 89 3.1.6 Transmission operating elements.................................................... 90 3.1.7 Tachograph......................................................................... 91 3.1.8 ECOS control unit.................................................................. 92 3.1.9 ECOS display – Main menu........................................................... 94 3.1.10 ECOS display – Submenus........................................................... 96 Level adjustment system submenu...................................................... 96 Settings submenu..................................................................... 98 Submenu Checking..................................................................... 99 Operating hours submenu..............................................................100 Warning submenu......................................................................100 Error submenu........................................................................101 3.1.11 Heating/Air-conditioning system...................................................102 Standard heating system..............................................................102 Auxiliary water heating system.......................................................103 3.1.12 Sockets for hand-held control.....................................................104 3.1.13 Outrigger control units...........................................................105 3.1.14 Control unit of the rear outrigger box............................................106 3.2 Short description of the operating elements..............................................107 3.2.1 Definition of direction information................................................107 Basic rule...........................................................................107 Switches and buttons.................................................................108 3.2.2 General notes on the operating elements............................................108 3.2.3 General rules for buttons and symbols on the display...............................109 3.2.4 Engine.............................................................................110 Steering column......................................................................110 Multipurpose switch..................................................................110 Instrument panel.....................................................................111 3.2.5 DEF system.........................................................................113 Instrument panel.....................................................................113 Display, driving mode................................................................114 ECOS display.........................................................................114 3.2.6 Electrical system..................................................................115 Control unit.........................................................................115 3.2.8 Transmission.......................................................................118 Transmission control unit............................................................118 Display, driving mode................................................................119 3.2.9 Reverse camera.....................................................................122 3.2.10 Final drive.......................................................................123 3.2.11 Brakes............................................................................124 Service brake........................................................................124 Additional brakes....................................................................124 Parking brake........................................................................125 3.2.12 Steering/separate steering........................................................126 Instrument panel.....................................................................126 ECOS display.........................................................................127 Driver's door........................................................................128 3.2.13 Suspension........................................................................129 3.2.14 Control unit of the rear outrigger box............................................130 3.2.15 Lighting/windscreen wipers/horn...................................................131 Steering column......................................................................131 Instrument panel.....................................................................131 Roof.................................................................................134 3.2.16 Level adjustment system...........................................................134 3.2.17 Tachograph/speedometer............................................................136 Tachograph...........................................................................136 Speedometer..........................................................................136 3.2.18 Diagnostics.......................................................................137 Displays/ submenu....................................................................137 3.2.19 Windows, doors, keys..............................................................138 Window winder........................................................................138 Doors................................................................................139 Keys.................................................................................139 3.2.20 Front flap........................................................................140 4 Starting/turning off the engine for driving....................................................143 4.1 Starting the engine from the driver's cab................................................143 4.1.1 CHECKLIST: Starting the engine.....................................................143 4.1.2 CHECKLIST: At low temperatures.....................................................146 4.1.3 Ladders and access ladders.........................................................146 Access ladders.......................................................................146 Ladders..............................................................................147 4.1.4 Refuelling.........................................................................150 Standard tank........................................................................150 Dual tank............................................................................151 DEF..................................................................................152 4.1.5 Inspections before starting the engine.............................................153 On the hydraulic tank................................................................153 Battery master switch................................................................154 Checking the hand-held control.......................................................154 4.1.6 Switch on the ignition.............................................................154 4.1.7 Lamp test/equalisation of the switching states.....................................155 Lamp test............................................................................155 Equalisation of the switching states.................................................156 4.1.8 Display – setting the brightness...................................................157 4.1.9 Start the engine...................................................................158 Without flame start system...........................................................159 With flame start system..............................................................160 4.1.10 Inspections after starting the engine.............................................161 Checking in the main menu............................................................161 Indicator lamps on the instrument panel..............................................162 4.1.11 Monitoring elements...............................................................164 Instrument panel.....................................................................164 4.1.12 Monitoring submenu................................................................165 4.1.13 Setting the idling speed..........................................................166 4.2 Turning off the engine...................................................................167 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.........167 After parking........................................................................167 4.2.2 Using the emergency stop switches..................................................168 Resetting the emergency stop switch..................................................168 4.3 Air intake inhibitor.....................................................................169 Releasing the air intake inhibitor.......................................................169 5 Driving........................................................................................173 5.1 Before driving...........................................................................173 5.1.1 CHECKLIST: Checks before on-road driving...........................................173 5.1.2 Checking the condition of the truck crane..........................................178 Electrical system....................................................................178 Adjusting the mirrors................................................................178 Warning plates for vehicle width.....................................................180 Displaying vehicle height............................................................180 Supply pressure......................................................................181 Parking brake........................................................................182 5.1.3 Adjusting the seats and steering column............................................183 Driver's seat........................................................................183 Passenger's seat.....................................................................184 Adjusting the steering column.......................................................185 5.1.4 Switching the suspension on/off....................................................186 Opening the submenu.................................................................186 Switching on the suspension.........................................................187 Switching off the suspension........................................................187 5.1.5 Setting the tachograph.............................................................188 Requirements.........................................................................188 If malfunction occurs................................................................188 Setting the tachograph..............................................................189 5.1.6 Displaying the operating hours.....................................................193 5.1.7 Settings/indications on the driving display........................................194 5.2 Operating the transmission...............................................................195 5.2.1 Switching on.......................................................................195 5.2.2 Switching the transmission to neutral position.....................................196 5.2.3 Selecting the direction of travel and starting gear................................197 Selecting the driving direction....................................................197 Selecting the starting gear .......................................................198 5.2.4 Changing the operating mode........................................................199 Change to automatic mode.............................................................199 Change to manual mode................................................................199 5.2.5 Starting...........................................................................200 5.2.6 Driving and changing gears.........................................................202 In automatic operating mode.........................................................202 In manual operating mode............................................................203 5.2.7 Changing the driving direction.....................................................204 5.2.8 Stopping...........................................................................204 Stopping for long periods...........................................................204 5.2.9 DM and RM transmission mode........................................................205 Switching on.........................................................................205 Switching off........................................................................206 Limiting maximum speed..............................................................206 5.2.10 On the roller type dynamometer....................................................208 5.2.11 Preheating transmission...........................................................208 5.3 Driving and turning off the truck crane..................................................209 5.3.1 Checks while driving...............................................................209 Right after starting................................................................209 While driving........................................................................211 5.3.2 Cruise control.....................................................................212 Switching on.........................................................................212 Switching off........................................................................213 5.3.3 Cruise control.....................................................................213 Switching on.........................................................................213 Switching off........................................................................213 5.3.4 Driving downhill...................................................................214 Starting.............................................................................214 Checks when driving downhill.......................................................215 Downshifting.........................................................................215 Additional brakes....................................................................216 5.3.5 Driving uphill.....................................................................218 Starting.............................................................................218 Driving..............................................................................218 5.3.6 Warning submenu....................................................................219 Meaning of the symbols...............................................................219 Exiting the submenu.................................................................221 5.3.7 Warning or malfunction messages on the instrument panel............................222 Meaning of the lamps.................................................................222 5.3.8 Overriding torque reduction........................................................224 5.3.9 Errors submenu.....................................................................225 5.3.10 Turning off the truck crane.......................................................225 Securing against rolling away........................................................225 When stationary for more than 8hours................................................226 5.3.11 Folding berth.....................................................................228 5.4 Off-road driving.........................................................................229 Adjustments to the transmission..........................................................229 Connections..............................................................................229 Changing the vehicle level...............................................................229 Rocking the vehicle free andtowing.....................................................229 5.4.1 Longitudinal and transverse differential locks.....................................230 5.4.2 Operating the level adjustment system..............................................232 Opening the submenu.................................................................232 Setting the onroad level...........................................................233 Pre-selecting suspension struts....................................................233 Changing the vehicle level...........................................................234 Viewing the current inclination.....................................................234 Exiting the submenu.................................................................235 5.4.3 Freeing truck crane stuck in terrain...............................................236 Rocking the truck crane free........................................................236 Towing free forward.................................................................237 Towing free backward................................................................237 5.5 Separate steering........................................................................238 5.5.1 Switching to separate steering.....................................................238 Manual...............................................................................239 Automatic............................................................................240 Switching to normal steering mode....................................................241 5.6 Heating and air-conditioning system......................................................242 5.6.1 Standard heating system............................................................242 Switching on.........................................................................242 Heating..............................................................................242 Air distribution.....................................................................243 Examples.............................................................................244 Switching off........................................................................244 5.6.2 Air-conditioning system............................................................245 Notes................................................................................245 Switching on/off.....................................................................245 Cooling..............................................................................246 Drying...............................................................................246 5.6.3 Auxiliary water heater.............................................................247 Preheating the engine................................................................247 Preheating the driver's cab.........................................................248 Switching on the auxiliary heater....................................................249 Switching off the auxiliary heater...................................................250 Setting the time and weekday.........................................................250 Saving the automatic heating start.................................................251 Setting the heating period..........................................................252 Switching the automatic heating start on and off....................................252 Setting the remaining time..........................................................253 5.7 Towing a trailer.........................................................................254 Effects on the axle loads................................................................254 Coupling the trailer....................................................................255 Connecting the supply lines.............................................................256 Removing supply lines..................................................................257 Uncoupling the trailer..................................................................257 Checking the braking force..............................................................259 6 Driving modes and rigging for on-road driving..................................................263 6.1 Driving modes............................................................................263 Information on the axle loads............................................................263 6.1.1 Information on how to use the tables...............................................264 6.1.2 Tables for a maximum axle load of 12 t.............................................265 Without removable supporting box.....................................................265 With removable supporting box........................................................266 6.1.3 Maximum permitted speeds with an axle load of over 12 t............................267 6.2 Rigging work for driving with a trailer..................................................268 6.2.1 Switching on the slewing gear freewheel............................................269 6.2.2 Switching on boom floating position................................................270 6.2.3 Switching on boom pre-tensioning...................................................271 6.2.4 Switching the superstructure driving lights on/off.................................272 Switching off........................................................................272 Switching on.........................................................................272 6.3 Removing/installing main boom............................................................273 Additional equipment required............................................................273 6.3.1 CHECKLIST: Removing the main boom..................................................275 Requirements.........................................................................275 Checklist............................................................................275 6.3.2 CHECKLIST: Installing the main boom................................................277 Requirements.........................................................................277 Checklist............................................................................277 6.3.3 Slinging the main boom.............................................................280 Marking..............................................................................280 Installing the lifting gear.........................................................280 Removing the sling gear..............................................................281 6.3.4 Retracting/fitting the derricking cylinder head pin................................283 Retracting the derricking cylinder head axle........................................284 Fitting the derricking cylinder head axle............................................285 6.3.5 Retracting/extending the boom pivot pin............................................286 Before retracting....................................................................286 After extending......................................................................287 Retracting/ extending the pivot pin..................................................288 6.3.6 Disconnecting/connecting hydraulics/electrical.....................................289 Disconnecting........................................................................289 Establishing.........................................................................290 6.3.7 Lifting the main boom off/on the turntable.........................................291 Lifting from the turntable...........................................................291 Lifting on to the turntable..........................................................292 6.3.8 Aligning the connecting points.....................................................293 6.3.9 Securing/releasing the derricking cylinder.........................................293 6.3.10 Transporting the main boom........................................................294 6.3.11 Inspections after main boom mounting..............................................295 6.4 Installing/removing outrigger beams......................................................297 6.4.1 CHECKLIST: Removing the outrigger beams............................................298 6.4.2 CHECKLIST: Installing the outrigger beams..........................................300 6.4.3 Preparing the truck crane..........................................................302 Requirements.........................................................................302 For removal..........................................................................302 6.4.4 Removing/attaching outrigger pads..................................................303 Removing outrigger pads.............................................................303 Attaching outrigger pads............................................................304 6.4.5 Disconnecting/establishing the hydraulic connection................................305 6.4.6 Establishing/disconnecting the electrical connection...............................306 6.4.7 Unscrewing/screwing in the spacers.................................................307 Unscrewing...........................................................................307 Screwing in..........................................................................308 6.4.8 Disconnecting/establishing the connections to the outrigger box....................309 6.4.9 Extending/retracting the outrigger beam............................................309 Extending outrigger beam............................................................309 Inserting the outrigger beam........................................................311 6.4.10 Transporting the outrigger beams..................................................313 6.5 Installing/removing the supporting box...................................................315 6.5.1 CHECKLIST: Removing the supporting box.............................................316 6.5.2 CHECKLIST: Installing the supporting box...........................................319 6.5.3 Rigging the outrigger span 7.98x8.50/1.00m......................................321 Front outrigger......................................................................322 Auxiliary supports...................................................................322 6.5.4 Establishing/disconnecting the pneumatic connection................................324 6.5.5 Establishing/disconnecting the electrical connection...............................325 6.5.6 Disconnecting/establishing the hydraulic connection................................326 6.5.7 Attaching/raising the supporting box with the truck crane..........................327 Requirements.........................................................................327 Lifting..............................................................................328 Attaching............................................................................329 6.5.8 Installing the reverse camera......................................................330 6.5.9 Crane movements during installation and removal....................................331 Requirements.........................................................................331 Before installation..................................................................331 After removal........................................................................331 6.5.10 Slinging points on the supporting box.............................................332 6.5.11 Fixing/releasing the outrigger pins...............................................333 Locking..............................................................................333 Releasing the locking pin............................................................334 6.5.12 Transporting the supporting box on the separate vehicle...........................335 Lashing eyelets......................................................................335 7 Malfunctions in driving mode...................................................................339 7.1 Emergency stop switch....................................................................339 7.2 What to do when a malfunction occurs in road traffic.....................................341 7.3 Towing the truck crane...................................................................343 7.3.1 Towing after engine/transmission damage............................................344 Compressed-air supply................................................................344 Electric power supply................................................................345 On the transmission.................................................................345 Axle drives..........................................................................346 Parking brake........................................................................346 Towing the truck crane out of the danger area........................................347 7.3.2 Starting to tow....................................................................347 7.4 Other emergency operations...............................................................349 7.4.1 Externally starting the truck crane................................................349 7.4.2 Battery charger....................................................................349 7.5 Wheels and tyres.........................................................................351 7.5.1 Wheel change.......................................................................351 Removing adamaged wheel.............................................................352 On the spare wheel holder............................................................352 Mounting a wheel.....................................................................353 7.5.2 Inflating the tyres yourself.......................................................355 Connecting the filling hose..........................................................355 Inflating the tyres..................................................................356 Removing the filling hose...........................................................356 7.6 Fuses....................................................................................357 Information on replacing fuses...........................................................357 7.6.1 Fuses in the driver's cab..........................................................358 Group F1.............................................................................358 Group F2.............................................................................359 Group F3.............................................................................359 Group F4.............................................................................360 Group F5.............................................................................360 Group F6.............................................................................361 Group F7.............................................................................361 Group F8.............................................................................361 Group F9.............................................................................362 Group F10............................................................................362 7.6.2 Fuses in the battery box...........................................................363 7.7 Troubleshooting..........................................................................365 7.7.1 Malfunctions in the engine.........................................................365 7.7.2 Malfunctions in the DEF system.....................................................367 7.7.3 Malfunctions in the transmission...................................................368 7.7.4 Malfunctions in the hydraulic drive (MegaDrive)....................................368 7.7.5 Service brake malfunctions.........................................................369 7.7.6 Steering malfunctions..............................................................370 7.7.7 Differential lock malfunctions.....................................................371 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler..........................371 7.7.9 Malfunctions on the suspension.....................................................372 7.7.10 Malfunctions on the level adjustment system.......................................372 7.7.11 Malfunctions on the ECOS carrier..................................................373 ECOS program version.................................................................373 General malfunctions................................................................373 Error messages.......................................................................374 Exiting the submenu.................................................................375 7.8 Procedure during malfunctions............................................................377 7.8.1 Switching on emergency operation in coolant circuit................................377 7.8.2 Procedure during engine malfunctions...............................................378 7.8.3 Procedure during transmission malfunctions.........................................379 Error messages.......................................................................379 Displaying error codes...............................................................381 8 Index..........................................................................................385 A............................................................................................387 B............................................................................................387 C............................................................................................387 D............................................................................................389 E............................................................................................390 F............................................................................................392 H............................................................................................393 I............................................................................................394 K............................................................................................394 L............................................................................................394 M............................................................................................395 O............................................................................................396 P............................................................................................397 R............................................................................................397 S............................................................................................399 T............................................................................................400 V............................................................................................402 W............................................................................................402 Operating manual Part 2 – Crane operation............................................................407 Additional pages ................................................................................417 Possible reeving methods on the main boom....................................................409 Technical Data...............................................................................417 Safety harness on the main boom..............................................................419 Anemometer and air traffic control light.....................................................425 Use of additional head sheaves...............................................................427 Mega Wing Lift (MWL).........................................................................429 Rigging with double-hook block...........................................................429 Correction Sheets................................................................................859 Axle load table..............................................................................859 9 Operating elements for crane operation.........................................................435 9.1 Overview of the operating elements.......................................................435 9.1.1 Exterior of the truck crane........................................................436 9.1.2 Crane cab..........................................................................438 9.1.3 Front panel........................................................................440 9.1.4 Side panel.........................................................................441 Below................................................................................441 Above................................................................................442 Console, rear........................................................................444 Standard heating system..............................................................445 Auxiliary water heater...............................................................446 Auxiliary air heater.................................................................447 9.1.5 Control panels.....................................................................448 Left.................................................................................448 Right................................................................................449 9.1.6 Control lever configuration........................................................450 Version 1............................................................................450 Version 2............................................................................451 9.1.7 ECOS control unit..................................................................452 9.1.8 ECOS display – main menu...........................................................454 9.1.9 ECOS display – submenus............................................................457 Superstructure lock submenu..........................................................457 Outriggers submenu..................................................................458 Telescoping submenu.................................................................460 Power unit speeds submenu............................................................462 Monitoring submenu..................................................................463 Settings submenu.....................................................................464 Operating hours submenu..............................................................466 Warning submenu......................................................................467 Errors submenu.......................................................................469 Working range limiter submenu........................................................470 9.1.10 RCL control unit..................................................................472 9.1.11 RCL display – main menu...........................................................474 9.1.12 RCL display – submenus............................................................475 Enter rigging mode submenu...........................................................475 Monitoring submenu..................................................................476 Rigging mode monitoring submenu.....................................................478 Lifting capacity table submenu.......................................................479 Working range submenu................................................................480 Errors submenu.......................................................................481 Settings submenu.....................................................................482 9.1.13 Hand-held controls................................................................483 Outriggers control panel.............................................................484 Rigging control panel................................................................485 9.1.14 Outrigger control units...........................................................486 Button...............................................................................486 Outrigger button.....................................................................487 Inclination and outrigger pressure display...........................................488 Raise axle display...................................................................489 9.2 Short description of the operating elements..............................................491 9.2.1 Definition of direction references.................................................491 Basic rule...........................................................................491 Switches.............................................................................491 9.2.2 General rules for buttons and symbols on the display...............................492 9.2.3 Engine.............................................................................493 Side panel...........................................................................493 Console, rear........................................................................494 ECOS display.........................................................................494 9.2.4 Seat contact switch and dead man's switch..........................................495 9.2.5 ECOS crane control.................................................................496 Control unit.........................................................................496 9.2.6 Outriggers.........................................................................499 Hand-held control....................................................................499 In the Outriggers submenu............................................................500 In the Settings submenu..............................................................501 On the outrigger control units.......................................................502 9.2.7 Inclination indicators.............................................................504 9.2.8 Raise axle.........................................................................505 Outrigger control units..............................................................505 9.2.9 Outrigger pressure displays........................................................507 Outriggers submenu..................................................................507 Outriggers control units............................................................507 9.2.10 Anemometer display................................................................507 9.2.11 Main hoist........................................................................508 9.2.12 Auxiliary hoist...................................................................510 9.2.13 Slewing gear......................................................................511 Submenu..............................................................................512 9.2.14 Derricking gear...................................................................513 9.2.15 Telescoping mechanism.............................................................515 Control panels.......................................................................515 Submenu..............................................................................516 In the Settings submenu..............................................................520 9.2.16 Hydraulic system..................................................................522 9.2.17 Superstructure lock/houselock submenu.............................................523 Houselock............................................................................524 9.2.18 Rated capacity limiter (RCL)......................................................525 Control unit.........................................................................525 Main menu............................................................................527 Rigging mode entry submenu...........................................................528 Monitoring submenu..................................................................532 Lifting capacity table submenu.......................................................536 Working range submenu................................................................537 Other................................................................................538 9.2.19 Electrical system.................................................................539 9.2.20 Lighting, windscreen wiper/washing system.........................................539 Lighting.............................................................................539 Windscreen wiper/washing system......................................................541 9.2.21 Hand-held control.................................................................542 Sockets for hand- held control.......................................................542 Engine control panel.................................................................543 Horn.................................................................................543 Outriggers control panel............................................................544 9.2.22 Windows, doors, keys..............................................................546 Windows..............................................................................546 Crane cab door.......................................................................546 Keys.................................................................................547 9.2.23 Diagnostics.......................................................................548 10 Starting/turning off the engine – for crane operation.........................................551 10.1 When starting the engine for the first time of the day..................................551 10.1.1 Refuelling........................................................................552 Fuel.................................................................................552 10.1.2 Checks before starting the engine.................................................553 On hydraulic tank....................................................................553 Checking hand- held control..........................................................554 10.1.3 Switching on the ignition.........................................................554 10.1.4 Lamp test/switching state equalisation............................................555 Lamp test............................................................................555 10.1.5 Adjusting display brightness......................................................557 10.1.6 Start the engine..................................................................558 Without flame start system...........................................................558 With flame start system..............................................................559 10.1.7 Checks after starting the engine..................................................560 10.1.8 Monitoring submenu................................................................561 10.1.9 Setting the idling speed..........................................................562 10.1.10 Switching off Economy mode.......................................................563 10.1.11 Overriding torque reduction......................................................564 10.2 Starting the engine – with the hand-held control........................................565 Requirements.............................................................................565 Starting the engine......................................................................565 10.3 Turning off the engine..................................................................567 10.3.1 During normal operation, with the ignition lock/with the hand- held control.......567 After turning off....................................................................567 10.3.2 In emergencies, with the emergency stop switches..................................568 Resetting the emergency stop switch..................................................568 11 Crane operation...............................................................................571 11.1 Before operating the crane..............................................................571 11.1.1 CHECKLIST: Checks before operating the crane......................................571 11.1.2 Checking the condition of the truck crane.........................................575 Fuel tank auxiliary heater...........................................................575 Visual inspection....................................................................575 Checking the position of the hoist ropes............................................576 Checking the electrical system......................................................576 11.1.3 Adjusting the crane cab seat and front control panel..............................577 Crane cab seat.......................................................................577 Front panel..........................................................................578 11.1.4 Checking the safety equipment.....................................................579 Rated capacity limiter...............................................................579 Lifting limit switch................................................................579 Emergency stop switch................................................................580 Seat contact switch..................................................................581 11.1.5 Earthing the load.................................................................582 11.1.6 Locking/unlocking the superstructure..............................................583 Locking points.......................................................................583 Locking the superstructure..........................................................584 Unlocking the superstructure........................................................584 11.1.7 Switching the houselock on/off....................................................585 Switching on the houselock..........................................................585 Switching off the houselock.........................................................587 11.2 Operation of the rated capacity limiter.................................................589 11.2.1 Switching on the RCL..............................................................590 Switching on.........................................................................590 Brightness of the displays...........................................................592 11.2.2 Entering the rigging mode.........................................................593 Entering individual components.......................................................594 Entering the RCL code...............................................................598 Entering the reeving value.........................................................599 Accepting the rigging mode..........................................................599 11.2.3 Checks before operating the crane.................................................601 Opening the submenu.................................................................601 Checks...............................................................................602 11.2.4 Displays during crane operation...................................................604 11.2.5 RCL early warning.................................................................607 11.2.6 RCL shutdown......................................................................607 Shutdown due to overload.............................................................607 11.2.7 Display during errors.............................................................609 11.2.8 RCL override......................................................................610 Table – error/ information codes.....................................................618 11.2.9 Displaying the lifting capacity tables............................................619 11.2.10 Entering the time/date...........................................................621 11.3 Crane operation with main boom..........................................................623 11.3.1 Checks during crane operation.....................................................623 Horizontal alignment................................................................623 Safe distances......................................................................623 Checking the wind speed..............................................................624 11.3.2 Permissible slewing ranges and working positions..................................625 360 slewing range...................................................................625 0 to the rear working position......................................................625 180 to the front rigging position...................................................625 11.3.3 Main hoist........................................................................626 Switching on the main hoist..........................................................627 Lifting and lowering................................................................627 Switching off the main hoist........................................................628 11.3.4 Auxiliary hoist...................................................................629 Switching on the auxiliary hoist....................................................629 Lifting and lowering................................................................630 Switching off the auxiliary hoist...................................................631 11.3.5 Lifting limit switch and lowering limit switch....................................632 Lifting limit switch.................................................................632 Lowering limit switch................................................................633 11.3.6 Derricking gear...................................................................634 Switching on the derricking gear....................................................634 Raising and lowering................................................................635 Re-enabling raising function........................................................636 Switching off the derricking gear....................................................636 Derricking gear warning..............................................................636 Lowering the main boom to ahorizontal position.....................................637 11.3.7 Telescoping mechanism.............................................................638 Overview.............................................................................639 Telescoping process.................................................................639 Assignment for display...............................................................641 Fixed length, intermediate length, telescoping length...............................643 Telescope status.....................................................................644 Telescoping sequence................................................................644 Checks before starting work.........................................................645 Switching on the telescoping mechanism..............................................646 Function of the control lever........................................................646 Switching off the telescoping mechanism.............................................648 Manual telescoping..................................................................649 Checking the initial position.......................................................649 Unlocking the telescoping cylinder.................................................651 Extending/retracting the telescoping cylinder........................................654 Locking the telescoping cylinder...................................................655 Unlocking the telescopic section....................................................656 Telescoping the telescopic section..................................................658 Locking telescopic sections........................................................659 Locking the telescopic section for on-road driving.................................660 Telescoping with teleautomation......................................................661 Telescoping the main boom when horizontal............................................665 11.3.8 High-speed mode...................................................................666 Switch on function..................................................................666 Derricking gear/ telescoping mechanism..............................................666 Hoists...............................................................................667 11.3.9 Slewing gear......................................................................668 Braking the slewing movement.......................................................668 Switching on the slewing gear........................................................669 Releasing the slewing gear brake.....................................................669 Engaging the slewing gear brake......................................................669 Slewing..............................................................................670 Braking the slewing movement.......................................................672 Slewing gear freewheel..............................................................672 Switch off the slewing gear..........................................................673 11.3.10 Possible movement combinations...................................................673 11.3.11 Hydraulic oil cooling............................................................674 11.4 Settings and displays for crane operation...............................................675 11.4.1 Inclining the crane cab...........................................................675 11.4.2 Setting idling speed..............................................................676 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.......................676 11.4.4 Limiting the power unit speeds....................................................677 11.4.5 Setting the characteristic curves for the control levers..........................678 11.4.6 Using the slewable spotlights.....................................................679 11.4.7 Displaying the operating hours....................................................680 11.4.8 Warning submenu...................................................................681 Meaning of the symbols...............................................................681 Exiting the submenu.................................................................684 11.4.9 Errors submenu....................................................................684 11.5 Working range limiter...................................................................685 11.5.1 Opening the working range limiter submenu.........................................686 11.5.2 Viewing current settings..........................................................686 11.5.3 Entering limit values.............................................................688 Overall height/ working radius......................................................688 Slewing angle........................................................................689 Entering objects.....................................................................691 11.5.4 Entering limit values/objects manually............................................694 Limit values.........................................................................694 Objects..............................................................................695 11.5.5 Switching monitoring functions on/off.............................................696 11.5.6 Shutdown by working range limiter.................................................697 11.6 Work break..............................................................................698 11.6.1 In case of short work breaks......................................................698 11.6.2 In case of work breaks of more than 8 hours.......................................699 To secure the truck crane............................................................699 11.7 Heating and air-conditioning system.....................................................700 11.7.1 Standard heating system...........................................................700 Switching on.........................................................................700 Heating..............................................................................700 Air distribution.....................................................................701 Switching off........................................................................701 11.7.2 Air-conditioning system...........................................................702 Warnings.............................................................................702 Switching on/off.....................................................................702 Cooling..............................................................................703 Drying the air.......................................................................703 11.7.3 Auxiliary water heater............................................................704 Preheating the engine...............................................................704 Preheating the crane cab............................................................705 Switching on.........................................................................706 Setting the day and time.............................................................707 Storing the heating start..........................................................708 Setting the heating period..........................................................709 Switching heating start on/off......................................................709 Switching off........................................................................710 Setting the remaining time..........................................................710 11.7.4 Auxiliary air heater..............................................................711 Switching on.........................................................................711 Temperature..........................................................................712 Switching off........................................................................712 Additional functions................................................................712 11.8 CraneSTAR system........................................................................713 11.8.1 Overview..........................................................................713 11.8.2 Position of the components........................................................713 12 Rigging work..................................................................................717 12.1 Rigging work checklists for crane operation with the main boom..........................717 12.1.1 CHECKLIST: Rigging................................................................717 12.1.2 CHECKLIST: Unrigging..............................................................721 12.2 Choosing a suitable site................................................................725 12.2.1 Determining the required ground bearing area......................................725 12.2.2 Safe distance from slopes and pits................................................728 12.2.3 Earthing the truck crane..........................................................729 12.2.4 Safe distance from electrical cables..............................................730 12.3 Rigging work after driving with a trailer...............................................733 12.3.1 Switching off the boom floating position..........................................733 12.3.2 Switching off the slewing gear freewheel..........................................734 Before slewing.......................................................................734 12.3.3 Switching off boom pre-tensioning.................................................735 12.4 Connecting/disconnecting the hand-held control..........................................737 12.5 Starting the engine for driving for rigging work........................................739 12.5.1 Starting/turning off the engine with the hand-held control........................739 Requirements.........................................................................739 Starting the engine..................................................................740 Turning off the engine...............................................................740 12.5.2 Starting/turning off the engine from the crane cab................................741 Requirements.........................................................................741 Starting the engine..................................................................741 After starting the engine............................................................742 Turning off the engine...............................................................742 12.5.3 Starting/turning off the engine from the outrigger control units..................743 Requirements.........................................................................743 Starting the engine..................................................................743 Turning off the engine...............................................................743 12.6 Outriggers..............................................................................745 12.6.1 CHECKLIST: Extending the outriggers...............................................745 12.6.2 CHECKLIST: Retracting the outriggers..............................................747 12.6.3 Permissible outrigger spans.......................................................748 12.6.4 Preparing the truck crane.........................................................749 In the driver's cab..................................................................749 Outriggers control units............................................................749 12.6.5 Setting the outrigger spans.......................................................750 For on-road driving.................................................................752 12.6.6 Extending/retracting outrigger beams..............................................753 From the control units...............................................................754 With the hand- held control..........................................................755 From the crane cab...................................................................757 12.6.7 Moving the outrigger pads into working/driving position...........................759 12.6.8 Enlarging the ground bearing area.................................................760 12.6.9 Extending/retracting supporting cylinders.........................................761 From the control units...............................................................762 With the hand- held control..........................................................763 From the crane cab...................................................................764 12.6.10 Levelling the truck crane on outriggers..........................................766 Inclination indicators..............................................................766 Requirements.........................................................................767 Manual alignment....................................................................768 Automatic alignment.................................................................769 12.6.11 Levelling the free-standing truck crane..........................................771 12.6.12 Outrigger pressure display.......................................................773 12.7 Rigging/unrigging the counterweight.....................................................775 12.7.1 Counterweight sections............................................................775 Version A............................................................................775 Version B............................................................................775 12.7.2 Identification....................................................................776 12.7.3 Slinging points on the counterweight sections.....................................777 12.7.4 CHECKLIST: Counterweight, rigging.................................................778 12.7.5 CHECKLIST: Counterweight, unrigging...............................................781 12.7.6 Assembling counterweight combination..............................................783 Setting down 10t sections/blocks version A.........................................784 Combinations for the basic equipment in version A....................................785 Setting down 10t sections/blocks version B.........................................790 Combinations for the basic equipment in version B....................................791 12.7.7 Securing/releasing 10 t blocks....................................................795 Tensioning device....................................................................795 Securing 10t blocks................................................................796 Releasing 10t blocks...............................................................796 12.7.8 Establishing/disconnecting the hydraulic connection...............................797 Establishing.........................................................................797 Disconnecting........................................................................797 12.7.9 Making/breaking the electrical connection.........................................798 Establishing.........................................................................798 Disconnecting........................................................................798 12.7.10 Rigging counterweight............................................................799 Hand-held control....................................................................799 Counterweight rigging...............................................................800 Unrigging counterweight.............................................................801 Counterweight safety valve...........................................................803 12.7.11 Raising and lowering 10 t counterweight blocks with a mounted auxiliary hoist....804 12.7.12 Slewing with rigged counterweight................................................805 12.8 Rigging the auxiliary hoist.............................................................807 12.8.1 Identification....................................................................807 12.8.2 Slinging points and transport.....................................................808 Slinging points......................................................................808 Transport............................................................................809 12.8.3 CHECKLIST: Mounting the auxiliary hoist...........................................810 Requirements.........................................................................810 12.8.4 CHECKLIST: Removing the auxiliary hoist...........................................812 Requirements.........................................................................812 12.8.5 Lifting the auxiliary hoist onto the 15 t base plate..............................814 12.8.6 Raising/setting down the catcher..................................................815 Raising..............................................................................815 Setting down.........................................................................815 12.8.7 Establishing/disconnecting the hydraulic connection...............................816 Establishing.........................................................................816 Disconnecting........................................................................816 12.8.8 Making/breaking the electrical connection.........................................817 Establishing.........................................................................817 Disconnecting........................................................................817 12.8.9 Locking/unlocking the auxiliary hoist.............................................818 Auxiliary hoist safety valve.........................................................818 Locking..............................................................................819 Releasing the locking pin............................................................820 Releasing the locking pin............................................................820 12.8.10 Checking the auxiliary hoist for correct functioning.............................821 With the hand- held control..........................................................821 In the crane cab.....................................................................821 12.8.11 Securing the upper hook block in the catcher.....................................822 12.8.12 Railings on the auxiliary hoist..................................................822 12.8.13 Permissible applications for the auxiliary hoist.................................823 Replacement for the main hoist.......................................................823 Alternating operation with themain and the auxiliary hoist.........................824 12.9 Rigging work on the main boom...........................................................825 12.9.1 Hook block on the bumper..........................................................825 Picking up the hook block............................................................825 Attaching the hook block.............................................................826 12.9.2 Hook block on a separate vehicle..................................................827 Picking up the hook block...........................................................828 Setting down the hook block.........................................................828 12.9.3 Reeving and unreeving the hoist rope..............................................830 Rope end fitting.....................................................................830 Reeving the hoist rope...............................................................831 Unreeving the hoist rope............................................................834 12.9.4 Possible reeving methods on the main boom.........................................835 With 7 head sheaves..................................................................835 With 10 head sheaves.................................................................838 12.9.5 Installing/removing the lifting limit switch......................................842 Installing the lifting limit switch..................................................842 Removing the lifting limit switch....................................................845 12.9.6 Locking/Unlocking the lifting limit switch........................................847 Locking..............................................................................847 Unlocking...........................................................................847 12.9.7 Anemometer and air traffic control light..........................................848 Installing...........................................................................848 Removing.............................................................................849 12.10 Other rigging work.....................................................................851 12.10.1 Railings on the turntable........................................................851 12.10.2 Cameras for crane operation......................................................852 Cameras on the hoists................................................................852 Camera on main boom..................................................................853 13 Driving with rigged truck crane...............................................................857 13.1 Driving path............................................................................857 13.2 Permissible rigging modes and axle loads................................................858 Axle load table..........................................................................859 13.3 Before driving..........................................................................860 13.3.1 Securing the superstructure against slewing.......................................860 13.3.2 Checking tyre pressure and wind speed.............................................861 13.3.3 Putting the truck crane on the wheels.............................................862 13.3.4 Transmission/connections..........................................................864 Transmission.........................................................................864 Switching on separate steering......................................................864 13.4 While driving...........................................................................864 13.5 After driving...........................................................................866 14 Malfunctions during crane operation...........................................................869 14.1 Emergency stop switch...................................................................869 14.2 What to do when a malfunction occurs during crane operation.............................871 Load can be lowered.....................................................................871 Load cannot be lowered...................................................................871 14.3 Fuses...................................................................................873 Information on replacing fuses.........................................................873 14.3.1 Fuses on the turntable............................................................874 Fuse groups F1/F2/F3................................................................874 Fuses on the circuit board..........................................................875 14.3.2 Fuses in the crane cab............................................................877 14.3.3 RCL fuses.........................................................................879 14.4 Troubleshooting.........................................................................880 14.4.1 Malfunctions on the engine........................................................880 14.4.2 Malfunctions on the main hoist/auxiliary hoist....................................881 14.4.3 Malfunctions in the hoist cameras.................................................882 14.4.4 Malfunctions in the main boom camera..............................................882 14.4.5 Malfunctions in the derricking gear...............................................883 14.4.6 Malfunctions in the telescoping mechanism.........................................884 Telescoping mechanism error messages.................................................885 14.4.7 Malfunctions in the slewing gear..................................................887 14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.........................888 14.4.9 Malfunctions when inclining the crane cab.........................................888 14.4.10 Malfunctions when operating with the hand-held control...........................888 14.4.11 Malfunctions on the outriggers...................................................889 14.4.12 Troubleshooting on the RCL.......................................................890 General malfunctions................................................................890 Error messages in the Monitoring submenu.............................................891 Displays in the Error submenu........................................................893 Error codes table....................................................................895 Switch off sensor/ tachogenerator...................................................898 14.4.13 Malfunctions ECOS – superstructure...............................................899 ECOS programme version...............................................................899 General malfunctions................................................................899 Error messages.......................................................................900 Exiting the submenu.................................................................901 14.4.14 Malfunctions on the CraneSTAR system.............................................902 14.5 Emergency operations and programmes.....................................................907 14.5.1 Mechanical emergency activation for retracting....................................908 Checks before emergency operation...................................................908 Procedure............................................................................908 Mechanical emergency operation......................................................909 14.5.2 Telescoping emergency programme...................................................911 Starting the emergency programme...................................................911 Determining type of error...........................................................912 Error on length indicator............................................................913 Error on proximity switch............................................................917 Terminating emergency programme....................................................918 Tables for approaching the locking points............................................919 14.5.3 Entering the current telescoping..................................................921 14.5.4 Emergency operation with the hand-held control....................................923 Preparations.........................................................................923 Operating a power unit...............................................................924 Stopping operations.................................................................926 Stopping movements in emergencies...................................................926 Turning off the engine...............................................................926 14.6 Hydraulic emergency operation...........................................................927 14.6.1 Functionality.....................................................................927 14.6.2 Connecting/disconnecting hoses....................................................928 Establishing.........................................................................928 Disconnecting.......................................................................929 14.6.3 Switching emergency operation on/off..............................................930 14.6.4 Establishing the required hydraulic circuits......................................931 Switching over valves................................................................931 14.6.5 Performing emergency operation....................................................933 Slewing..............................................................................933 Derricking...........................................................................934 Lifting/lowering.....................................................................934 14.6.6 After emergency operation.........................................................935 Switching off emergency operation...................................................935 Switching over to crane operation....................................................935 Disconnecting the hoses..............................................................935 14.6.7 Emergency supply of another crane.................................................936 For emergency supply.................................................................936 After emergency supply...............................................................936 15 Index.........................................................................................939 A............................................................................................941 B............................................................................................941 C............................................................................................941 D............................................................................................943 E............................................................................................944 F............................................................................................946 H............................................................................................947 I............................................................................................948 K............................................................................................948 L............................................................................................948 M............................................................................................949 O............................................................................................950 P............................................................................................951 R............................................................................................951 S............................................................................................953 T............................................................................................954 V............................................................................................956 W............................................................................................956
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