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Grove Crane GMK 6400 Driving Operating Manual 3112992 – PDF DOWNLOAD
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Description
Grove Crane GMK 6400 Driving Operating Manual 3112992 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6400 Driving Operating Manual 3112992 – PDF DOWNLOAD
Language : English
Pages : 956
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 6400 Driving 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; à Technical
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 unau- thorized use of the GMK
6400 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 6400 Driving 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 1 Overview....................................................................................... 27 1.1 Accidents................................................................................ 27 1.2 Branch offices........................................................................... 28 1.2.1 Manitowoc Crane Care............................................................... 28 1.2.2 Dealer list........................................................................ 28 1.3 Warranty specifications.................................................................. 28 1.4 Terms used............................................................................... 30 1.5 Technical data........................................................................... 33 1.5.1 Maximum lifting capacity........................................................... 33 1.5.2 Dimensions and weights of the truck crane, axle loads.............................. 34 Dimensions........................................................................... 35 Weight and axle loads................................................................ 35 1.5.3 Dimensions and weights of removable parts.......................................... 36 Spare wheel.......................................................................... 36 Outriggers........................................................................... 36 Main boom............................................................................ 37 Hook blocks and hook tackle.......................................................... 37 Auxiliary hoist...................................................................... 37 Counterweightsections version A...................................................... 38 Counterweightsections version B...................................................... 38 1.5.4 Carrier............................................................................ 39 Engine............................................................................... 39 Transmission......................................................................... 39 Transfer case........................................................................ 39 Axle lines........................................................................... 39 Steering............................................................................. 39 Tyres................................................................................ 40 Electrical system.................................................................... 40 Tool................................................................................. 40 Towing coupling...................................................................... 40 Driving speeds....................................................................... 40 Climbing ability..................................................................... 40 Outriggers........................................................................... 41 Turning radii........................................................................ 42 1.5.5 Superstructure..................................................................... 43 Main hoist........................................................................... 43 Auxiliary hoist...................................................................... 43 Slewing gears........................................................................ 43 Derricking gear...................................................................... 44 Main boom............................................................................ 44 Lattice extension.................................................................... 44 Operating speeds..................................................................... 44 1.6 Documentation supplied................................................................... 45 1.6.1 Questions on documentation......................................................... 46 1.7 Notes on the operating instructions...................................................... 47 1.7.1 What do the symbols used mean?..................................................... 47 1.7.2 How are the operating instructions structured?..................................... 49 Division............................................................................. 49 Structure of the chapters............................................................ 49 Structure of the pages............................................................... 50 1.7.3 How do I find the information I need?.............................................. 51 Cross-references example............................................................. 52 1.7.4 What information is available for operations planning?............................. 54 1.8 Conversion table for US measuring units.................................................. 55 1.9 Training – Information................................................................... 57 1.10 Identification.......................................................................... 58 1.11 EC Declaration of Conformity............................................................ 60 2 Basic safety instructions...................................................................... 63 2.1 Intended use............................................................................. 63 2.1.1 Improper use....................................................................... 64 2.2 Organisational measures.................................................................. 65 2.3 Qualifications of the staff.............................................................. 67 2.4 Safety instructions for driving the truck crane.......................................... 68 2.5 Safety instructions for crane operation.................................................. 68 2.6 Notes on transporting persons............................................................ 70 Equipment for lifting persons............................................................ 70 Personnel................................................................................ 70 Operation................................................................................ 71 Truck crane.............................................................................. 72 3 Operating elements for driving................................................................. 75 3.1 Overview of the operating elements....................................................... 75 3.1.1 On the outside of the truck crane.................................................. 76 3.1.2 Driver's cab....................................................................... 78 Overview............................................................................. 78 Behind the cover..................................................................... 80 In the rear of the driver's cab...................................................... 80 3.1.3 Instrument panel................................................................... 81 Left/right........................................................................... 81 Middle............................................................................... 82 Middle............................................................................... 84 3.1.4 Display, driving mode.............................................................. 86 3.1.5 Steering column/steering wheel..................................................... 87 3.1.6 Transmission operating elements.................................................... 88 3.1.7 Tachograph......................................................................... 89 3.1.8 ECOS control unit.................................................................. 90 3.1.9 ECOS display – Main menu........................................................... 92 3.1.10 ECOS display – Submenus........................................................... 94 Level adjustment system submenu...................................................... 94 Settings submenu..................................................................... 96 Submenu Checking..................................................................... 97 Operating hours submenu.............................................................. 98 Warning submenu...................................................................... 98 Error submenu........................................................................ 99 3.1.11 Heating/Air-conditioning system...................................................100 Standard heating system..............................................................100 Auxiliary water heating system.......................................................101 3.1.12 Sockets for hand-held control.....................................................102 3.1.13 Outrigger control units...........................................................103 3.1.14 Control unit of the rear outrigger box............................................104 3.2 Short description of the operating elements..............................................105 3.2.1 Definition of direction information................................................105 Basic rule...........................................................................105 Switches and buttons.................................................................106 3.2.2 General notes on the operating elements............................................106 3.2.3 General rules for buttons and symbols on the display...............................107 3.2.4 Engine.............................................................................108 Steering column......................................................................108 Multipurpose switch..................................................................108 Instrument panel.....................................................................109 3.2.5 DEF system.........................................................................111 Instrument panel.....................................................................111 Display, driving mode................................................................112 ECOS display.........................................................................112 3.2.6 Electrical system..................................................................113 Control unit.........................................................................113 3.2.8 Transmission.......................................................................116 Transmission control unit............................................................116 Display, driving mode................................................................117 3.2.9 Reverse camera.....................................................................120 3.2.10 Final drive.......................................................................121 3.2.11 Brakes............................................................................122 Service brake........................................................................122 Additional brakes....................................................................122 Parking brake........................................................................123 3.2.12 Steering/separate steering........................................................124 Instrument panel.....................................................................124 ECOS display.........................................................................125 Driver's door........................................................................126 3.2.13 Suspension........................................................................127 3.2.14 Control unit of the rear outrigger box............................................128 3.2.15 Lighting/windscreen wipers/horn...................................................129 Steering column......................................................................129 Instrument panel.....................................................................129 Roof.................................................................................132 3.2.16 Level adjustment system...........................................................132 3.2.17 Tachograph/speedometer............................................................134 Tachograph...........................................................................134 Speedometer..........................................................................134 3.2.18 Diagnostics.......................................................................135 Displays/ submenu....................................................................135 3.2.19 Windows, doors, keys..............................................................136 Window winder........................................................................136 Doors................................................................................137 Keys.................................................................................137 3.2.20 Front flap........................................................................138 4 Starting/turning off the engine for driving....................................................141 4.1 Starting the engine from the driver's cab................................................141 4.1.1 CHECKLIST: Starting the engine.....................................................141 4.1.2 CHECKLIST: At low temperatures.....................................................144 4.1.3 Ladders and access ladders.........................................................144 Access ladders.......................................................................144 Ladders..............................................................................145 4.1.4 Refuelling.........................................................................148 Standard tank........................................................................148 Dual tank............................................................................149 DEF..................................................................................150 4.1.5 Inspections before starting the engine.............................................151 On the hydraulic tank................................................................151 Battery master switch................................................................152 Checking the hand-held control.......................................................152 4.1.6 Switch on the ignition.............................................................152 4.1.7 Lamp test/equalisation of the switching states.....................................153 Lamp test............................................................................153 Equalisation of the switching states.................................................154 4.1.8 Display – setting the brightness...................................................155 4.1.9 Start the engine...................................................................156 Without flame start system...........................................................157 With flame start system..............................................................158 4.1.10 Inspections after starting the engine.............................................159 Checking in the main menu............................................................159 Indicator lamps on the instrument panel..............................................160 4.1.11 Monitoring elements...............................................................162 Instrument panel.....................................................................162 4.1.12 Monitoring submenu................................................................163 4.1.13 Setting the idling speed..........................................................164 4.2 Turning off the engine...................................................................165 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.........165 After parking........................................................................165 4.2.2 Using the emergency stop switches..................................................166 Resetting the emergency stop switch..................................................166 4.3 Air intake inhibitor.....................................................................167 Releasing the air intake inhibitor.......................................................167 5 Driving........................................................................................171 5.1 Before driving...........................................................................171 5.1.1 CHECKLIST: Checks before on-road driving...........................................171 5.1.2 Checking the condition of the truck crane..........................................176 Electrical system....................................................................176 Adjusting the mirrors................................................................176 Warning plates for vehicle width.....................................................178 Displaying vehicle height............................................................178 Supply pressure......................................................................179 Parking brake........................................................................180 5.1.3 Adjusting the seats and steering column............................................181 Driver's seat........................................................................181 Passenger's seat.....................................................................182 Adjusting the steering column.......................................................183 5.1.4 Switching the suspension on/off....................................................184 Opening the submenu.................................................................184 Switching on the suspension.........................................................185 Switching off the suspension........................................................185 5.1.5 Setting the tachograph.............................................................186 Requirements.........................................................................186 If malfunction occurs................................................................186 Setting the tachograph..............................................................187 5.1.6 Displaying the operating hours.....................................................191 5.1.7 Settings/indications on the driving display........................................192 5.2 Operating the transmission...............................................................193 5.2.1 Switching on.......................................................................193 5.2.2 Switching the transmission to neutral position.....................................194 5.2.3 Selecting the direction of travel and starting gear................................195 Selecting the driving direction....................................................195 Selecting the starting gear .......................................................196 5.2.4 Changing the operating mode........................................................197 Change to automatic mode.............................................................197 Change to manual mode................................................................197 5.2.5 Starting...........................................................................198 5.2.6 Driving and changing gears.........................................................200 In automatic operating mode.........................................................200 In manual operating mode............................................................201 5.2.7 Changing the driving direction.....................................................202 5.2.8 Stopping...........................................................................202 Stopping for long periods...........................................................202 5.2.9 DM and RM transmission mode........................................................203 Switching on.........................................................................203 Switching off........................................................................204 Limiting maximum speed..............................................................204 5.2.10 On the roller type dynamometer....................................................206 5.2.11 Preheating transmission...........................................................206 5.3 Driving and turning off the truck crane..................................................207 5.3.1 Checks while driving...............................................................207 Right after starting................................................................207 While driving........................................................................209 5.3.2 Cruise control.....................................................................210 Switching on.........................................................................210 Switching off........................................................................211 5.3.3 Cruise control.....................................................................211 Switching on.........................................................................211 Switching off........................................................................211 5.3.4 Driving downhill...................................................................212 Starting.............................................................................212 Checks when driving downhill.......................................................213 Downshifting.........................................................................213 Additional brakes....................................................................214 5.3.5 Driving uphill.....................................................................216 Starting.............................................................................216 Driving..............................................................................216 5.3.6 Warning submenu....................................................................217 Meaning of the symbols...............................................................217 Exiting the submenu.................................................................219 5.3.7 Warning or malfunction messages on the instrument panel............................220 Meaning of the lamps.................................................................220 5.3.8 Overriding torque reduction........................................................222 5.3.9 Errors submenu.....................................................................223 5.3.10 Turning off the truck crane.......................................................223 Securing against rolling away........................................................223 When stationary for more than 8hours................................................224 5.3.11 Folding berth.....................................................................226 5.4 Off-road driving.........................................................................227 Adjustments to the transmission..........................................................227 Connections..............................................................................227 Changing the vehicle level...............................................................227 Rocking the vehicle free andtowing.....................................................227 5.4.1 Longitudinal and transverse differential locks.....................................228 5.4.2 Operating the level adjustment system..............................................230 Opening the submenu.................................................................230 Setting the onroad level...........................................................231 Pre-selecting suspension struts....................................................231 Changing the vehicle level...........................................................232 Viewing the current inclination.....................................................232 Exiting the submenu.................................................................233 5.4.3 Freeing truck crane stuck in terrain...............................................234 Rocking the truck crane free........................................................234 Towing free forward.................................................................235 Towing free backward................................................................235 5.5 Separate steering........................................................................236 5.5.1 Switching to separate steering.....................................................236 Manual...............................................................................237 Automatic............................................................................238 Switching to normal steering mode....................................................239 5.6 Heating and air-conditioning system......................................................240 5.6.1 Standard heating system............................................................240 Switching on.........................................................................240 Heating..............................................................................240 Air distribution.....................................................................241 Examples.............................................................................242 Switching off........................................................................242 5.6.2 Air-conditioning system............................................................243 Notes................................................................................243 Switching on/off.....................................................................243 Cooling..............................................................................244 Drying...............................................................................244 5.6.3 Auxiliary water heater.............................................................245 Preheating the engine................................................................245 Preheating the driver's cab.........................................................246 Switching on the auxiliary heater....................................................247 Switching off the auxiliary heater...................................................248 Setting the time and weekday.........................................................248 Saving the automatic heating start.................................................249 Setting the heating period..........................................................250 Switching the automatic heating start on and off....................................250 Setting the remaining time..........................................................251 5.7 Towing a trailer.........................................................................252 Effects on the axle loads................................................................252 Coupling the trailer....................................................................253 Connecting the supply lines.............................................................254 Removing supply lines..................................................................255 Uncoupling the trailer..................................................................255 Checking the braking force..............................................................257 6 Driving modes and rigging for on-road driving..................................................261 6.1 Driving modes............................................................................261 Information on the axle loads............................................................261 6.1.1 Information on how to use the tables...............................................262 6.1.2 Tables for a maximum axle load of 12 t.............................................263 Without removable supporting box.....................................................263 With removable supporting box........................................................264 6.1.3 Maximum permitted speeds with an axle load of over 12 t............................265 6.2 Rigging work for driving with a trailer..................................................266 6.2.1 Switching on the slewing gear freewheel............................................267 6.2.2 Switching on boom floating position................................................268 6.2.3 Switching on boom pre-tensioning...................................................269 6.2.4 Switching the superstructure driving lights on/off.................................270 Switching off........................................................................270 Switching on.........................................................................270 6.3 Removing/installing main boom............................................................271 Additional equipment required............................................................271 6.3.1 CHECKLIST: Removing the main boom..................................................273 Requirements.........................................................................273 Checklist............................................................................273 6.3.2 CHECKLIST: Installing the main boom................................................275 Requirements.........................................................................275 Checklist............................................................................275 6.3.3 Slinging the main boom.............................................................278 Marking..............................................................................278 Installing the lifting gear.........................................................278 Removing the sling gear..............................................................279 6.3.4 Retracting/fitting the derricking cylinder head pin................................281 Retracting the derricking cylinder head axle........................................282 Fitting the derricking cylinder head axle............................................283 6.3.5 Retracting/extending the boom pivot pin............................................284 Before retracting....................................................................284 After extending......................................................................285 Retracting/ extending the pivot pin..................................................286 6.3.6 Disconnecting/connecting hydraulics/electrical.....................................287 Disconnecting........................................................................287 Establishing.........................................................................288 6.3.7 Lifting the main boom off/on the turntable.........................................289 Lifting from the turntable...........................................................289 Lifting on to the turntable..........................................................290 6.3.8 Aligning the connecting points.....................................................291 6.3.9 Securing/releasing the derricking cylinder.........................................291 6.3.10 Transporting the main boom........................................................292 6.3.11 Inspections after main boom mounting..............................................293 6.4 Installing/removing outrigger beams......................................................295 6.4.1 CHECKLIST: Removing the outrigger beams............................................296 6.4.2 CHECKLIST: Installing the outrigger beams..........................................298 6.4.3 Preparing the truck crane..........................................................300 Requirements.........................................................................300 For removal..........................................................................300 6.4.4 Removing/attaching outrigger pads..................................................301 Removing outrigger pads.............................................................301 Attaching outrigger pads............................................................302 6.4.5 Disconnecting/establishing the hydraulic connection................................303 6.4.6 Establishing/disconnecting the electrical connection...............................304 6.4.7 Unscrewing/screwing in the spacers.................................................305 Unscrewing...........................................................................305 Screwing in..........................................................................306 6.4.8 Disconnecting/establishing the connections to the outrigger box....................307 6.4.9 Extending/retracting the outrigger beam............................................307 Extending outrigger beam............................................................307 Inserting the outrigger beam........................................................309 6.4.10 Transporting the outrigger beams..................................................311 6.5 Installing/removing the supporting box...................................................313 6.5.1 CHECKLIST: Removing the supporting box.............................................314 6.5.2 CHECKLIST: Installing the supporting box...........................................317 6.5.3 Rigging the outrigger span 7.98x8.50/1.00m......................................319 Front outrigger......................................................................320 Auxiliary supports...................................................................320 6.5.4 Establishing/disconnecting the pneumatic connection................................322 6.5.5 Establishing/disconnecting the electrical connection...............................323 6.5.6 Disconnecting/establishing the hydraulic connection................................324 6.5.7 Attaching/raising the supporting box with the truck crane..........................325 Requirements.........................................................................325 Lifting..............................................................................326 Attaching............................................................................327 6.5.8 Installing the reverse camera......................................................328 6.5.9 Crane movements during installation and removal....................................329 Requirements.........................................................................329 Before installation..................................................................329 After removal........................................................................329 6.5.10 Slinging points on the supporting box.............................................330 6.5.11 Fixing/releasing the outrigger pins...............................................331 Locking..............................................................................331 Releasing the locking pin............................................................332 6.5.12 Transporting the supporting box on the separate vehicle...........................333 Lashing eyelets......................................................................333 7 Malfunctions in driving mode...................................................................337 7.1 Emergency stop switch....................................................................337 7.2 What to do when a malfunction occurs in road traffic.....................................339 7.3 Towing the truck crane...................................................................341 7.3.1 Towing after engine/transmission damage............................................342 Compressed-air supply................................................................342 Electric power supply................................................................343 On the transmission.................................................................343 Axle drives..........................................................................344 Parking brake........................................................................344 Towing the truck crane out of the danger area........................................345 7.3.2 Starting to tow....................................................................345 7.4 Other emergency operations...............................................................347 7.4.1 Externally starting the truck crane................................................347 7.4.2 Battery charger....................................................................347 7.5 Wheels and tyres.........................................................................349 7.5.1 Wheel change.......................................................................349 Removing adamaged wheel.............................................................350 On the spare wheel holder............................................................350 Mounting a wheel.....................................................................351 7.5.2 Inflating the tyres yourself.......................................................353 Connecting the filling hose..........................................................353 Inflating the tyres..................................................................354 Removing the filling hose...........................................................354 7.6 Fuses....................................................................................355 Information on replacing fuses...........................................................355 7.6.1 Fuses in the driver's cab..........................................................356 Group F1.............................................................................356 Group F2.............................................................................357 Group F3.............................................................................357 Group F4.............................................................................358 Group F5.............................................................................358 Group F6.............................................................................359 Group F7.............................................................................359 Group F8.............................................................................359 Group F9.............................................................................360 Group F10............................................................................360 7.6.2 Fuses in the battery box...........................................................361 7.7 Troubleshooting..........................................................................363 7.7.1 Malfunctions in the engine.........................................................363 7.7.2 Malfunctions in the DEF system.....................................................365 7.7.3 Malfunctions in the transmission...................................................366 7.7.4 Malfunctions in the hydraulic drive (MegaDrive)....................................366 7.7.5 Service brake malfunctions.........................................................367 7.7.6 Steering malfunctions..............................................................368 7.7.7 Differential lock malfunctions.....................................................369 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler..........................369 7.7.9 Malfunctions on the suspension.....................................................370 7.7.10 Malfunctions on the level adjustment system.......................................370 7.7.11 Malfunctions on the ECOS carrier..................................................371 ECOS program version.................................................................371 General malfunctions................................................................371 Error messages.......................................................................372 Exiting the submenu.................................................................373 7.8 Procedure during malfunctions............................................................375 7.8.1 Switching on emergency operation in coolant circuit................................375 7.8.2 Procedure during engine malfunctions...............................................376 7.8.3 Procedure during transmission malfunctions.........................................377 Error messages.......................................................................377 Displaying error codes...............................................................379 8 Index..........................................................................................383 A............................................................................................385 B............................................................................................385 C............................................................................................385 D............................................................................................387 E............................................................................................388 F............................................................................................390 H............................................................................................391 I............................................................................................392 K............................................................................................392 L............................................................................................392 M............................................................................................393 O............................................................................................394 P............................................................................................395 R............................................................................................395 S............................................................................................397 T............................................................................................398 V............................................................................................400 W............................................................................................400 Operating manual Part 2 – Crane operation............................................................405 Additional pages ................................................................................415 Possible reeving methods on the main boom....................................................407 Technical Data...............................................................................415 Safety harness on the main boom..............................................................417 Anemometer and air traffic control light.....................................................423 Use of additional head sheaves...............................................................425 Correction Sheets................................................................................855 Axle load table..............................................................................855 9 Operating elements for crane operation.........................................................431 9.1 Overview of the operating elements.......................................................431 9.1.1 Exterior of the truck crane........................................................432 9.1.2 Crane cab..........................................................................434 9.1.3 Front panel........................................................................436 9.1.4 Side panel.........................................................................437 Below................................................................................437 Above................................................................................438 Console, rear........................................................................440 Standard heating system..............................................................441 Auxiliary water heater...............................................................442 Auxiliary air heater.................................................................443 9.1.5 Control panels.....................................................................444 Left.................................................................................444 Right................................................................................445 9.1.6 Control lever configuration........................................................446 Version 1............................................................................446 Version 2............................................................................447 9.1.7 ECOS control unit..................................................................448 9.1.8 ECOS display – main menu...........................................................450 9.1.9 ECOS display – submenus............................................................453 Superstructure lock submenu..........................................................453 Outriggers submenu..................................................................454 Telescoping submenu.................................................................456 Power unit speeds submenu............................................................458 Monitoring submenu..................................................................459 Settings submenu.....................................................................460 Operating hours submenu..............................................................462 Warning submenu......................................................................463 Errors submenu.......................................................................465 Working range limiter submenu........................................................466 9.1.10 RCL control unit..................................................................468 9.1.11 RCL display – main menu...........................................................470 9.1.12 RCL display – submenus............................................................471 Enter rigging mode submenu...........................................................471 Monitoring submenu..................................................................472 Rigging mode monitoring submenu.....................................................474 Lifting capacity table submenu.......................................................475 Working range submenu................................................................476 Errors submenu.......................................................................477 Settings submenu.....................................................................478 9.1.13 Hand-held controls................................................................479 Outriggers control panel.............................................................480 Rigging control panel................................................................481 9.1.14 Outrigger control units...........................................................482 Button...............................................................................482 Outrigger button.....................................................................483 Inclination and outrigger pressure display...........................................484 Raise axle display...................................................................485 9.2 Short description of the operating elements..............................................487 9.2.1 Definition of direction references.................................................487 Basic rule...........................................................................487 Switches.............................................................................487 9.2.2 General rules for buttons and symbols on the display...............................488 9.2.3 Engine.............................................................................489 Side panel...........................................................................489 Console, rear........................................................................490 ECOS display.........................................................................490 9.2.4 Seat contact switch and dead man's switch..........................................491 9.2.5 ECOS crane control.................................................................492 Control unit.........................................................................492 9.2.6 Outriggers.........................................................................495 Hand-held control....................................................................495 In the Outriggers submenu............................................................496 In the Settings submenu..............................................................497 On the outrigger control units.......................................................498 9.2.7 Inclination indicators.............................................................500 9.2.8 Raise axle.........................................................................501 Outrigger control units..............................................................501 9.2.9 Outrigger pressure displays........................................................503 Outriggers submenu..................................................................503 Outriggers control units............................................................503 9.2.10 Anemometer display................................................................503 9.2.11 Main hoist........................................................................504 9.2.12 Auxiliary hoist...................................................................506 9.2.13 Slewing gear......................................................................507 Submenu..............................................................................508 9.2.14 Derricking gear...................................................................509 9.2.15 Telescoping mechanism.............................................................511 Control panels.......................................................................511 Submenu..............................................................................512 In the Settings submenu..............................................................516 9.2.16 Hydraulic system..................................................................518 9.2.17 Superstructure lock/houselock submenu.............................................519 Houselock............................................................................520 9.2.18 Rated capacity limiter (RCL)......................................................521 Control unit.........................................................................521 Main menu............................................................................523 Rigging mode entry submenu...........................................................524 Monitoring submenu..................................................................528 Lifting capacity table submenu.......................................................532 Working range submenu................................................................533 Other................................................................................534 9.2.19 Electrical system.................................................................535 9.2.20 Lighting, windscreen wiper/washing system.........................................535 Lighting.............................................................................535 Windscreen wiper/washing system......................................................537 9.2.21 Hand-held control.................................................................538 Sockets for hand- held control.......................................................538 Engine control panel.................................................................539 Horn.................................................................................539 Outriggers control panel............................................................540 9.2.22 Windows, doors, keys..............................................................542 Windows..............................................................................542 Crane cab door.......................................................................542 Keys.................................................................................543 9.2.23 Diagnostics.......................................................................544 10 Starting/turning off the engine – for crane operation.........................................547 10.1 When starting the engine for the first time of the day..................................547 10.1.1 Refuelling........................................................................548 Fuel.................................................................................548 10.1.2 Checks before starting the engine.................................................549 On hydraulic tank....................................................................549 Checking hand- held control..........................................................550 10.1.3 Switching on the ignition.........................................................550 10.1.4 Lamp test/switching state equalisation............................................551 Lamp test............................................................................551 10.1.5 Adjusting display brightness......................................................553 10.1.6 Start the engine..................................................................554 Without flame start system...........................................................554 With flame start system..............................................................555 10.1.7 Checks after starting the engine..................................................556 10.1.8 Monitoring submenu................................................................557 10.1.9 Setting the idling speed..........................................................558 10.1.10 Switching off Economy mode.......................................................559 10.1.11 Overriding torque reduction......................................................560 10.2 Starting the engine – with the hand-held control........................................561 Requirements.............................................................................561 Starting the engine......................................................................561 10.3 Turning off the engine..................................................................563 10.3.1 During normal operation, with the ignition lock/with the hand- held control.......563 After turning off....................................................................563 10.3.2 In emergencies, with the emergency stop switches..................................564 Resetting the emergency stop switch..................................................564 11 Crane operation...............................................................................567 11.1 Before operating the crane..............................................................567 11.1.1 CHECKLIST: Checks before operating the crane......................................567 11.1.2 Checking the condition of the truck crane.........................................571 Fuel tank auxiliary heater...........................................................571 Visual inspection....................................................................571 Checking the position of the hoist ropes............................................572 Checking the electrical system......................................................572 11.1.3 Adjusting the crane cab seat and front control panel..............................573 Crane cab seat.......................................................................573 Front panel..........................................................................574 11.1.4 Checking the safety equipment.....................................................575 Rated capacity limiter...............................................................575 Lifting limit switch................................................................575 Emergency stop switch................................................................576 Seat contact switch..................................................................577 11.1.5 Earthing the load.................................................................578 11.1.6 Locking/unlocking the superstructure..............................................579 Locking points.......................................................................579 Locking the superstructure..........................................................580 Unlocking the superstructure........................................................580 11.1.7 Switching the houselock on/off....................................................581 Switching on the houselock..........................................................581 Switching off the houselock.........................................................583 11.2 Operation of the rated capacity limiter.................................................585 11.2.1 Switching on the RCL..............................................................586 Switching on.........................................................................586 Brightness of the displays...........................................................588 11.2.2 Entering the rigging mode.........................................................589 Entering individual components.......................................................590 Entering the RCL code...............................................................594 Entering the reeving value.........................................................595 Accepting the rigging mode..........................................................595 11.2.3 Checks before operating the crane.................................................597 Opening the submenu.................................................................597 Checks...............................................................................598 11.2.4 Displays during crane operation...................................................600 11.2.5 RCL early warning.................................................................603 11.2.6 RCL shutdown......................................................................603 Shutdown due to overload.............................................................603 11.2.7 Display during errors.............................................................605 11.2.8 RCL override......................................................................606 Table – error/ information codes.....................................................614 11.2.9 Displaying the lifting capacity tables............................................615 11.2.10 Entering the time/date...........................................................617 11.3 Crane operation with main boom..........................................................619 11.3.1 Checks during crane operation.....................................................619 Horizontal alignment................................................................619 Safe distances......................................................................619 Checking the wind speed..............................................................620 11.3.2 Permissible slewing ranges and working positions..................................621 360 slewing range...................................................................621 0 to the rear working position......................................................621 180 to the front rigging position...................................................621 11.3.3 Main hoist........................................................................622 Switching on the main hoist..........................................................623 Lifting and lowering................................................................623 Switching off the main hoist........................................................624 11.3.4 Auxiliary hoist...................................................................625 Switching on the auxiliary hoist....................................................625 Lifting and lowering................................................................626 Switching off the auxiliary hoist...................................................627 11.3.5 Lifting limit switch and lowering limit switch....................................628 Lifting limit switch.................................................................628 Lowering limit switch................................................................629 11.3.6 Derricking gear...................................................................630 Switching on the derricking gear....................................................630 Raising and lowering................................................................631 Re-enabling raising function........................................................632 Switching off the derricking gear....................................................632 Derricking gear warning..............................................................632 Lowering the main boom to ahorizontal position.....................................633 11.3.7 Telescoping mechanism.............................................................634 Overview.............................................................................635 Telescoping process.................................................................635 Assignment for display...............................................................637 Fixed length, intermediate length, telescoping length...............................639 Telescope status.....................................................................640 Telescoping sequence................................................................640 Checks before starting work.........................................................641 Switching on the telescoping mechanism..............................................642 Function of the control lever........................................................642 Switching off the telescoping mechanism.............................................644 Manual telescoping..................................................................645 Checking the initial position.......................................................645 Unlocking the telescoping cylinder.................................................647 Extending/retracting the telescoping cylinder........................................650 Locking the telescoping cylinder...................................................651 Unlocking the telescopic section....................................................652 Telescoping the telescopic section..................................................654 Locking telescopic sections........................................................655 Locking the telescopic section for on-road driving.................................656 Telescoping with teleautomation......................................................657 Telescoping the main boom when horizontal............................................661 11.3.8 High-speed mode...................................................................662 Switch on function..................................................................662 Derricking gear/ telescoping mechanism..............................................662 Hoists...............................................................................663 11.3.9 Slewing gear......................................................................664 Braking the slewing movement.......................................................664 Switching on the slewing gear........................................................665 Releasing the slewing gear brake.....................................................665 Engaging the slewing gear brake......................................................665 Slewing..............................................................................666 Braking the slewing movement.......................................................668 Slewing gear freewheel..............................................................668 Switch off the slewing gear..........................................................669 11.3.10 Possible movement combinations...................................................669 11.3.11 Hydraulic oil cooling............................................................670 11.4 Settings and displays for crane operation...............................................671 11.4.1 Inclining the crane cab...........................................................671 11.4.2 Setting idling speed..............................................................672 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.......................672 11.4.4 Limiting the power unit speeds....................................................673 11.4.5 Setting the characteristic curves for the control levers..........................674 11.4.6 Using the slewable spotlights.....................................................675 11.4.7 Displaying the operating hours....................................................676 11.4.8 Warning submenu...................................................................677 Meaning of the symbols...............................................................677 Exiting the submenu.................................................................680 11.4.9 Errors submenu....................................................................680 11.5 Working range limiter...................................................................681 11.5.1 Opening the working range limiter submenu.........................................682 11.5.2 Viewing current settings..........................................................682 11.5.3 Entering limit values.............................................................684 Overall height/ working radius......................................................684 Slewing angle........................................................................685 Entering objects.....................................................................687 11.5.4 Entering limit values/objects manually............................................690 Limit values.........................................................................690 Objects..............................................................................691 11.5.5 Switching monitoring functions on/off.............................................692 11.5.6 Shutdown by working range limiter.................................................693 11.6 Work break..............................................................................694 11.6.1 In case of short work breaks......................................................694 11.6.2 In case of work breaks of more than 8 hours.......................................695 To secure the truck crane............................................................695 11.7 Heating and air-conditioning system.....................................................696 11.7.1 Standard heating system...........................................................696 Switching on.........................................................................696 Heating..............................................................................696 Air distribution.....................................................................697 Switching off........................................................................697 11.7.2 Air-conditioning system...........................................................698 Warnings.............................................................................698 Switching on/off.....................................................................698 Cooling..............................................................................699 Drying the air.......................................................................699 11.7.3 Auxiliary water heater............................................................700 Preheating the engine...............................................................700 Preheating the crane cab............................................................701 Switching on.........................................................................702 Setting the day and time.............................................................703 Storing the heating start..........................................................704 Setting the heating period..........................................................705 Switching heating start on/off......................................................705 Switching off........................................................................706 Setting the remaining time..........................................................706 11.7.4 Auxiliary air heater..............................................................707 Switching on.........................................................................707 Temperature..........................................................................708 Switching off........................................................................708 Additional functions................................................................708 11.8 CraneSTAR system........................................................................709 11.8.1 Overview..........................................................................709 11.8.2 Position of the components........................................................709 12 Rigging work..................................................................................713 12.1 Rigging work checklists for crane operation with the main boom..........................713 12.1.1 CHECKLIST: Rigging................................................................713 12.1.2 CHECKLIST: Unrigging..............................................................717 12.2 Choosing a suitable site................................................................721 12.2.1 Determining the required ground bearing area......................................721 12.2.2 Safe distance from slopes and pits................................................724 12.2.3 Earthing the truck crane..........................................................725 12.2.4 Safe distance from electrical cables..............................................726 12.3 Rigging work after driving with a trailer...............................................729 12.3.1 Switching off the boom floating position..........................................729 12.3.2 Switching off the slewing gear freewheel..........................................730 Before slewing.......................................................................730 12.3.3 Switching off boom pre-tensioning.................................................731 12.4 Connecting/disconnecting the hand-held control..........................................733 12.5 Starting the engine for driving for rigging work........................................735 12.5.1 Starting/turning off the engine with the hand-held control........................735 Requirements.........................................................................735 Starting the engine..................................................................736 Turning off the engine...............................................................736 12.5.2 Starting/turning off the engine from the crane cab................................737 Requirements.........................................................................737 Starting the engine..................................................................737 After starting the engine............................................................738 Turning off the engine...............................................................738 12.5.3 Starting/turning off the engine from the outrigger control units..................739 Requirements.........................................................................739 Starting the engine..................................................................739 Turning off the engine...............................................................739 12.6 Outriggers..............................................................................741 12.6.1 CHECKLIST: Extending the outriggers...............................................741 12.6.2 CHECKLIST: Retracting the outriggers..............................................743 12.6.3 Permissible outrigger spans.......................................................744 12.6.4 Preparing the truck crane.........................................................745 In the driver's cab..................................................................745 Outriggers control units............................................................745 12.6.5 Setting the outrigger spans.......................................................746 For on-road driving.................................................................748 12.6.6 Extending/retracting outrigger beams..............................................749 From the control units...............................................................750 With the hand- held control..........................................................751 From the crane cab...................................................................753 12.6.7 Moving the outrigger pads into working/driving position...........................755 12.6.8 Enlarging the ground bearing area.................................................756 12.6.9 Extending/retracting supporting cylinders.........................................757 From the control units...............................................................758 With the hand- held control..........................................................759 From the crane cab...................................................................760 12.6.10 Levelling the truck crane on outriggers..........................................762 Inclination indicators..............................................................762 Requirements.........................................................................763 Manual alignment....................................................................764 Automatic alignment.................................................................765 12.6.11 Levelling the free-standing truck crane..........................................767 12.6.12 Outrigger pressure display.......................................................769 12.7 Rigging/unrigging the counterweight.....................................................771 12.7.1 Counterweight sections............................................................771 Version A............................................................................771 Version B............................................................................771 12.7.2 Identification....................................................................772 12.7.3 Slinging points on the counterweight sections.....................................773 12.7.4 CHECKLIST: Counterweight, rigging.................................................774 12.7.5 CHECKLIST: Counterweight, unrigging...............................................777 12.7.6 Assembling counterweight combination..............................................779 Setting down 10t sections/blocks version A.........................................780 Combinations for the basic equipment in version A....................................781 Setting down 10t sections/blocks version B.........................................786 Combinations for the basic equipment in version B....................................787 12.7.7 Securing/releasing 10 t blocks....................................................791 Tensioning device....................................................................791 Securing 10t blocks................................................................792 Releasing 10t blocks...............................................................792 12.7.8 Establishing/disconnecting the hydraulic connection...............................793 Establishing.........................................................................793 Disconnecting........................................................................793 12.7.9 Making/breaking the electrical connection.........................................794 Establishing.........................................................................794 Disconnecting........................................................................794 12.7.10 Rigging counterweight............................................................795 Hand-held control....................................................................795 Counterweight rigging...............................................................796 Unrigging counterweight.............................................................797 Counterweight safety valve...........................................................799 12.7.11 Raising and lowering 10 t counterweight blocks with a mounted auxiliary hoist....800 12.7.12 Slewing with rigged counterweight................................................801 12.8 Rigging the auxiliary hoist.............................................................803 12.8.1 Identification....................................................................803 12.8.2 Slinging points and transport.....................................................804 Slinging points......................................................................804 Transport............................................................................805 12.8.3 CHECKLIST: Mounting the auxiliary hoist...........................................806 Requirements.........................................................................806 12.8.4 CHECKLIST: Removing the auxiliary hoist...........................................808 Requirements.........................................................................808 12.8.5 Lifting the auxiliary hoist onto the 15 t base plate..............................810 12.8.6 Raising/setting down the catcher..................................................811 Raising..............................................................................811 Setting down.........................................................................811 12.8.7 Establishing/disconnecting the hydraulic connection...............................812 Establishing.........................................................................812 Disconnecting........................................................................812 12.8.8 Making/breaking the electrical connection.........................................813 Establishing.........................................................................813 Disconnecting........................................................................813 12.8.9 Locking/unlocking the auxiliary hoist.............................................814 Auxiliary hoist safety valve.........................................................814 Locking..............................................................................815 Releasing the locking pin............................................................816 Releasing the locking pin............................................................816 12.8.10 Checking the auxiliary hoist for correct functioning.............................817 With the hand- held control..........................................................817 In the crane cab.....................................................................817 12.8.11 Securing the upper hook block in the catcher.....................................818 12.8.12 Railings on the auxiliary hoist..................................................818 12.8.13 Permissible applications for the auxiliary hoist.................................819 Replacement for the main hoist.......................................................819 Alternating operation with themain and the auxiliary hoist.........................820 12.9 Rigging work on the main boom...........................................................821 12.9.1 Hook block on the bumper..........................................................821 Picking up the hook block............................................................821 Attaching the hook block.............................................................822 12.9.2 Hook block on a separate vehicle..................................................823 Picking up the hook block...........................................................824 Setting down the hook block.........................................................824 12.9.3 Reeving and unreeving the hoist rope..............................................826 Rope end fitting.....................................................................826 Reeving the hoist rope...............................................................827 Unreeving the hoist rope............................................................830 12.9.4 Possible reeving methods on the main boom.........................................831 With 7 head sheaves..................................................................831 With 10 head sheaves.................................................................834 12.9.5 Installing/removing the lifting limit switch......................................838 Installing the lifting limit switch..................................................838 Removing the lifting limit switch....................................................841 12.9.6 Locking/Unlocking the lifting limit switch........................................843 Locking..............................................................................843 Unlocking...........................................................................843 12.9.7 Anemometer and air traffic control light..........................................844 Installing...........................................................................844 Removing.............................................................................845 12.10 Other rigging work.....................................................................847 12.10.1 Railings on the turntable........................................................847 12.10.2 Cameras for crane operation......................................................848 Cameras on the hoists................................................................848 Camera on main boom..................................................................849 13 Driving with rigged truck crane...............................................................853 13.1 Driving path............................................................................853 13.2 Permissible rigging modes and axle loads................................................854 Axle load table..........................................................................855 13.3 Before driving..........................................................................856 13.3.1 Securing the superstructure against slewing.......................................856 13.3.2 Checking tyre pressure and wind speed.............................................857 13.3.3 Putting the truck crane on the wheels.............................................858 13.3.4 Transmission/connections..........................................................860 Transmission.........................................................................860 Switching on separate steering......................................................860 13.4 While driving...........................................................................860 13.5 After driving...........................................................................862 14 Malfunctions during crane operation...........................................................865 14.1 Emergency stop switch...................................................................865 14.2 What to do when a malfunction occurs during crane operation.............................867 Load can be lowered.....................................................................867 Load cannot be lowered...................................................................867 14.3 Fuses...................................................................................869 Information on replacing fuses.........................................................869 14.3.1 Fuses on the turntable............................................................870 Fuse groups F1/F2/F3................................................................870 Fuses on the circuit board..........................................................871 14.3.2 Fuses in the crane cab............................................................873 14.3.3 RCL fuses.........................................................................875 14.4 Troubleshooting.........................................................................876 14.4.1 Malfunctions on the engine........................................................876 14.4.2 Malfunctions on the main hoist/auxiliary hoist....................................877 14.4.3 Malfunctions in the hoist cameras.................................................878 14.4.4 Malfunctions in the main boom camera..............................................878 14.4.5 Malfunctions in the derricking gear...............................................879 14.4.6 Malfunctions in the telescoping mechanism.........................................880 Telescoping mechanism error messages.................................................881 14.4.7 Malfunctions in the slewing gear..................................................883 14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.........................884 14.4.9 Malfunctions when inclining the crane cab.........................................884 14.4.10 Malfunctions when operating with the hand-held control...........................884 14.4.11 Malfunctions on the outriggers...................................................885 14.4.12 Troubleshooting on the RCL.......................................................886 General malfunctions................................................................886 Error messages in the Monitoring submenu.............................................887 Displays in the Error submenu........................................................889 Error codes table....................................................................891 Switch off sensor/ tachogenerator...................................................894 14.4.13 Malfunctions ECOS – superstructure...............................................895 ECOS programme version...............................................................895 General malfunctions................................................................895 Error messages.......................................................................896 Exiting the submenu.................................................................897 14.4.14 Malfunctions on the CraneSTAR system.............................................898 14.5 Emergency operations and programmes.....................................................903 14.5.1 Mechanical emergency activation for retracting....................................904 Checks before emergency operation...................................................904 Procedure............................................................................904 Mechanical emergency operation......................................................905 14.5.2 Telescoping emergency programme...................................................907 Starting the emergency programme...................................................907 Determining type of error...........................................................908 Error on length indicator............................................................909 Error on proximity switch............................................................913 Terminating emergency programme....................................................914 Tables for approaching the locking points............................................915 14.5.3 Entering the current telescoping..................................................917 14.5.4 Emergency operation with the hand-held control....................................919 Preparations.........................................................................919 Operating a power unit...............................................................920 Stopping operations.................................................................922 Stopping movements in emergencies...................................................922 Turning off the engine...............................................................922 14.6 Hydraulic emergency operation...........................................................923 14.6.1 Functionality.....................................................................923 14.6.2 Connecting/disconnecting hoses....................................................924 Establishing.........................................................................924 Disconnecting.......................................................................925 14.6.3 Switching emergency operation on/off..............................................926 14.6.4 Establishing the required hydraulic circuits......................................927 Switching over valves................................................................927 14.6.5 Performing emergency operation....................................................929 Slewing..............................................................................929 Derricking...........................................................................930 Lifting/lowering.....................................................................930 14.6.6 After emergency operation.........................................................931 Switching off emergency operation...................................................931 Switching over to crane operation....................................................931 Disconnecting the hoses..............................................................931 14.6.7 Emergency supply of another crane.................................................932 For emergency supply.................................................................932 After emergency supply...............................................................932 15 Index.........................................................................................935 A............................................................................................937 B............................................................................................937 C............................................................................................937 D............................................................................................939 E............................................................................................940 F............................................................................................942 H............................................................................................943 I............................................................................................944 K............................................................................................944 L............................................................................................944 M............................................................................................945 O............................................................................................946 P............................................................................................947 R............................................................................................947 S............................................................................................949 T............................................................................................950 V............................................................................................952 W............................................................................................952
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