Grove Crane GMK 6400 Driving Operating Manual 3112993 – PDF DOWNLOAD

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Grove Crane GMK 6400 Driving Operating Manual 3112993 – PDF DOWNLOAD

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Grove Crane GMK 6400 Driving Operating Manual 3112993 – PDF DOWNLOAD

Language : English
Pages : 944
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Grove Crane GMK 6400 Driving Operating Manual 3112993 – 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 3112993 – PDF DOWNLOAD

Operating manual Part 1 – Driving....................................................................  1
	Additional pages.................................................................................  3
		Technical data...............................................................................  3
			Operating speeds.........................................................................  3
		Safety harness on the main boom..............................................................  5
			Attaching/detaching fall prevention safety system to/from safety harness.................  7
				Attachment...........................................................................  7
				Detachment...........................................................................  8
		Anemometer and air traffic control light..................................................... 11
		Use of additional head sheaves............................................................... 13
		Instructions for operation with a trailer.................................................... 15
			Maximum permitted load.................................................................. 16
	Correction sheet ................................................................................843
		Axle load table..............................................................................843
	1 Overview....................................................................................... 21
		1.1 Accidents................................................................................ 21
		1.2 Branch offices........................................................................... 22
			1.2.1 Manitowoc Crane Care............................................................... 22
			1.2.2 Dealer list........................................................................ 22
		1.3 Warranty specifications.................................................................. 22
		1.4 Terms used............................................................................... 24
		1.5 Technical data........................................................................... 27
			1.5.1 Maximum lifting capacity........................................................... 27
			1.5.2 Dimensions and weights of the truck crane, axle loads.............................. 28
				Dimensions........................................................................... 29
				Weight and axle loads................................................................ 29
			1.5.3 Dimensions and weights of removable parts.......................................... 30
				Spare wheel.......................................................................... 30
				Outriggers........................................................................... 30
				Main boom............................................................................ 31
				Hook blocks and hook tackle.......................................................... 31
				Auxiliary hoist...................................................................... 31
				Counterweightsections version A...................................................... 32
				Counterweightsections version B...................................................... 32
			1.5.4 Carrier............................................................................ 33
				Engine............................................................................... 33
				Transmission......................................................................... 33
				Transfer case........................................................................ 33
				Axle lines........................................................................... 33
				Steering............................................................................. 33
				Tyres................................................................................ 34
				Electrical system.................................................................... 34
				Tool................................................................................. 34
				Towing coupling...................................................................... 34
				Driving speeds....................................................................... 34
				Climbing ability..................................................................... 34
				Outriggers........................................................................... 35
				Turning radii........................................................................ 36
			1.5.5 Superstructure..................................................................... 37
				Main hoist........................................................................... 37
				Auxiliary hoist...................................................................... 37
				Slewing gears........................................................................ 37
				Derricking gear...................................................................... 38
				Main boom............................................................................ 38
				Lattice extension.................................................................... 38
				Operating speeds..................................................................... 38
		1.6 Documentation supplied................................................................... 39
			1.6.1 Questions on documentation......................................................... 40
		1.7 Notes on the operating instructions...................................................... 41
			1.7.1 What do the symbols used mean?..................................................... 41
			1.7.2 How are the operating instructions structured?..................................... 43
				Division............................................................................. 43
				Structure of the chapters............................................................ 43
				Structure of the pages............................................................... 44
			1.7.3 How do I find the information I need?.............................................. 45
				Cross-references example............................................................. 46
			1.7.4 What information is available for operations planning?............................. 48
		1.8 Conversion table for US measuring units.................................................. 49
		1.9 Training – Information................................................................... 51
		1.10 Identification.......................................................................... 52
		1.11 EC Declaration of Conformity............................................................ 54
	2 Basic safety instructions...................................................................... 57
		2.1 Intended use............................................................................. 57
			2.1.1 Improper use....................................................................... 58
		2.2 Organisational measures.................................................................. 59
		2.3 Qualifications of the staff.............................................................. 61
		2.4 Safety instructions for driving the truck crane.......................................... 62
		2.5 Safety instructions for crane operation.................................................. 62
		2.6 Notes on transporting persons............................................................ 64
			Equipment for lifting persons............................................................ 64
			Personnel................................................................................ 64
			Operation................................................................................ 65
			Truck crane.............................................................................. 66
	3 Operating elements for driving................................................................. 69
		3.1 Overview of the operating elements....................................................... 69
			3.1.1 On the outside of the truck crane.................................................. 70
			3.1.2 Driver's cab....................................................................... 72
				Overview............................................................................. 72
				Behind the cover..................................................................... 74
				In the rear of the driver's cab...................................................... 74
			3.1.3 Instrument panel................................................................... 75
				Left/right........................................................................... 75
				Middle............................................................................... 76
				Middle............................................................................... 78
			3.1.4 Display, driving mode.............................................................. 80
			3.1.5 Steering column/steering wheel..................................................... 81
			3.1.6 Transmission operating elements.................................................... 82
			3.1.7 Tachograph......................................................................... 83
			3.1.8 ECOS control unit.................................................................. 84
			3.1.9 ECOS display – Main menu........................................................... 86
			3.1.10 ECOS display – Submenus........................................................... 88
				Level adjustment system submenu...................................................... 88
				Settings submenu..................................................................... 90
				Submenu Checking..................................................................... 91
				Operating hours submenu.............................................................. 92
				Warning submenu...................................................................... 92
				Error submenu........................................................................ 93
			3.1.11 Heating/Air-conditioning system................................................... 94
				Standard heating system.............................................................. 94
				Auxiliary water heating system....................................................... 95
			3.1.12 Sockets for hand-held control..................................................... 96
			3.1.13 Outrigger control units........................................................... 97
			3.1.14 Control unit of the rear outrigger box............................................ 98
		3.2 Short description of the operating elements.............................................. 99
			3.2.1 Definition of direction information................................................ 99
				Basic rule........................................................................... 99
				Switches and buttons.................................................................100
			3.2.2 General notes on the operating elements............................................100
			3.2.3 General rules for buttons and symbols on the display...............................101
			3.2.4 Engine.............................................................................102
				Steering column......................................................................102
				Multipurpose switch..................................................................102
				Instrument panel.....................................................................103
			3.2.5 DEF system.........................................................................105
				Instrument panel.....................................................................105
				Display, driving mode................................................................106
				ECOS display.........................................................................106
			3.2.6 Electrical system..................................................................107
				Control unit.........................................................................107
			3.2.8 Transmission.......................................................................110
				Transmission control unit............................................................110
				Display, driving mode................................................................111
			3.2.9 Reverse camera.....................................................................114
			3.2.10 Final drive.......................................................................115
			3.2.11 Brakes............................................................................116
				Service brake........................................................................116
				Additional brakes....................................................................116
				Parking brake........................................................................117
			3.2.12 Steering/separate steering........................................................118
				Instrument panel.....................................................................118
				ECOS display.........................................................................119
				Driver's door........................................................................120
			3.2.13 Suspension........................................................................121
			3.2.14 Control unit of the rear outrigger box............................................122
			3.2.15 Lighting/windscreen wipers/horn...................................................123
				Steering column......................................................................123
				Instrument panel.....................................................................123
				Roof.................................................................................126
			3.2.16 Level adjustment system...........................................................126
			3.2.17 Tachograph/speedometer............................................................128
				Tachograph...........................................................................128
				Speedometer..........................................................................128
			3.2.18 Diagnostics.......................................................................129
				Displays/ submenu....................................................................129
			3.2.19 Windows, doors, keys..............................................................130
				Window winder........................................................................130
				Doors................................................................................131
				Keys.................................................................................131
			3.2.20 Front flap........................................................................132
	4 Starting/turning off the engine for driving....................................................135
		4.1 Starting the engine from the driver's cab................................................135
			4.1.1 CHECKLIST: Starting the engine.....................................................135
			4.1.2 CHECKLIST: At low temperatures.....................................................138
			4.1.3 Ladders and access ladders.........................................................138
				Access ladders.......................................................................138
				Ladders..............................................................................139
			4.1.4 Refuelling.........................................................................142
				Standard tank........................................................................142
				Dual tank............................................................................143
				DEF..................................................................................144
			4.1.5 Inspections before starting the engine.............................................145
				On the hydraulic tank................................................................145
				Battery master switch................................................................146
				Checking the hand-held control.......................................................146
			4.1.6 Switch on the ignition.............................................................146
			4.1.7 Lamp test/equalisation of the switching states.....................................147
				Lamp test............................................................................147
				Equalisation of the switching states.................................................148
			4.1.8 Display – setting the brightness...................................................149
			4.1.9 Start the engine...................................................................150
				Without flame start system...........................................................151
				With flame start system..............................................................152
			4.1.10 Inspections after starting the engine.............................................153
				Checking in the main menu............................................................153
				Indicator lamps on the instrument panel..............................................154
			4.1.11 Monitoring elements...............................................................156
				Instrument panel.....................................................................156
			4.1.12 Monitoring submenu................................................................157
			4.1.13 Setting the idling speed..........................................................158
		4.2 Turning off the engine...................................................................159
			4.2.1 On the ignition lock/with hand-held control/on the outrigger control units.........159
				After parking........................................................................159
			4.2.2 Using the emergency stop switches..................................................160
				Resetting the emergency stop switch..................................................160
		4.3 Air intake inhibitor.....................................................................161
			Releasing the air intake inhibitor.......................................................161
	5 Driving........................................................................................165
		5.1 Before driving...........................................................................165
			5.1.1 CHECKLIST: Checks before on-road driving...........................................165
			5.1.2 Checking the condition of the truck crane..........................................170
				Electrical system....................................................................170
				Adjusting the mirrors................................................................170
				Warning plates for vehicle width.....................................................172
				Displaying vehicle height............................................................172
				Supply pressure......................................................................173
				Parking brake........................................................................174
			5.1.3 Adjusting the seats and steering column............................................175
				Driver's seat........................................................................175
				Passenger's seat.....................................................................176
				Adjusting the steering column.......................................................177
			5.1.4 Switching the suspension on/off....................................................178
				Opening the submenu.................................................................178
				Switching on the suspension.........................................................179
				Switching off the suspension........................................................179
			5.1.5 Setting the tachograph.............................................................180
				Requirements.........................................................................180
				If malfunction occurs................................................................180
				Setting the tachograph..............................................................181
			5.1.6 Displaying the operating hours.....................................................185
			5.1.7 Settings/indications on the driving display........................................186
		5.2 Operating the transmission...............................................................187
			5.2.1 Switching on.......................................................................187
			5.2.2 Switching the transmission to neutral position.....................................188
			5.2.3 Selecting the direction of travel and starting gear................................189
				Selecting the driving direction....................................................189
				Selecting the starting gear .......................................................190
			5.2.4 Changing the operating mode........................................................191
				Change to automatic mode.............................................................191
				Change to manual mode................................................................191
			5.2.5 Starting...........................................................................192
			5.2.6 Driving and changing gears.........................................................194
				In automatic operating mode.........................................................194
				In manual operating mode............................................................195
			5.2.7 Changing the driving direction.....................................................196
			5.2.8 Stopping...........................................................................196
				Stopping for long periods...........................................................196
			5.2.9 DM and RM transmission mode........................................................197
				Switching on.........................................................................197
				Switching off........................................................................198
				Limiting maximum speed..............................................................198
			5.2.10 On the roller type dynamometer....................................................200
			5.2.11 Preheating transmission...........................................................200
		5.3 Driving and turning off the truck crane..................................................201
			5.3.1 Checks while driving...............................................................201
				Right after starting................................................................201
				While driving........................................................................203
			5.3.2 Cruise control.....................................................................204
				Switching on.........................................................................204
				Switching off........................................................................205
			5.3.3 Cruise control.....................................................................205
				Switching on.........................................................................205
				Switching off........................................................................205
			5.3.4 Driving downhill...................................................................206
				Starting.............................................................................206
				Checks when driving downhill.......................................................207
				Downshifting.........................................................................207
				Additional brakes....................................................................208
			5.3.5 Driving uphill.....................................................................210
				Starting.............................................................................210
				Driving..............................................................................210
			5.3.6 Warning submenu....................................................................211
				Meaning of the symbols...............................................................211
				Exiting the submenu.................................................................213
			5.3.7 Warning or malfunction messages on the instrument panel............................214
				Meaning of the lamps.................................................................214
			5.3.8 Overriding torque reduction........................................................216
			5.3.9 Errors submenu.....................................................................217
			5.3.10 Turning off the truck crane.......................................................217
				Securing against rolling away........................................................217
				When stationary for more than 8hours................................................218
			5.3.11 Folding berth.....................................................................220
		5.4 Off-road driving.........................................................................221
			Adjustments to the transmission..........................................................221
			Connections..............................................................................221
			Changing the vehicle level...............................................................221
			Rocking the vehicle free andtowing.....................................................221
			5.4.1 Longitudinal and transverse differential locks.....................................222
			5.4.2 Operating the level adjustment system..............................................224
				Opening the submenu.................................................................224
				Setting the onroad level...........................................................225
				Pre-selecting suspension struts....................................................225
				Changing the vehicle level...........................................................226
				Viewing the current inclination.....................................................226
				Exiting the submenu.................................................................227
			5.4.3 Freeing truck crane stuck in terrain...............................................228
				Rocking the truck crane free........................................................228
				Towing free forward.................................................................229
				Towing free backward................................................................229
		5.5 Separate steering........................................................................230
			5.5.1 Switching to separate steering.....................................................230
				Manual...............................................................................231
				Automatic............................................................................232
				Switching to normal steering mode....................................................233
		5.6 Heating and air-conditioning system......................................................234
			5.6.1 Standard heating system............................................................234
				Switching on.........................................................................234
				Heating..............................................................................234
				Air distribution.....................................................................235
				Examples.............................................................................236
				Switching off........................................................................236
			5.6.2 Air-conditioning system............................................................237
				Notes................................................................................237
				Switching on/off.....................................................................237
				Cooling..............................................................................238
				Drying...............................................................................238
			5.6.3 Auxiliary water heater.............................................................239
				Preheating the engine................................................................239
				Preheating the driver's cab.........................................................240
				Switching on the auxiliary heater....................................................241
				Switching off the auxiliary heater...................................................242
				Setting the time and weekday.........................................................242
				Saving the automatic heating start.................................................243
				Setting the heating period..........................................................244
				Switching the automatic heating start on and off....................................244
				Setting the remaining time..........................................................245
		5.7 Towing a trailer.........................................................................246
			Effects on the axle loads................................................................246
			Coupling the trailer....................................................................247
			Connecting the supply lines.............................................................248
			Removing supply lines..................................................................249
			Uncoupling the trailer..................................................................249
			Checking the braking force..............................................................251
	6 Driving modes and rigging for on-road driving..................................................255
		6.1 Driving modes............................................................................255
			Information on the axle loads............................................................255
			6.1.1 Information on how to use the tables...............................................256
			6.1.2 Tables for a maximum axle load of 12 t (26500 lbs)................................257
				Without removable supporting box.....................................................257
				With removable supporting box........................................................258
			6.1.3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs)...............259
		6.2 Rigging work for driving with a trailer..................................................260
			6.2.1 Switching on the slewing gear freewheel............................................261
			6.2.2 Switching on boom floating position................................................262
			6.2.3 Switching on boom pre-tensioning...................................................263
			6.2.4 Switching the superstructure driving lights on/off.................................264
				Switching off........................................................................264
				Switching on.........................................................................264
		6.3 Removing/installing main boom............................................................265
			Additional equipment required............................................................265
			6.3.1 CHECKLIST: Removing the main boom..................................................267
				Requirements.........................................................................267
				Checklist............................................................................267
			6.3.2 CHECKLIST: Installing the main boom................................................269
				Requirements.........................................................................269
				Checklist............................................................................269
			6.3.3 Slinging the main boom.............................................................272
				Marking..............................................................................272
				Installing the lifting gear.........................................................272
				Removing the sling gear..............................................................273
			6.3.4 Retracting/fitting the derricking cylinder head pin................................275
				Retracting the derricking cylinder head axle........................................276
				Fitting the derricking cylinder head axle............................................277
			6.3.5 Retracting/extending the boom pivot pin............................................278
				Before retracting....................................................................278
				After extending......................................................................279
				Retracting/ extending the pivot pin..................................................280
			6.3.6 Disconnecting/connecting hydraulics/electrical.....................................281
				Disconnecting........................................................................281
				Establishing.........................................................................282
			6.3.7 Lifting the main boom off/on the turntable.........................................283
				Lifting from the turntable...........................................................283
				Lifting on to the turntable..........................................................284
			6.3.8 Aligning the connecting points.....................................................285
			6.3.9 Securing/releasing the derricking cylinder.........................................285
			6.3.10 Transporting the main boom........................................................286
			6.3.11 Inspections after main boom mounting..............................................287
		6.4 Installing/removing outrigger beams......................................................289
			6.4.1 CHECKLIST: Removing the outrigger beams............................................290
			6.4.2 CHECKLIST: Installing the outrigger beams..........................................292
			6.4.3 Preparing the truck crane..........................................................294
				Requirements.........................................................................294
				For removal..........................................................................294
			6.4.4 Removing/attaching outrigger pads..................................................295
				Removing outrigger pads.............................................................295
				Attaching outrigger pads............................................................296
			6.4.5 Disconnecting/establishing the hydraulic connection................................297
			6.4.6 Establishing/disconnecting the electrical connection...............................298
			6.4.7 Unscrewing/screwing in the spacers.................................................299
				Unscrewing...........................................................................299
				Screwing in..........................................................................300
			6.4.8 Disconnecting/establishing the connections to the outrigger box....................301
			6.4.9 Extending/retracting the outrigger beam............................................301
				Extending outrigger beam............................................................301
				Inserting the outrigger beam........................................................303
			6.4.10 Transporting the outrigger beams..................................................305
		6.5 Installing/removing the supporting box...................................................307
			6.5.1 CHECKLIST: Removing the supporting box.............................................308
			6.5.2 CHECKLIST: Installing the supporting box...........................................311
			6.5.3 Rigging the outrigger span 7.98x8.50/1.00m (26.1x27.9/3.3ft).................313
				Front outrigger......................................................................314
				Auxiliary supports...................................................................314
			6.5.4 Establishing/disconnecting the pneumatic connection................................316
			6.5.5 Establishing/disconnecting the electrical connection...............................317
			6.5.6 Disconnecting/establishing the hydraulic connection................................318
			6.5.7 Attaching/raising the supporting box with the truck crane..........................319
				Requirements.........................................................................319
				Lifting..............................................................................320
				Attaching............................................................................321
			6.5.8 Installing the reverse camera......................................................322
			6.5.9 Crane movements during installation and removal....................................323
				Requirements.........................................................................323
				Before installation..................................................................323
				After removal........................................................................323
			6.5.10 Slinging points on the supporting box.............................................324
			6.5.11 Fixing/releasing the outrigger pins...............................................325
				Locking..............................................................................325
				Releasing the locking pin............................................................326
			6.5.12 Transporting the supporting box on the separate vehicle...........................327
				Lashing eyelets......................................................................327
	7 Malfunctions in driving mode...................................................................331
		7.1 Emergency stop switch....................................................................331
		7.2 What to do when a malfunction occurs in road traffic.....................................333
		7.3 Towing the truck crane...................................................................335
			7.3.1 Towing after engine/transmission damage............................................336
				Compressed-air supply................................................................336
				Electric power supply................................................................  0
				On the transmission.................................................................  0
				Axle drives..........................................................................338
				Parking brake........................................................................338
				Towing the truck crane out of the danger area........................................339
			7.3.2 Starting to tow....................................................................339
		7.4 Other emergency operations...............................................................341
			7.4.1 Externally starting the truck crane................................................341
			7.4.2 Battery charger....................................................................341
		7.5 Wheels and tyres.........................................................................343
			7.5.1 Wheel change.......................................................................343
				Removing adamaged wheel.............................................................344
				On the spare wheel holder............................................................344
				Mounting a wheel.....................................................................345
			7.5.2 Inflating the tyres yourself.......................................................347
				Connecting the filling hose..........................................................347
				Inflating the tyres..................................................................348
				Removing the filling hose...........................................................348
		7.6 Fuses....................................................................................349
			Information on replacing fuses...........................................................349
			7.6.1 Fuses in the driver's cab..........................................................350
				Group F1.............................................................................350
				Group F2.............................................................................351
				Group F3.............................................................................351
				Group F4.............................................................................352
				Group F5.............................................................................352
				Group F6.............................................................................353
				Group F7.............................................................................353
				Group F8.............................................................................353
				Group F9.............................................................................354
				Group F10............................................................................354
			7.6.2 Fuses in the battery box...........................................................355
		7.7 Troubleshooting..........................................................................357
			7.7.1 Malfunctions in the engine.........................................................357
			7.7.2 Malfunctions in the DEF system.....................................................359
			7.7.3 Malfunctions in the transmission...................................................360
			7.7.4 Malfunctions in the hydraulic drive (MegaDrive)....................................360
			7.7.5 Service brake malfunctions.........................................................361
			7.7.6 Steering malfunctions..............................................................362
			7.7.7 Differential lock malfunctions.....................................................363
			7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler..........................363
			7.7.9 Malfunctions on the suspension.....................................................364
			7.7.10 Malfunctions on the level adjustment system.......................................364
			7.7.11 Malfunctions on the ECOS carrier..................................................365
				ECOS program version.................................................................365
				General malfunctions................................................................365
				Error messages.......................................................................366
				Exiting the submenu.................................................................367
		7.8 Procedure during malfunctions............................................................369
			7.8.1 Switching on emergency operation in coolant circuit................................369
			7.8.2 Procedure during engine malfunctions...............................................370
			7.8.3 Procedure during transmission malfunctions.........................................371
				Error messages.......................................................................371
				Displaying error codes...............................................................373
	8 Index..........................................................................................377
		A............................................................................................379
		B............................................................................................379
		C............................................................................................379
		D............................................................................................381
		E............................................................................................382
		F............................................................................................385
		H............................................................................................385
		I............................................................................................386
		K............................................................................................386
		L............................................................................................386
		M............................................................................................387
		O............................................................................................388
		P............................................................................................389
		R............................................................................................390
		S............................................................................................391
		T............................................................................................392
		V............................................................................................394
		W............................................................................................394
Operating manual Part 2 – Crane operation............................................................399
	Additional pages.................................................................................401
		Technical data...............................................................................401
			Operating speeds.........................................................................401
		Safety harness on the main boom..............................................................403
			Attaching/detaching fall prevention safety system to/from safety harness.................405
				Attachment...........................................................................405
				Detachment...........................................................................406
			Inspecting/replacing safety harness......................................................407
				Inspection...........................................................................407
				Replacement..........................................................................407
		Anemometer and air traffic control light.....................................................409
		Use of additional head sheaves...............................................................411
		Instructions for operation with a trailer....................................................413
			Maximum permitted load..................................................................414
	Correction sheet ................................................................................843
		Axle load table..............................................................................843
	9 Operating elements for crane operation.........................................................419
		9.1 Overview of the operating elements.......................................................419
			9.1.1 Exterior of the truck crane........................................................420
			9.1.2 Crane cab..........................................................................422
			9.1.3 Front panel........................................................................424
			9.1.4 Side panel.........................................................................425
				Below................................................................................425
				Above................................................................................426
				Console, rear........................................................................428
				Standard heating system..............................................................429
				Auxiliary water heater...............................................................430
				Auxiliary air heater.................................................................431
			9.1.5 Control panels.....................................................................432
				Left.................................................................................432
				Right................................................................................433
			9.1.6 Control lever configuration........................................................434
				Version 1............................................................................434
				Version 2............................................................................435
			9.1.7 ECOS control unit..................................................................436
			9.1.8 ECOS display – main menu...........................................................438
			9.1.9 ECOS display – submenus............................................................441
				Superstructure lock submenu..........................................................441
				Outriggers submenu..................................................................442
				Telescoping submenu.................................................................444
				Power unit speeds submenu............................................................446
				Monitoring submenu..................................................................447
				Settings submenu.....................................................................448
				Operating hours submenu..............................................................450
				Warning submenu......................................................................451
				Errors submenu.......................................................................453
				Working range limiter submenu........................................................454
			9.1.10 RCL control unit..................................................................456
			9.1.11 RCL display – main menu...........................................................458
			9.1.12 RCL display – submenus............................................................459
				Enter rigging mode submenu...........................................................459
				Monitoring submenu..................................................................460
				Rigging mode monitoring submenu.....................................................462
				Lifting capacity table submenu.......................................................463
				Working range submenu................................................................464
				Errors submenu.......................................................................465
				Settings submenu.....................................................................466
			9.1.13 Hand-held controls................................................................467
				Outriggers control panel.............................................................468
				Rigging control panel................................................................469
			9.1.14 Outrigger control units...........................................................470
				Button...............................................................................470
				Outrigger button.....................................................................471
				Inclination and outrigger pressure display...........................................472
				Raise axle display...................................................................473
		9.2 Short description of the operating elements..............................................475
			9.2.1 Definition of direction references.................................................475
				Basic rule...........................................................................475
				Switches.............................................................................475
			9.2.2 General rules for buttons and symbols on the display...............................476
			9.2.3 Engine.............................................................................477
				Side panel...........................................................................477
				Console, rear........................................................................478
				ECOS display.........................................................................478
			9.2.4 Seat contact switch and dead man's switch..........................................479
			9.2.5 ECOS crane control.................................................................480
				Control unit.........................................................................480
			9.2.6 Outriggers.........................................................................483
				Hand-held control....................................................................483
				In the Outriggers submenu............................................................484
				In the Settings submenu..............................................................485
				On the outrigger control units.......................................................486
			9.2.7 Inclination indicators.............................................................488
			9.2.8 Raise axle.........................................................................489
				Outrigger control units..............................................................489
			9.2.9 Outrigger pressure displays........................................................491
				Outriggers submenu..................................................................491
				Outriggers control units............................................................491
			9.2.10 Anemometer display................................................................491
			9.2.11 Main hoist........................................................................492
			9.2.12 Auxiliary hoist...................................................................494
			9.2.13 Slewing gear......................................................................495
				Submenu..............................................................................496
			9.2.14 Derricking gear...................................................................497
			9.2.15 Telescoping mechanism.............................................................499
				Control panels.......................................................................499
				Submenu..............................................................................500
				In the Settings submenu..............................................................504
			9.2.16 Hydraulic system..................................................................506
			9.2.17 Superstructure lock/houselock submenu.............................................507
				Houselock............................................................................508
			9.2.18 Rated capacity limiter (RCL)......................................................509
				Control unit.........................................................................509
				Main menu............................................................................511
				Rigging mode entry submenu...........................................................512
				Monitoring submenu..................................................................516
				Lifting capacity table submenu.......................................................520
				Working range submenu................................................................521
				Other................................................................................522
			9.2.19 Electrical system.................................................................523
			9.2.20 Lighting, windscreen wiper/washing system.........................................523
				Lighting.............................................................................523
				Windscreen wiper/washing system......................................................525
			9.2.21 Hand-held control.................................................................526
				Sockets for hand- held control.......................................................526
				Engine control panel.................................................................527
				Horn.................................................................................527
				Outriggers control panel............................................................528
			9.2.22 Windows, doors, keys..............................................................530
				Windows..............................................................................530
				Crane cab door.......................................................................530
				Keys.................................................................................531
			9.2.23 Diagnostics.......................................................................532
	10 Starting/turning off the engine – for crane operation.........................................535
		10.1 When starting the engine for the first time of the day..................................535
			10.1.1 Refuelling........................................................................536
				Fuel.................................................................................536
			10.1.2 Checks before starting the engine.................................................537
				On hydraulic tank....................................................................537
				Checking hand- held control..........................................................538
			10.1.3 Switching on the ignition.........................................................538
			10.1.4 Lamp test/switching state equalisation............................................539
				Lamp test............................................................................539
			10.1.5 Adjusting display brightness......................................................541
			10.1.6 Start the engine..................................................................542
				Without flame start system...........................................................542
				With flame start system..............................................................543
			10.1.7 Checks after starting the engine..................................................544
			10.1.8 Monitoring submenu................................................................545
			10.1.9 Setting the idling speed..........................................................546
			10.1.10 Switching off Economy mode.......................................................547
			10.1.11 Overriding torque reduction......................................................548
		10.2 Starting the engine – with the hand-held control........................................549
			Requirements.............................................................................549
			Starting the engine......................................................................549
		10.3 Turning off the engine..................................................................551
			10.3.1 During normal operation, with the ignition lock/with the hand- held control.......551
				After turning off....................................................................551
			10.3.2 In emergencies, with the emergency stop switches..................................552
				Resetting the emergency stop switch..................................................552
	11 Crane operation...............................................................................555
		11.1 Before operating the crane..............................................................555
			11.1.1 CHECKLIST: Checks before operating the crane......................................555
			11.1.2 Checking the condition of the truck crane.........................................559
				Fuel tank auxiliary heater...........................................................559
				Visual inspection....................................................................559
				Checking the position of the hoist ropes............................................560
				Checking the electrical system......................................................560
			11.1.3 Adjusting the crane cab seat and front control panel..............................561
				Crane cab seat.......................................................................561
				Front panel..........................................................................562
			11.1.4 Checking the safety equipment.....................................................563
				Rated capacity limiter...............................................................563
				Lifting limit switch................................................................563
				Emergency stop switch................................................................564
				Seat contact switch..................................................................565
			11.1.5 Earthing the load.................................................................566
			11.1.6 Locking/unlocking the superstructure..............................................567
				Locking points.......................................................................567
				Locking the superstructure..........................................................568
				Unlocking the superstructure........................................................568
			11.1.7 Switching the houselock on/off....................................................569
				Switching on the houselock..........................................................569
				Switching off the houselock.........................................................571
		11.2 Operation of the rated capacity limiter.................................................573
			11.2.1 Switching on the RCL..............................................................574
				Switching on.........................................................................574
				Brightness of the displays...........................................................576
			11.2.2 Entering the rigging mode.........................................................577
				Entering individual components.......................................................578
				Entering the RCL code...............................................................582
				Entering the reeving value.........................................................583
				Accepting the rigging mode..........................................................583
			11.2.3 Checks before operating the crane.................................................585
				Opening the submenu.................................................................585
				Checks...............................................................................586
			11.2.4 Displays during crane operation...................................................588
			11.2.5 RCL early warning.................................................................591
			11.2.6 RCL shutdown......................................................................591
				Shutdown due to overload.............................................................591
			11.2.7 Display during errors.............................................................593
			11.2.8 RCL override......................................................................594
				Table – error/ information codes.....................................................602
			11.2.9 Displaying the lifting capacity tables............................................603
			11.2.10 Entering the time/date...........................................................605
		11.3 Crane operation with main boom..........................................................607
			11.3.1 Checks during crane operation.....................................................607
				Horizontal alignment................................................................607
				Safe distances......................................................................607
				Checking the wind speed..............................................................608
			11.3.2 Permissible slewing ranges and working positions..................................609
				360 slewing range...................................................................609
				0 to the rear working position......................................................609
				180 to the front rigging position...................................................609
			11.3.3 Main hoist........................................................................610
				Switching on the main hoist..........................................................611
				Lifting and lowering................................................................611
				Switching off the main hoist........................................................612
			11.3.4 Auxiliary hoist...................................................................613
				Switching on the auxiliary hoist....................................................613
				Lifting and lowering................................................................614
				Switching off the auxiliary hoist...................................................615
			11.3.5 Lifting limit switch and lowering limit switch....................................616
				Lifting limit switch.................................................................616
				Lowering limit switch................................................................617
			11.3.6 Derricking gear...................................................................618
				Switching on the derricking gear....................................................618
				Raising and lowering................................................................619
				Re-enabling raising function........................................................620
				Switching off the derricking gear....................................................620
				Derricking gear warning..............................................................620
				Lowering the main boom to ahorizontal position.....................................621
			11.3.7 Telescoping mechanism.............................................................622
				Overview.............................................................................623
				Telescoping process.................................................................623
				Assignment for display...............................................................625
				Fixed length, intermediate length, telescoping length...............................627
				Telescope status.....................................................................628
				Telescoping sequence................................................................628
				Checks before starting work.........................................................629
				Switching on the telescoping mechanism..............................................630
				Function of the control lever........................................................630
				Switching off the telescoping mechanism.............................................632
				Manual telescoping..................................................................633
				Checking the initial position.......................................................633
				Unlocking the telescoping cylinder.................................................635
				Extending/retracting the telescoping cylinder........................................638
				Locking the telescoping cylinder...................................................639
				Unlocking the telescopic section....................................................640
				Telescoping the telescopic section..................................................642
				Locking telescopic sections........................................................643
				Locking the telescopic section for on-road driving.................................644
				Telescoping with teleautomation......................................................645
				Telescoping the main boom when horizontal............................................649
			11.3.8 High-speed mode...................................................................650
				Switch on function..................................................................650
				Derricking gear/ telescoping mechanism..............................................650
				Hoists...............................................................................651
			11.3.9 Slewing gear......................................................................652
				Braking the slewing movement.......................................................652
				Switching on the slewing gear........................................................653
				Releasing the slewing gear brake.....................................................653
				Engaging the slewing gear brake......................................................653
				Slewing..............................................................................654
				Braking the slewing movement.......................................................656
				Slewing gear freewheel..............................................................656
				Switch off the slewing gear..........................................................657
			11.3.10 Possible movement combinations...................................................657
			11.3.11 Hydraulic oil cooling............................................................658
		11.4 Settings and displays for crane operation...............................................659
			11.4.1 Inclining the crane cab...........................................................659
			11.4.2 Setting idling speed..............................................................660
			11.4.3 Adjusting the wiper stroke interval of the windscreen wiper.......................660
			11.4.4 Limiting the power unit speeds....................................................661
			11.4.5 Setting the characteristic curves for the control levers..........................662
			11.4.6 Using the slewable spotlights.....................................................663
			11.4.7 Displaying the operating hours....................................................664
			11.4.8 Warning submenu...................................................................665
				Meaning of the symbols...............................................................665
				Exiting the submenu.................................................................668
			11.4.9 Errors submenu....................................................................668
		11.5 Working range limiter...................................................................669
			11.5.1 Opening the working range limiter submenu.........................................670
			11.5.2 Viewing current settings..........................................................670
			11.5.3 Entering limit values.............................................................672
				Overall height/ working radius......................................................672
				Slewing angle........................................................................673
				Entering objects.....................................................................675
			11.5.4 Entering limit values/objects manually............................................678
				Limit values.........................................................................678
				Objects..............................................................................679
			11.5.5 Switching monitoring functions on/off.............................................680
			11.5.6 Shutdown by working range limiter.................................................681
		11.6 Work break..............................................................................682
			11.6.1 In case of short work breaks......................................................682
			11.6.2 In case of work breaks of more than 8 hours.......................................683
				To secure the truck crane............................................................683
		11.7 Heating and air-conditioning system.....................................................684
			11.7.1 Standard heating system...........................................................684
				Switching on.........................................................................684
				Heating..............................................................................684
				Air distribution.....................................................................685
				Switching off........................................................................685
			11.7.2 Air-conditioning system...........................................................686
				Warnings.............................................................................686
				Switching on/off.....................................................................686
				Cooling..............................................................................687
				Drying the air.......................................................................687
			11.7.3 Auxiliary water heater............................................................688
				Preheating the engine...............................................................688
				Preheating the crane cab............................................................689
				Switching on.........................................................................690
				Setting the day and time.............................................................691
				Storing the heating start..........................................................692
				Setting the heating period..........................................................693
				Switching heating start on/off......................................................693
				Switching off........................................................................694
				Setting the remaining time..........................................................694
			11.7.4 Auxiliary air heater..............................................................695
				Switching on.........................................................................695
				Temperature..........................................................................696
				Switching off........................................................................696
				Additional functions................................................................696
		11.8 CraneSTAR system........................................................................697
			11.8.1 Overview..........................................................................697
			11.8.2 Position of the components........................................................697
	12 Rigging work..................................................................................701
		12.1 Rigging work checklists for crane operation with the main boom..........................701
			12.1.1 CHECKLIST: Rigging................................................................701
			12.1.2 CHECKLIST: Unrigging..............................................................705
		12.2 Choosing a suitable site................................................................709
			12.2.1 Determining the required ground bearing area......................................709
			12.2.2 Safe distance from slopes and pits................................................712
			12.2.3 Earthing the truck crane..........................................................713
			12.2.4 Safe distance from electrical cables..............................................714
		12.3 Rigging work after driving with a trailer...............................................717
			12.3.1 Switching off the boom floating position..........................................717
			12.3.2 Switching off the slewing gear freewheel..........................................718
				Before slewing.......................................................................718
			12.3.3 Switching off boom pre-tensioning.................................................719
		12.4 Connecting/disconnecting the hand-held control..........................................721
		12.5 Starting the engine for driving for rigging work........................................723
			12.5.1 Starting/turning off the engine with the hand-held control........................723
				Requirements.........................................................................723
				Starting the engine..................................................................724
				Turning off the engine...............................................................724
			12.5.2 Starting/turning off the engine from the crane cab................................725
				Requirements.........................................................................725
				Starting the engine..................................................................725
				After starting the engine............................................................726
				Turning off the engine...............................................................726
			12.5.3 Starting/turning off the engine from the outrigger control units..................727
				Requirements.........................................................................727
				Starting the engine..................................................................727
				Turning off the engine...............................................................727
		12.6 Outriggers..............................................................................729
			12.6.1 CHECKLIST: Extending the outriggers...............................................729
			12.6.2 CHECKLIST: Retracting the outriggers..............................................731
			12.6.3 Permissible outrigger spans.......................................................732
			12.6.4 Preparing the truck crane.........................................................733
				In the driver's cab..................................................................733
				Outriggers control units............................................................733
			12.6.5 Setting the outrigger spans.......................................................734
				For on-road driving.................................................................736
			12.6.6 Extending/retracting outrigger beams..............................................737
				From the control units...............................................................738
				With the hand- held control..........................................................739
				From the crane cab...................................................................741
			12.6.7 Moving the outrigger pads into working/driving position...........................743
			12.6.8 Enlarging the ground bearing area.................................................744
			12.6.9 Extending/retracting supporting cylinders.........................................745
				From the control units...............................................................746
				With the hand- held control..........................................................747
				From the crane cab...................................................................748
			12.6.10 Levelling the truck crane on outriggers..........................................750
				Inclination indicators..............................................................750
				Requirements.........................................................................751
				Manual alignment....................................................................752
				Automatic alignment.................................................................753
			12.6.11 Levelling the free-standing truck crane..........................................755
			12.6.12 Outrigger pressure display.......................................................757
		12.7 Rigging/unrigging the counterweight.....................................................759
			12.7.1 Counterweight sections............................................................759
				Version A............................................................................759
				Version B............................................................................759
			12.7.2 Identification....................................................................760
			12.7.3 Slinging points on the counterweight sections.....................................761
			12.7.4 CHECKLIST: Counterweight, rigging.................................................762
			12.7.5 CHECKLIST: Counterweight, unrigging...............................................765
			12.7.6 Assembling counterweight combination..............................................767
				Setting down 10t sections/blocks version A.........................................768
				Combinations for the basic equipment in version A....................................769
				Setting down 10t sections/blocks version B.........................................774
				Combinations for the basic equipment in version B....................................775
			12.7.7 Securing/releasing 10 t blocks....................................................779
				Tensioning device....................................................................779
				Securing 10t blocks................................................................780
				Releasing 10t blocks...............................................................780
			12.7.8 Establishing/disconnecting the hydraulic connection...............................781
				Establishing.........................................................................781
				Disconnecting........................................................................781
			12.7.9 Making/breaking the electrical connection.........................................782
				Establishing.........................................................................782
				Disconnecting........................................................................782
			12.7.10 Rigging counterweight............................................................783
				Hand-held control....................................................................783
				Counterweight rigging...............................................................784
				Unrigging counterweight.............................................................785
				Counterweight safety valve...........................................................787
			12.7.11 Raising and lowering 10 t counterweight blocks with a mounted auxiliary hoist....788
			12.7.12 Slewing with rigged counterweight................................................789
		12.8 Rigging the auxiliary hoist.............................................................791
			12.8.1 Identification....................................................................791
			12.8.2 Slinging points and transport.....................................................792
				Slinging points......................................................................792
				Transport............................................................................793
			12.8.3 CHECKLIST: Mounting the auxiliary hoist...........................................794
				Requirements.........................................................................794
			12.8.4 CHECKLIST: Removing the auxiliary hoist...........................................796
				Requirements.........................................................................796
			12.8.5 Lifting the auxiliary hoist onto the 15 t base plate..............................798
			12.8.6 Raising/setting down the catcher..................................................799
				Raising..............................................................................799
				Setting down.........................................................................799
			12.8.7 Establishing/disconnecting the hydraulic connection...............................800
				Establishing.........................................................................800
				Disconnecting........................................................................800
			12.8.8 Making/breaking the electrical connection.........................................801
				Establishing.........................................................................801
				Disconnecting........................................................................801
			12.8.9 Locking/unlocking the auxiliary hoist.............................................802
				Auxiliary hoist safety valve.........................................................802
				Locking..............................................................................803
				Releasing the locking pin............................................................804
				Releasing the locking pin............................................................804
			12.8.10 Checking the auxiliary hoist for correct functioning.............................805
				With the hand- held control..........................................................805
				In the crane cab.....................................................................805
			12.8.11 Securing the upper hook block in the catcher.....................................806
			12.8.12 Railings on the auxiliary hoist..................................................806
			12.8.13 Permissible applications for the auxiliary hoist.................................807
				Replacement for the main hoist.......................................................807
				Alternating operation with themain and the auxiliary hoist.........................808
		12.9 Rigging work on the main boom...........................................................809
			12.9.1 Hook block on the bumper..........................................................809
				Picking up the hook block............................................................809
				Attaching the hook block.............................................................810
			12.9.2 Hook block on a separate vehicle..................................................811
				Picking up the hook block...........................................................812
				Setting down the hook block.........................................................812
			12.9.3 Reeving and unreeving the hoist rope..............................................814
				Rope end fitting.....................................................................814
				Reeving the hoist rope...............................................................815
				Unreeving the hoist rope............................................................818
			12.9.4 Possible reeving methods on the main boom.........................................819
				With 7 head sheaves..................................................................819
				With 10 head sheaves.................................................................822
				Maximum reeving......................................................................825
			12.9.5 Installing/removing the lifting limit switch......................................826
				Installing the lifting limit switch..................................................826
				Removing the lifting limit switch....................................................829
			12.9.6 Locking/Unlocking the lifting limit switch........................................831
				Locking..............................................................................831
				Unlocking...........................................................................831
			12.9.7 Anemometer and air traffic control light..........................................832
				Installing...........................................................................832
				Removing.............................................................................833
		12.10 Other rigging work.....................................................................835
			12.10.1 Railings on the turntable........................................................835
			12.10.2 Cameras for crane operation......................................................836
				Cameras on the hoists................................................................836
				Camera on main boom..................................................................837
	13 Driving with rigged truck crane...............................................................841
		13.1 Driving path............................................................................841
		13.2 Permissible rigging modes and axle loads................................................842
			Axle load table..........................................................................843
		13.3 Before driving..........................................................................844
			13.3.1 Securing the superstructure against slewing.......................................844
			13.3.2 Checking tyre pressure and wind speed.............................................845
			13.3.3 Putting the truck crane on the wheels.............................................846
			13.3.4 Transmission/connections..........................................................848
				Transmission.........................................................................848
				Switching on separate steering......................................................848
		13.4 While driving...........................................................................848
		13.5 After driving...........................................................................850
	14 Malfunctions during crane operation...........................................................853
		14.1 Emergency stop switch...................................................................853
		14.2 What to do when a malfunction occurs during crane operation.............................855
			Load can be lowered.....................................................................855
			Load cannot be lowered...................................................................855
		14.3 Fuses...................................................................................857
			Information on replacing fuses.........................................................857
			14.3.1 Fuses on the turntable............................................................858
				Fuse groups F1/F2/F3................................................................858
				Fuses on the circuit board..........................................................859
			14.3.2 Fuses in the crane cab............................................................861
			14.3.3 RCL fuses.........................................................................863
		14.4 Troubleshooting.........................................................................864
			14.4.1 Malfunctions on the engine........................................................864
			14.4.2 Malfunctions on the main hoist/auxiliary hoist....................................865
			14.4.3 Malfunctions in the hoist cameras.................................................866
			14.4.4 Malfunctions in the main boom camera..............................................866
			14.4.5 Malfunctions in the derricking gear...............................................867
			14.4.6 Malfunctions in the telescoping mechanism.........................................868
				Telescoping mechanism error messages.................................................869
			14.4.7 Malfunctions in the slewing gear..................................................871
			14.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler.........................872
			14.4.9 Malfunctions when inclining the crane cab.........................................872
			14.4.10 Malfunctions when operating with the hand-held control...........................872
			14.4.11 Malfunctions on the outriggers...................................................873
			14.4.12 Troubleshooting on the RCL.......................................................874
				General malfunctions................................................................874
				Error messages in the Monitoring submenu.............................................875
				Displays in the Error submenu........................................................877
				Error codes table....................................................................879
				Switch off sensor/ tachogenerator...................................................882
			14.4.13 Malfunctions ECOS – superstructure...............................................883
				ECOS programme version...............................................................883
				General malfunctions................................................................883
				Error messages.......................................................................884
				Exiting the submenu.................................................................885
			14.4.14 Malfunctions on the CraneSTAR system.............................................886
		14.5 Emergency operations and programmes.....................................................891
			14.5.1 Mechanical emergency activation for retracting....................................892
				Checks before emergency operation...................................................892
				Procedure............................................................................892
				Mechanical emergency operation......................................................893
			14.5.2 Telescoping emergency programme...................................................895
				Starting the emergency programme...................................................895
				Determining type of error...........................................................896
				Error on length indicator............................................................897
				Error on proximity switch............................................................901
				Terminating emergency programme....................................................902
				Tables for approaching the locking points............................................903
			14.5.3 Entering the current telescoping..................................................905
			14.5.4 Emergency operation with the hand-held control....................................907
				Preparations.........................................................................907
				Operating a power unit...............................................................908
				Stopping operations.................................................................910
				Stopping movements in emergencies...................................................910
				Turning off the engine...............................................................910
		14.6 Hydraulic emergency operation...........................................................911
			14.6.1 Functionality.....................................................................911
			14.6.2 Connecting/disconnecting hoses....................................................912
				Establishing.........................................................................912
				Disconnecting.......................................................................913
			14.6.3 Switching emergency operation on/off..............................................914
			14.6.4 Establishing the required hydraulic circuits......................................915
				Switching over valves................................................................915
			14.6.5 Performing emergency operation....................................................917
				Slewing..............................................................................917
				Derricking...........................................................................918
				Lifting/lowering.....................................................................918
			14.6.6 After emergency operation.........................................................919
				Switching off emergency operation...................................................919
				Switching over to crane operation....................................................919
				Disconnecting the hoses..............................................................919
			14.6.7 Emergency supply of another crane.................................................920
				For emergency supply.................................................................920
				After emergency supply...............................................................920
	15 Index.........................................................................................923
		A............................................................................................925
		B............................................................................................925
		C............................................................................................925
		D............................................................................................927
		E............................................................................................928
		F............................................................................................931
		H............................................................................................931
		I............................................................................................932
		K............................................................................................932
		L............................................................................................932
		M............................................................................................933
		O............................................................................................934
		P............................................................................................935
		R............................................................................................936
		S............................................................................................937
		T............................................................................................938
		V............................................................................................940
		W............................................................................................940

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