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Grove Crane GMK3060L Operating Manual 3302949 – PDF DOWNLOAD
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Description
Grove Crane GMK3060L Operating Manual 3302949 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK3060L Operating Manual 3302949 – PDF DOWNLOAD
Language : English
Pages : 936
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK3060L Operating Manual 3302949 – PDF DOWNLOAD
Intended use:
- The GMK3060L truck crane is constructed in accordance with the latest technology
and the recognised 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 be modified only with the consent of
Manitowoc Crane Group Germany GmbH. - The GMK3060L truck crane may be used only 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 GMK3060L truck crane may only be operated without the corresponding
special equipment within thepermitted temperature range; àTechnical data,
p. 1 – 7. - The GMK3060L truck crane is designed solely for lifting loads which are within
the permitted GMK3060L lifting capacities. The load must be slung as prescribed
to a hook block which is positioned vertically over the load prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
manual(s), the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
- The GMK3060L may only be operated with parts of equipment that have been
approved by Manitowoc Crane Group Germany GmbH and which are labelled with
the serial number of the GMK3060L. - The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK3060L truck crane. The user alone bears the risk.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK3060L Operating Manual 3302949 – PDF DOWNLOAD
Additional pages.............................................................................................. 3 Steering circuit warning.................................................................................. 3 Steering circuit 3 display (emergency steering pump).................................................. 3 Driving from the crane cab................................................................................ 5 Crane movement partially blocked...................................................................... 5 Outrigger control units................................................................................... 7 Switching over the display between metre/feet and percent............................................. 7 Battery spray............................................................................................. 9 Voltage monitoring display after engine start......................................................... 9 1 Overview.................................................................................................... 43 Accidents................................................................................................. 43 Branch offices............................................................................................ 45 Manitowoc Crane Care.................................................................................. 45 Dealer list........................................................................................... 45 Warranty specifications................................................................................... 45 Terms used................................................................................................ 46 Technical data............................................................................................ 49 Maximum lifting capacity (DIN/ ISO/ EN)............................................................... 49 Dimensions and weights of the truck crane, axle loads................................................. 0 Dimensions........................................................................................ 51 Weight and axle loads............................................................................. 51 Dimensions and weights of removable parts............................................................. 52 Spare wheel....................................................................................... 52 Outriggers........................................................................................ 52 Hook blocks....................................................................................... 52 Counterweight sections............................................................................ 53 Auxiliary hoist................................................................................... 54 Carrier............................................................................................... 55 Engine............................................................................................ 55 Transmission...................................................................................... 55 Transfer case..................................................................................... 55 Axle lines........................................................................................ 55 Steering.......................................................................................... 56 Tyres............................................................................................. 56 Turning radii..................................................................................... 56 Outriggers........................................................................................ 57 Electrical system................................................................................. 58 Tool.............................................................................................. 58 Towing couplings.................................................................................. 58 Driving speeds.................................................................................... 58 Climbing ability.................................................................................. 58 Superstructure........................................................................................ 59 Main hoist........................................................................................ 59 Auxiliary hoist................................................................................... 59 Slewing gear...................................................................................... 59 Derricking gear................................................................................... 59 Main boom......................................................................................... 60 Lattice extension................................................................................. 60 Operating speeds.................................................................................. 60 Documentation supplied.................................................................................... 61 Questions on documentation............................................................................ 62 Notes on the operating manual............................................................................. 63 What do the symbols used mean?........................................................................ 63 How is the operating manual structured?............................................................... 65 Division.......................................................................................... 65 Structure of the chapters......................................................................... 65 Structure of the pages............................................................................ 66 How do I find the information I need?................................................................. 67 Cross-references example.......................................................................... 68 What information is available for operations planning?................................................ 70 Conversion table for US measuring units................................................................... 71 Training – Information.................................................................................... 73 Identification............................................................................................ 74 EC Declaration of Conformity.............................................................................. 76 Notes on the engine....................................................................................... 77 Information on the engine............................................................................. 77 2 Basic safety instructions................................................................................... 79 Intended use.............................................................................................. 79 Improper use.......................................................................................... 80 Organisational measures................................................................................... 81 Personnel qualifications.................................................................................. 83 Safety instructions for driving the truck crane........................................................... 84 Safety instructions for crane operation................................................................... 85 Instructions on transporting persons...................................................................... 88 Equipment for lifting persons......................................................................... 88 Personnel............................................................................................. 89 Operation............................................................................................. 89 Truck crane........................................................................................... 90 3 Operating elements for driving.............................................................................. 91 Overview of the operating elements........................................................................ 91 On the outside of the truck crane..................................................................... 92 Driver's cab – Overview............................................................................... 96 Overview.......................................................................................... 96 Front overview.................................................................................... 98 Side overview..................................................................................... 99 Rear overview.....................................................................................100 Overview of doors.................................................................................101 Steering column/steering wheel........................................................................102 Instrument panel......................................................................................103 Left/right........................................................................................103 Middle............................................................................................104 Driving mode display..............................................................................108 Transmission operating elements.......................................................................109 Tachograph............................................................................................110 Heating and air-conditioning system...................................................................111 Standard heating system...........................................................................111 Auxiliary water heating system....................................................................112 CCS control unit......................................................................................113 CCS – Menu-independent displays.......................................................................114 CCS – Start menu......................................................................................115 CCS – Overview of menu groups.........................................................................116 Carrier menu group....................................................................................118 Suspension/level adjustment menu..................................................................119 Driving menu......................................................................................120 Exhaust system menu...............................................................................121 Air intake inhibitor menu.........................................................................122 Settings menu group...................................................................................123 Set display brightness menu.......................................................................124 Information menu group................................................................................125 Operating hours menu..............................................................................126 Engine/ transmission error menu...................................................................127 Crane operation error menu........................................................................128 Various controls menu group...........................................................................129 Outrigger control units...............................................................................130 Brief description of the operating elements...............................................................131 Definition of direction information...................................................................132 Basic rule........................................................................................132 General rules for buttons and symbols on the display..................................................133 Engine................................................................................................134 Steering column...................................................................................134 Multipurpose switch...............................................................................134 Instrument panel..................................................................................135 CCS display.......................................................................................136 AdBlue (DEF) system/Exhaust gas emission control system...............................................137 Instrument panel..................................................................................137 CCS display.......................................................................................138 Air intake inhibitor..................................................................................139 Battery master switch.................................................................................141 Electrical system.....................................................................................141 Crane control CCS.....................................................................................142 Transmission..........................................................................................144 Transmission control unit.........................................................................144 Driving mode display..............................................................................147 Reverse camera........................................................................................148 BirdView system 270°..................................................................................149 Final drive...........................................................................................150 Brakes................................................................................................152 Service brake.....................................................................................152 Additional brakes.................................................................................153 Parking brake.....................................................................................154 Steering/separate steering............................................................................155 Instrument panel..................................................................................155 Driver's door.....................................................................................155 CCS display.......................................................................................156 Suspension............................................................................................159 CCS display.......................................................................................159 Lighting/windscreen wipers/horn.......................................................................160 Steering column...................................................................................160 Instrument panel..................................................................................160 CCS display.......................................................................................163 Roof..............................................................................................163 Level adjustment system...............................................................................164 CCS display.......................................................................................165 Tachograph/speedometer................................................................................166 Tachograph........................................................................................166 Cover.............................................................................................166 Speedometer.......................................................................................166 Diagnostics...........................................................................................167 Front flap............................................................................................167 Windows and doors.....................................................................................168 Window winder.....................................................................................168 Doors.............................................................................................168 Access ladders and ladders............................................................................169 4 Starting/stopping the engine – for driving..................................................................173 Starting the engine – from the driver's cab...............................................................173 CHECKLIST: Starting the engine........................................................................174 CHECKLIST: At low temperatures........................................................................177 Refuelling............................................................................................178 Fuel tank.........................................................................................178 AdBlue (DEF) tank.................................................................................180 Checks before starting the engine.....................................................................181 At the hydraulic tank.............................................................................181 Battery master switch.............................................................................182 Switching the ignition on.............................................................................182 Lamp test/comparison of the switching states..........................................................183 Lamp test.........................................................................................183 Comparison of the switching states................................................................183 Display – setting the brightness......................................................................184 In the driver's cab...............................................................................184 In the crane cab..................................................................................184 Adjusting the brightness..........................................................................184 Temperature on the display........................................................................184 Starting the engine...................................................................................185 Without flame start system........................................................................186 With flame start system...........................................................................187 Checks after starting the engine......................................................................188 Starting the engine – at the outrigger control units......................................................190 Prerequisites.........................................................................................190 Starting the engine...................................................................................190 Switching off the engine..................................................................................192 In the driver's cab...................................................................................192 After switching off...............................................................................192 On the outrigger control units........................................................................192 With emergency stop switches..........................................................................193 Resetting the emergency stop switch...............................................................193 Air intake inhibitor......................................................................................194 Opening the air intake inhibitor......................................................................194 5 Driving mode................................................................................................195 Before driving............................................................................................195 CHECKLIST: Checks before on-road driving..............................................................195 Checking the condition of the truck crane.............................................................200 Electrical system.................................................................................200 Adjusting the mirrors.............................................................................200 Warning plates for vehicle width..................................................................202 Checking the vehicle height.......................................................................202 Supply pressure...................................................................................203 Parking brake.....................................................................................204 Third brake light.................................................................................205 Adjusting the seat and the steering column............................................................206 Adjusting the driver's seat.......................................................................206 Adjusting the passenger seat......................................................................208 Adjusting the steering column.....................................................................209 Storage compartment...............................................................................209 Switching the suspension on/off.......................................................................210 Opening the menu..................................................................................210 Switching on the suspension.......................................................................211 Switching off the suspension......................................................................211 Setting the tachograph................................................................................212 Prerequisites.....................................................................................212 In the event of malfunctions......................................................................212 Setting the tachograph............................................................................213 Displaying and resetting operating hours..............................................................217 Settings/indicators on the driving mode display.......................................................218 Operating the transmission................................................................................219 Switching on..........................................................................................219 Switching the transmission to the neutral position....................................................220 Selecting the direction of travel and starting gear...................................................221 Selecting the driving direction...................................................................221 Selecting the starting gear.......................................................................222 Changing the operating mode...........................................................................223 Changing to automatic mode........................................................................223 Changing to manual mode...........................................................................223 Starting..............................................................................................224 Driving and changing gears............................................................................225 In Automatic operating mode.......................................................................225 In Manual operating mode..........................................................................226 Changing the driving direction........................................................................227 Stopping the truck crane..............................................................................227 Stopping for a long period of time................................................................227 DM and RM transmission mode...........................................................................228 Switching on......................................................................................228 Switching off.....................................................................................229 On the roller type dynamometer........................................................................230 Preheating the transmission...........................................................................230 Driving and parking the truck crane.......................................................................231 Checks while driving..................................................................................231 Brakes............................................................................................231 ABS system........................................................................................231 Steering..........................................................................................232 Warning messages..................................................................................232 Cruise control........................................................................................233 Switching on......................................................................................233 Switching off.....................................................................................234 Driving downhill......................................................................................235 Starting..........................................................................................235 Inspections when driving downhill.................................................................236 Downshifting......................................................................................236 Additional brakes.................................................................................237 Driving uphill........................................................................................238 Starting..........................................................................................238 Driving...........................................................................................238 Torque reduction......................................................................................239 AdBlue (DEF) supply...............................................................................239 System malfunction................................................................................240 Overriding torque reduction...........................................................................242 Cleaning the exhaust system...........................................................................243 Automatic cleaning................................................................................243 Manual cleaning...................................................................................244 Disabling cleaning................................................................................245 Parking the truck crane...............................................................................246 Securing against rolling away.....................................................................246 When stationary for more than 8 hours.............................................................247 Fold-up berth.........................................................................................248 Off-road driving..........................................................................................249 Adjustments to the transmission.......................................................................249 Connections...........................................................................................249 Changing the vehicle level............................................................................249 Rocking the vehicle free and towing...................................................................249 Longitudinal and transverse differential locks........................................................250 Operating the level adjustment system.................................................................252 Opening the menu..................................................................................252 Setting the on-road level.........................................................................253 Pre-selecting suspension struts...................................................................254 Changing the vehicle level........................................................................254 Viewing the current inclination...................................................................255 Exiting the menu..................................................................................255 Freeing a stuck truck crane...........................................................................256 Rocking the truck crane free......................................................................256 Towing free forwards..............................................................................257 Towing free in reverse gear.......................................................................257 Separate steering.........................................................................................259 Switching to separate steering........................................................................260 Switching to normal steering mode.....................................................................262 Heating and air-conditioning system.......................................................................263 Standard heating system...............................................................................263 Switching on......................................................................................263 Heating...........................................................................................263 Air distribution..................................................................................264 Examples..........................................................................................265 Switching off.....................................................................................265 Air-conditioning system...............................................................................266 Notes.............................................................................................266 Switching on/off..................................................................................266 Cooling...........................................................................................267 Drying............................................................................................267 Auxiliary water heating system........................................................................268 Preheating the engine.............................................................................268 Preheating the driver's cab.......................................................................269 Switching on......................................................................................269 Setting the date and time.........................................................................271 Storing the heating start.........................................................................272 Battery heater........................................................................................274 Radio.....................................................................................................274 Towing a trailer..........................................................................................275 Effects on the axle loads.............................................................................275 Coupling the trailer..................................................................................276 Connecting the supply lines...........................................................................277 Removing the supply lines.............................................................................278 Uncoupling the trailer................................................................................278 Checking the braking force............................................................................280 6 Driving modes...............................................................................................281 Driving modes.............................................................................................281 Information about the axle loads......................................................................281 Notes on how to use the tables........................................................................282 Table for a maximum axle load of 12 t.................................................................283 Tyres 385/95 R25..................................................................................283 Tyres 445/95 R25..................................................................................284 Tyres 525/80 R25..................................................................................285 Maximum permitted speeds with an axle load of over 12 t...............................................286 Weighing the truck crane..................................................................................287 Axle groups...........................................................................................288 Weighing procedure....................................................................................289 Evaluation............................................................................................290 7 Transport...................................................................................................291 Transport with transport vehicle..........................................................................291 CHECKLIST: Checks before transport....................................................................292 Driving the truck crane on to the transport vehicle and lashing down..................................294 Transport by ship.........................................................................................295 8 Malfunctions in driving mode................................................................................297 Emergency stop switch.....................................................................................297 What to do when malfunctions occur........................................................................298 Procedure in the event of a malfunction in road traffic...............................................298 Warning and error messages................................................................................299 Warning and malfunction messages on the instrument panel..............................................299 Meaning of the lamps..............................................................................299 Warning messages on the driving mode display..........................................................304 Error messages....................................................................................304 Warning messages on the CCS display...................................................................306 Representation of the symbol frame................................................................306 Symbols on the CCS display........................................................................307 Error messages on the CCS display.....................................................................319 Exiting the menu..................................................................................320 Troubleshooting...........................................................................................321 Engine malfunctions...................................................................................321 Faults on the Adblue (DEF) system.....................................................................323 Differential lock malfunctions........................................................................323 Malfunctions in the transmission......................................................................324 Steering malfunctions.................................................................................325 Service brake malfunctions............................................................................326 Malfunctions of the level adjustment system...........................................................327 Malfunctions in the hydraulic system/hydraulic oil cooler.............................................327 Malfunctions in the CCS control unit..................................................................327 Emergency operation and breakdown assistance..............................................................329 Externally starting the truck crane...................................................................329 Battery charger.......................................................................................330 Prerequisites.....................................................................................330 Towing the truck crane................................................................................331 In the case of engine/ transmission damage........................................................331 Longer towing distances...........................................................................334 Tow starting......................................................................................334 Wheel change..........................................................................................335 Removing a damaged wheel..........................................................................335 On the spare wheel holder.........................................................................336 Mounting a wheel..................................................................................337 Inflating the tyres yourself..........................................................................339 Connecting the filling hose.......................................................................339 Inflating the tyres...............................................................................340 Removing the filling hose.........................................................................340 Tilting/lowering the driver's cab.........................................................................341 Prerequisites and information on tilting..............................................................341 Tilting and lowering the driver's cab.................................................................342 Operating the hand pump...........................................................................342 Tilting the driver's cab..........................................................................343 Lowering the driver's cab.........................................................................344 Fuses on the carrier......................................................................................345 Notes on changing fuses...............................................................................345 Fuses in the driver's cab.............................................................................346 Fuses in the battery box..............................................................................352 9 Operating elements for crane operation......................................................................353 Overview of the operating elements........................................................................353 Exterior of the truck crane...........................................................................354 Crane cab.............................................................................................358 Side panel........................................................................................360 Crane cab, rear...................................................................................362 Control panels........................................................................................364 Left..............................................................................................364 Right.............................................................................................365 Control lever configuration...........................................................................366 Version 1.........................................................................................366 Version 2.........................................................................................367 Heating/Air-conditioning system.......................................................................368 CCS control unit......................................................................................370 Menu-independent displays.............................................................................372 CCS – Start menu......................................................................................373 RCL display.......................................................................................374 Slewing ranges/ working radii display.............................................................375 CCS – Overview of menu groups.........................................................................376 Superstructure menu group.............................................................................380 Superstructure lock menu..........................................................................381 Counterweight menu................................................................................382 Outrigger/driving menu group..........................................................................383 Outrigger beam menu...............................................................................384 Outrigger cylinders menu..........................................................................386 Driving menu......................................................................................388 Exhaust system menu...............................................................................390 Air intake inhibitor menu.........................................................................391 RCL/Telescoping menu group............................................................................393 Enter rigging mode/telescope status menu..........................................................394 Pre-selection telescoping menu....................................................................398 Lifting capacity tables menu......................................................................400 Telescoping semi-automation menu..................................................................401 Manual telescoping menu...........................................................................402 Working range limiter menu group......................................................................403 Overall height menu...............................................................................404 Working radius menu...............................................................................405 Slewing angle menu................................................................................406 Hoist rope travel limitation menu.................................................................407 Information menu group 1..............................................................................408 Hydraulic pressure and fuel consumption menu......................................................409 Heating/Engine/Additional equipment menu group........................................................410 Remote control menu...............................................................................411 Telescoping emergency program menu group..............................................................412 Telescoping emergency program menu................................................................414 Unknown telescoping menu..........................................................................416 Settings menu group...................................................................................417 Crane cab menu....................................................................................418 Set display brightness and date/time menu.........................................................419 Switch units menu.................................................................................420 Set control lever characteristic curve menu.......................................................421 Power unit speeds menu............................................................................422 Information menu group 2..............................................................................423 Operating hours menu..............................................................................424 Engine/ transmission error menu...................................................................425 Crane operation error menu........................................................................426 Program version menu..............................................................................427 Various controls......................................................................................428 Query menus...........................................................................................429 RCL control unit......................................................................................430 Menu-independent displays.............................................................................431 RCL – menus...........................................................................................432 Monitoring menu...................................................................................432 Lifting capacity tables menu......................................................................434 Datalogger menu...................................................................................435 Hand-held control.....................................................................................436 Outrigger control units...............................................................................437 Menu-independent buttons..........................................................................437 Outrigger menu....................................................................................438 Brief description of the operating elements...............................................................441 Definition of direction information...................................................................441 Basic rule........................................................................................441 General rules for buttons and symbols on the display..................................................442 Engine................................................................................................443 CCS display.......................................................................................443 Side panel........................................................................................443 AdBlue (DEF) system/Exhaust gas emission control system...............................................444 CCS display.......................................................................................444 Air intake inhibitor..................................................................................445 CCS display.......................................................................................445 Seat contact switch and dead man's switch.............................................................446 Crane control CCS.....................................................................................447 Outrigger – crane cab.................................................................................452 Control panels....................................................................................452 CCS display.......................................................................................453 Outrigger control units...............................................................................455 General information...............................................................................455 Outrigger menu....................................................................................456 Inclination indicators................................................................................458 Outrigger pressure displays...........................................................................459 Outrigger menu....................................................................................459 Outrigger control units...........................................................................459 Anemometer displays...................................................................................459 Counterweight menu....................................................................................460 CCS display.......................................................................................463 Main hoist............................................................................................464 Control panels....................................................................................464 CCS display.......................................................................................464 Auxiliary hoist.......................................................................................466 Control panels....................................................................................466 CCS display.......................................................................................466 Slewing gear..........................................................................................468 Control panels....................................................................................468 CCS display.......................................................................................469 Derricking gear.......................................................................................470 Control panels....................................................................................470 CCS display.......................................................................................471 Side panel........................................................................................471 Telescoping mechanism.................................................................................472 Control panels....................................................................................472 CCS display.......................................................................................473 Telescoping semi-automation menu..................................................................473 Manual telescoping menu...........................................................................475 Hydraulic system......................................................................................478 CCS display.......................................................................................478 Superstructure lock menu..............................................................................479 Turntable lock....................................................................................479 Houselock.........................................................................................481 CCS display.......................................................................................481 Remote control........................................................................................482 Rated capacity limiter (RCL)..........................................................................483 CCS display.......................................................................................483 RCL display.......................................................................................492 RCL override – version A..........................................................................493 RCL override – version B..........................................................................494 Electrical system.....................................................................................495 Lighting, windscreen wiper/washing system.............................................................496 Lighting..........................................................................................496 Windscreen wiper/ washing system..................................................................498 Horn..............................................................................................499 Hand-held control.....................................................................................500 Engine control panel..............................................................................500 Horn..............................................................................................500 Pre-select emergency operation....................................................................501 Windows and doors.....................................................................................502 Windows...........................................................................................502 Rear window.......................................................................................502 Crane cab door....................................................................................503 Diagnostics...........................................................................................504 Other.................................................................................................504 Short description of the operating elements – driving from the crane cab..................................505 Driving menu..........................................................................................505 Transmission..........................................................................................507 Final drive...........................................................................................509 Brakes................................................................................................510 CCS display.......................................................................................510 Side panel from above.............................................................................510 Steering..............................................................................................512 CCS display.......................................................................................512 Control panels....................................................................................515 10 Starting/switching off the engine – for crane operation....................................................517 When starting the engine for the first time in the day....................................................517 Starting the engine – from the crane cab..................................................................519 Checking the fuel level and AdBlue (DEF) level........................................................519 Fuel..............................................................................................519 AdBlue (DEF)......................................................................................519 Checks before starting the engine.....................................................................520 Checks on the carrier.............................................................................520 Checking the hand-held control....................................................................520 Switching on the ignition.............................................................................520 Control lever deflection query........................................................................521 Comparison of switching states........................................................................522 Display – setting the brightness......................................................................523 Starting the engine...................................................................................523 Checks after starting the engine......................................................................524 Setting idling speed..................................................................................525 Starting the engine – with the hand-held control..........................................................526 Switching off the engine..................................................................................526 When the hand-held control is connected...............................................................526 In the crane cab......................................................................................527 After switching off...............................................................................527 Using the emergency stop switches.....................................................................528 Resetting the emergency stop switch...............................................................528 11 Crane operation............................................................................................529 Before operating the crane................................................................................529 CHECKLIST: Checks before operating the crane..........................................................529 Checking the condition of the truck crane.............................................................533 Crane cab heater fuel tank........................................................................533 Visual inspection.................................................................................533 Checking the position of the hoist ropes..........................................................534 Checking the electrical system....................................................................535 Adjusting the crane cab seat and front control panel..................................................536 Crane cab seat....................................................................................536 Control panels....................................................................................537 Front control panel...............................................................................538 Checking the safety devices...........................................................................539 Rated capacity limiter............................................................................539 Lifting limit switch..............................................................................539 Emergency stop switch.............................................................................540 Seat contact switch...............................................................................541 Earthing the load.....................................................................................543 Locking/unlocking the turntable.......................................................................544 Locking points....................................................................................544 Locking the turntable.............................................................................545 Unlocking the turntable...........................................................................545 Switching the houselock on/off........................................................................546 Switching on the houselock........................................................................546 Switching off the houselock.......................................................................548 Setting the time......................................................................................549 Standard slewing range type...............................................................................551 Permissible slewing ranges and operating positions....................................................551 360° slewing range................................................................................551 Operating position 0° to the rear.................................................................551 180° to the front rigging position................................................................551 Free-on-wheels operating position.................................................................552 MAXbase slewing range type................................................................................553 Specifications in the lifting capacity tables.........................................................555 Enabled slewing ranges................................................................................556 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables....558 Operation of the rated capacity limiter...................................................................559 Switching on the RCL..................................................................................560 Switching on......................................................................................560 Entering the rigging mode.............................................................................562 Notes on Input....................................................................................562 Enter the slewing range type......................................................................563 Entering individual components....................................................................564 Entering the RCL code.............................................................................570 Pre-selecting telescoping.............................................................................570 Confirming the rigging mode and lifting capacity table................................................571 Slewing range type Standard.......................................................................571 Slewing range type MAXbase........................................................................573 Checks before operating the crane.....................................................................575 Monitoring menu...................................................................................575 Checking the rigging mode.........................................................................575 Hoist checking....................................................................................578 Displays during the crane operation...................................................................579 On the RCL display................................................................................579 On the CCS display................................................................................583 RCL early warning.....................................................................................587 RCL shutdown..........................................................................................587 Shutdown due to overload..........................................................................587 Displaying the lifting capacity tables................................................................589 Standard slewing range type.......................................................................589 Slewing range type MAXbase........................................................................591 RCL override – version A..............................................................................593 Overview status display...........................................................................593 When rigging......................................................................................594 To raise the boom.................................................................................595 In emergencies....................................................................................596 RCL override – version B..............................................................................597 Datalogger............................................................................................598 Export data.......................................................................................598 Display the data..................................................................................599 Crane operation with main boom............................................................................603 Checks during crane operation.........................................................................603 Horizontal alignment..............................................................................603 Safe distances....................................................................................603 Checking the wind speed...........................................................................604 Deformation of the main boom due to direct sunlight...............................................605 Main hoist............................................................................................607 Switching on the main hoist.......................................................................608 Lifting and lowering..............................................................................609 Maximum permissible hoist rope speed..............................................................610 Switching off the main hoist......................................................................610 Auxiliary hoist.......................................................................................611 Switching on the auxiliary hoist..................................................................611 Lifting and lowering..............................................................................612 Maximum permissible hoist rope speed..............................................................613 Switching off the auxiliary hoist.................................................................613 Lifting limit switch and lowering limit switch........................................................614 Lifting limit switch..............................................................................614 Lowering limit switch.............................................................................616 Derricking gear.......................................................................................617 Switching on the derricking gear..................................................................617 Raising and lowering..............................................................................618 Maximum derricking speed..........................................................................619 Re-enabling the raising function..................................................................619 Switching off the derricking gear.................................................................620 Lowering the main boom to a horizontal position...................................................620 Telescoping mechanism.................................................................................621 Overview..........................................................................................623 Telescoping process...............................................................................624 Assignment for display............................................................................626 Fixed length, intermediate length, telescoping length.............................................627 Telescoping.......................................................................................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.....................................................637 Lock telescoping cylinder.........................................................................638 Unlocking the telescopic section..................................................................639 Telescoping the telescopic section................................................................640 Locking the telescopic section....................................................................641 Locking the telescopic section for on-road driving................................................642 Telescoping with semi-automation..................................................................642 Telescoping with pre-selection....................................................................644 High-speed mode.......................................................................................645 Derricking gear/ telescoping mechanism............................................................645 Hoists............................................................................................646 Slewing gear..........................................................................................647 Slewing gear brake................................................................................647 Switching on the slewing gear.....................................................................648 Releasing the slewing gear brake..................................................................648 Engaging the slewing gear brake...................................................................648 Slewing...........................................................................................649 Maximum slewing speed.............................................................................650 Braking the slewing movement......................................................................651 Slewing gear freewheel............................................................................651 Switching off the slewing gear....................................................................652 Slewing speed – Switching the reduction on and off....................................................653 Switching reduction off...........................................................................653 Possible movement combinations........................................................................654 Settings and displays for crane operation.................................................................655 Inclining the crane cab...............................................................................655 Setting idling speed..................................................................................656 Adjusting the wiper stroke interval of the windscreen wiper...........................................656 Limiting the power unit speeds........................................................................657 Switching the units of measure........................................................................658 Setting the characteristic curves for the control levers..............................................659 Using the slewable spotlights.........................................................................660 Displaying the operating hours........................................................................661 Working range limiter.....................................................................................663 viewing current settings..............................................................................664 On the RCL display................................................................................664 In the CCS Start menu.............................................................................665 Opening the working range limiter menu................................................................665 Enter limit values – for the overall height...........................................................666 Entering limit values – for the working radius........................................................668 Enter limit values – for the slewing range............................................................670 Enter limit values – for the hoist rope travel........................................................673 Shutdown by working range limiter.....................................................................675 Work break................................................................................................677 In case of short work breaks..........................................................................677 In case of work breaks longer than 8 hours............................................................678 To secure the truck crane.........................................................................678 Heating and air-conditioning system.......................................................................679 Heating system........................................................................................679 Switching on......................................................................................679 Heating...........................................................................................680 Air distribution..................................................................................681 Setting the day and time..........................................................................682 Storing the heating start.........................................................................683 Setting the heating period........................................................................684 Switching the heating start on and off............................................................684 Switching off.....................................................................................685 Setting the remaining time........................................................................685 Air-conditioning system...............................................................................686 Notes.............................................................................................686 Switching on......................................................................................686 Drying the air....................................................................................687 Switching off.....................................................................................687 CraneSTAR system..........................................................................................688 Overview..............................................................................................688 Position of the components............................................................................688 12 Rigging work...............................................................................................689 Rigging work checklists for crane operation with the main boom............................................689 CHECKLIST: Rigging....................................................................................689 CHECKLIST: Unrigging..................................................................................694 Selecting the suitable site...............................................................................697 Determining the required load-bearing area............................................................697 Safe distance from slopes and pits....................................................................700 Earthing the truck crane..............................................................................701 Safe distance from overhead power lines...............................................................702 Outriggers – Overview – Standard slewing range type.......................................................705 representation in the lifting capacity tables.........................................................705 Enabled outrigger spans...............................................................................706 Outriggers – Overview – MAXbase slewing range type........................................................707 Definitions...........................................................................................707 Representation in the lifting capacity tables.........................................................709 Enabled outrigger spans...............................................................................710 Operating the outriggers..................................................................................715 CHECKLIST: Extending the outriggers...................................................................715 CHECKLIST: Retracting the outriggers..................................................................717 Preparing the truck crane.............................................................................718 Setting the spans.....................................................................................719 For on-road driving...............................................................................720 Extending/retracting outrigger beams..................................................................721 From the control units............................................................................722 From the crane cab................................................................................723 Moving the outrigger pads into operating/driving position.............................................725 Enlarging the load-bearing area.......................................................................726 Extending/retracting supporting cylinders.............................................................727 From the control units............................................................................728 From the crane cab................................................................................729 Levelling the truck crane on outriggers horizontally..................................................731 Inclination indicators............................................................................731 Prerequisites.....................................................................................732 Manual alignment..................................................................................733 Automatic alignment...............................................................................734 Levelling the free-standing truck crane...............................................................735 Outrigger pressure display............................................................................736 Rigging/unrigging the counterweight.......................................................................739 Information on rigging................................................................................739 When rigging......................................................................................739 When unrigging....................................................................................740 Counterweight sections................................................................................741 Identification........................................................................................742 Slinging points on the counterweight sections.........................................................743 CHECKLIST: Rigging the counterweight..................................................................745 CHECKLIST: Unrigging the counterweight................................................................746 Assembling counterweight versions – on the turntable..................................................748 Assembling counterweight versions – on the counterweight platform.....................................749 Setting down the 1.0 t base plate.................................................................750 Counterweight hoist unit..............................................................................753 Counterweight menu................................................................................753 Extending/ retracting the lifting cylinders.......................................................754 Automatic rigging.................................................................................756 Automatic unrigging...............................................................................758 Cancelling automatic mode.........................................................................759 Removing/installing the counterweight on the turntable................................................760 Removing..........................................................................................760 Installing........................................................................................761 Setting down the counterweight for driving............................................................761 Slewing with rigged counterweight.....................................................................763 Installing/removing the auxiliary hoist/0.5 t section.....................................................765 Slinging the auxiliary hoist..........................................................................765 CHECKLIST: Installing the auxiliary hoist/removing the 0.5 t plate....................................766 CHECKLIST: Removing the auxiliary hoist/installing the 0.5 t plate....................................767 Establishing/disconnecting the connection between the auxiliary hoist and the turntable...............768 Establishing/disconnecting the hydraulic connection...................................................769 Establishing/disconnecting the electrical connection..................................................770 Establishing/disconnecting the connection to the central lubrication..................................771 Checking that the auxiliary hoist is functioning properly.............................................772 Slewing direction.................................................................................772 Slewing indicator.................................................................................772 Rigging the 0.5 t section.................................................................................773 Prerequisites.........................................................................................773 Slinging the 0.5 t section............................................................................773 Establishing/disconnecting the connection between the 0.5 t section and the turntable.................774 Transporting the auxiliary hoist/0.5 t section........................................................775 Rigging work on the main boom.............................................................................777 Hook block on the bumper..............................................................................777 Picking up the hook block.........................................................................777 Attaching the hook block..........................................................................778 Hook block on a separate vehicle......................................................................779 Picking up the hook block.........................................................................780 Setting down the hook block.......................................................................780 Reeving and unreeving the hoist rope..................................................................782 Reeving the hoist rope............................................................................784 Unreeving the hoist rope..........................................................................787 Possible reeving methods on the main boom.............................................................789 With 5 head sheaves...............................................................................789 With 6 head sheaves...............................................................................792 Installing/removing the lifting limit switch..........................................................795 Installing the lifting limit switch...............................................................795 Removing the lifting limit switch.................................................................798 Locking/unlocking the lifting limit switch............................................................800 Locking...........................................................................................800 Unlocking.........................................................................................800 Anemometer and air traffic control light..............................................................801 Installing........................................................................................801 Switching on/off..................................................................................802 Removing..........................................................................................803 Other rigging work........................................................................................805 Folding the mirrors in and out, and adjusting them....................................................805 Cameras for crane operation...........................................................................806 Camera on main boom...............................................................................806 Camera on the hoists..............................................................................809 Camera on the driver's cab........................................................................809 Operating the camera..............................................................................810 Step at the crane cab.................................................................................812 13 Driving with a rigged truck crane..........................................................................813 Driving route.............................................................................................813 Permissible rigging modes and axle loads..................................................................814 Axle load table.......................................................................................814 To drive without a load...............................................................................817 To drive with a load..................................................................................818 Axle loads............................................................................................818 Before driving the rigged truck crane.....................................................................819 Checking tyre pressure and wind speed.................................................................819 Secure the superstructure against slewing.............................................................819 Putting the truck crane on the wheels.................................................................820 Driving from the driver's cab.............................................................................823 Preparing to drive....................................................................................823 Transmission......................................................................................823 Switching on separate steering....................................................................823 Connections.......................................................................................824 While driving.........................................................................................824 After driving.........................................................................................825 Driving from the crane cab................................................................................827 Preparing to drive....................................................................................828 Opening/closing the Driving menu......................................................................829 Opening menu......................................................................................829 Selecting the operating mode......................................................................829 Crane's hydraulic system Driving mode.............................................................831 Closing menu......................................................................................831 Steering..............................................................................................832 Switching on......................................................................................832 Display and steering direction....................................................................832 Changing the steering direction...................................................................833 Displays when steering............................................................................833 Separate steering.................................................................................834 Normal steering...................................................................................837 Operating the transmission............................................................................838 Selecting the transmission mode...................................................................838 While driving.........................................................................................839 DM and RM transmission mode.......................................................................839 Transmission mode D...............................................................................839 Warning messages..................................................................................839 Possible connections..................................................................................840 Longitudinal/ transverse differential locks.......................................................840 After driving.........................................................................................842 14 Malfunctions during crane operation........................................................................843 Emergency stop switch.....................................................................................843 What to do when malfunctions occur during crane operation.................................................844 The load can be set down..............................................................................844 Load cannot be set down...............................................................................844 Warning and error messages................................................................................845 Program version.......................................................................................845 Warning messages on the CCS display...................................................................845 Error messages on the CCS display.....................................................................846 Warning messages on the RCL display...................................................................848 Troubleshooting...........................................................................................853 Engine malfunctions...................................................................................853 Malfunctions on the main hoist/auxiliary hoist........................................................853 Malfunctions in the hoist cameras.....................................................................855 Malfunctions in the main boom camera..................................................................855 Malfunctions in the derricking gear...................................................................856 Malfunctions in the telescoping mechanism.............................................................857 Malfunctions in the slewing gear......................................................................858 Malfunctions in the counterweight hoist unit..........................................................860 Malfunctions in the hydraulic system/hydraulic oil cooler.............................................860 Malfunctions when operating with the hand-held control................................................861 Malfunctions crane cab................................................................................861 Malfunctions on the outriggers........................................................................862 Malfunctions on the turntable lock....................................................................862 Malfunctions on the CCS/RCL control units.............................................................863 Malfunctions when driving from the crane cab..........................................................863 Malfunctions on the CraneSTAR system..................................................................864 Emergency operations and programs.........................................................................867 Mechanical emergency activation for retracting........................................................868 Checks before emergency activation................................................................868 Procedure.........................................................................................868 Mechanical emergency activation...................................................................869 Telescoping emergency program.........................................................................871 Opening telescoping emergency program menu........................................................871 Notes on the displays.............................................................................872 Checks in the emergency program...................................................................874 Retracting with emergency program.................................................................878 Tables for approaching the locking points.........................................................880 Entering the current telescoping......................................................................882 Emergency operation with the hand-held control........................................................884 Sockets...........................................................................................884 Connection........................................................................................885 Button combinations...............................................................................886 Emergency operation...............................................................................887 Notes on slewing in emergency operation...............................................................889 For the standard slewing range type...............................................................889 For the MAXbase slewing range type................................................................890 Slewing with an overridden slewing gear shutdown......................................................891 Hydraulic emergency operation with the hand pump..........................................................892 Connecting/disconnecting hoses........................................................................893 Establishing the required hydraulic circuits..........................................................894 Switching over valves.............................................................................894 For lifting/lowering the load.....................................................................895 Performing emergency activation.......................................................................896 After emergency activation............................................................................897 Hydraulic emergency operation as per DGUV.................................................................898 Applications and function.............................................................................898 CHECKLIST: Emergency operation........................................................................900 CHECKLIST: After emergency operation..................................................................901 For self-supply – connecting/disconnecting hoses......................................................902 For external supply – connecting/disconnecting the transformer........................................903 Establishing the required hydraulic circuits..........................................................904 Valves at the control panel.......................................................................904 For lifting/lowering..............................................................................905 For slewing.......................................................................................906 Performing emergency operation........................................................................907 Lifting/lowering..................................................................................907 Slewing...........................................................................................908 Derricking........................................................................................909 Emergency supply of another crane.....................................................................910 For emergency supply..............................................................................910 After emergency supply............................................................................910 Switching emergency operation on/off..................................................................911 Fuses in the crane cab....................................................................................912 Notes on changing fuses...............................................................................912 15 Index......................................................................................................919 A.........................................................................................................921 B.........................................................................................................921 C.........................................................................................................921 D.........................................................................................................924 E.........................................................................................................925 F.........................................................................................................926 H.........................................................................................................926 I.........................................................................................................927 L.........................................................................................................928 M.........................................................................................................928 O.........................................................................................................929 R.........................................................................................................930 S.........................................................................................................931 T.........................................................................................................932 W.........................................................................................................933
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