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Grove Crane GMK4100-L Part 1 Driving Operating Manual 3113129 – PDF DOWNLOAD
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Description
Grove Crane GMK4100-L Part 1 Driving Operating Manual 3113129 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK4100-L Part 1 Driving Operating Manual 3113129 – PDF DOWNLOAD
Language : English
Pages : 914
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK4100-L Part 1 Driving Operating Manual 3113129 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
- The GMK 4100L is a state-of-the-art truck crane, designed in accordance
with approved safety regulations. Nevertheless, the operator or third parties
can still be endangered and the crane or other property put at risk while
using it. - The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK 4100L truck crane may only be used when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards. - Any malfunctions that could impair safety must be eliminated immediately.
Without the corresponding special equipment, the GMK 4100L truck crane
may only be operated within the permitted temperature range; àTechnical
data, p. 1 – 7. - The GMK 4100L truck crane is designed solely for lifting loads which are
within the permitted GMK 4100L lifting capacities. The load must be slung
as prescribed to a hook block which is positioned vertically over the load
prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
- The GMK 4100L may only be operated with parts of equipment which are
permitted by Manitowoc Crane Group Germany GmbH and which are labelled
with the serial number of the GMK 4100L. - The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK 4100L truck crane. The user alone bears the risk.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK4100-L Part 1 Driving Operating Manual 3113129 – PDF DOWNLOAD
Correction sheets ........................................................................... 3 Round outrigger pads made of synthetic material ......................................... 3 1 Overview................................................................................... 9 1.1 Accidents............................................................................ 9 1.2 Branch offices....................................................................... 11 1.2.1 Manitowoc Crane Care........................................................... 11 1.2.2 Dealer list.................................................................... 11 1.3 Warranty specifications.............................................................. 11 1.4 Terms used........................................................................... 12 1.5 Technical data....................................................................... 15 1.5.1 Maximum lifting capacity (ASME B 30.5)......................................... 15 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 16 Dimensions....................................................................... 17 Weight and axle loads............................................................ 17 1.5.3 Dimensions and weights of removable parts...................................... 18 Spare wheel...................................................................... 18 Outriggers....................................................................... 18 Counterweight combinations....................................................... 18 Counterweight parts.............................................................. 19 Hook blocks and hook tackle...................................................... 19 1.5.4 Carrier........................................................................ 21 Engine........................................................................... 21 Transmission..................................................................... 22 Transfer case.................................................................... 22 Axle lines....................................................................... 22 Steering......................................................................... 22 Tyres............................................................................ 22 Outriggers....................................................................... 23 Electrical system................................................................ 23 Tool............................................................................. 23 Towing couplings................................................................. 23 Driving speeds................................................................... 24 Climbing ability................................................................. 24 Turning radii.................................................................... 24 1.5.5 Superstructure................................................................. 25 Engine........................................................................... 25 Main hoist....................................................................... 25 Auxiliary hoist.................................................................. 26 Slewing gear..................................................................... 26 Derricking gear.................................................................. 26 Main boom........................................................................ 27 Lattice extension................................................................ 27 Operating speeds................................................................. 27 1.6 Documentation supplied............................................................... 29 1.6.1 Questions on documentation..................................................... 30 1.7 Notes on the operating instructions.................................................. 31 1.7.1 What do the symbols used mean?................................................. 31 1.7.2 How are the operating instructions structured?................................. 33 Division......................................................................... 33 Structure of the chapters........................................................ 33 Structure of the pages........................................................... 34 1.7.3 How do I find the information I need?.......................................... 35 Cross-references example......................................................... 36 1.7.4 What information is available for operations planning?......................... 38 1.8 Conversion table for US measuring units.............................................. 39 1.9 Training – Information............................................................... 41 1.10 Identification...................................................................... 42 1.11 EC Declaration of Conformity........................................................ 44 2 Basic safety instructions.................................................................. 47 2.1 Intended use......................................................................... 47 2.1.1 Improper use................................................................... 48 2.2 Organisational measures.............................................................. 49 2.3 Personnel qualifications............................................................. 51 2.4 Safety instructions for driving the truck crane...................................... 52 2.5 Safety instructions for crane operation.............................................. 53 2.6 Notes on transporting persons........................................................ 55 Equipment for lifting persons........................................................ 55 Personnel............................................................................ 55 Operation............................................................................ 56 Truck crane.......................................................................... 57 3 Operating elements for driving............................................................. 61 3.1 Overview of the operating elements................................................... 61 3.1.1 On the outside of the truck crane.............................................. 62 3.1.2 Driver's cab................................................................... 64 Overview......................................................................... 64 Behind the cover................................................................. 66 3.1.3 Instrument panel............................................................... 67 Left/right....................................................................... 67 Middle........................................................................... 68 3.1.4 On-board computer.............................................................. 70 Display, driving mode............................................................ 70 On-board computer time correction................................................ 71 3.1.5 Steering column/steering wheel................................................. 72 3.1.6 Transmission operating elements................................................ 73 3.1.7 Tachograph..................................................................... 75 3.1.8 ECOS control unit.............................................................. 76 3.1.9 ECOS display – main menu....................................................... 78 3.1.10 ECOS display – submenus....................................................... 80 Level adjustment system submenu................................................. 80 Settings submenu................................................................ 81 Operating hours submenu.......................................................... 82 Warning submenu.................................................................. 83 Transmission emergency program submenu........................................... 84 Error submenu.................................................................... 85 3.1.11 Heating/Air-conditioning system............................................... 86 Standard heating system.......................................................... 86 Auxiliary air heater............................................................. 87 Auxiliary water heater........................................................... 89 3.1.12 Sockets for hand-held control................................................. 90 3.1.13 Outrigger control units....................................................... 91 3.2 Short description of the operating elements.......................................... 93 3.2.1 Definition of direction information............................................ 93 Basic rule....................................................................... 93 Switches and buttons............................................................. 94 3.2.2 General rules for buttons and symbols on the display........................... 94 3.2.3 Engine......................................................................... 95 Steering column.................................................................. 95 Multipurpose switch.............................................................. 95 Instrument panel................................................................. 97 Main menu........................................................................ 97 3.2.4 DEF system..................................................................... 98 Instrument panel................................................................. 98 3.2.5 Electrical system.............................................................. 99 3.2.6 ECOS crane control.............................................................100 Control unit.....................................................................100 3.2.7 Transmission...................................................................103 Transmission display.............................................................103 ECOS display.....................................................................103 Operating elements...............................................................104 Instrument panel.................................................................105 3.2.8 Transfer case..................................................................106 Main menu........................................................................106 3.2.9 Final drive....................................................................107 3.2.10 Reverse camera................................................................108 3.2.11 Brakes........................................................................109 Service brake....................................................................109 Parking brake....................................................................110 Additional brakes................................................................111 3.2.12 Steering/separate steering....................................................112 ECOS display.....................................................................112 Driver's door....................................................................113 3.2.13 Suspension....................................................................113 3.2.14 Lighting/windscreen wipers/horn...............................................114 Steering column..................................................................114 Instrument panel.................................................................114 Roof.............................................................................116 3.2.15 Level adjustment system.......................................................116 3.2.16 Tachograph/speedometer........................................................118 Tachograph.......................................................................118 Speedometer......................................................................118 3.2.17 Diagnostics...................................................................119 Displays/ submenu................................................................119 3.2.18 On-board computer.............................................................120 3.2.19 Push-up roof..................................................................122 3.2.20 Windows, doors, keys..........................................................122 Window winder....................................................................122 Doors............................................................................123 Keys.............................................................................123 3.2.21 Front flap....................................................................124 3.2.22 Storage compartment...........................................................124 3.2.23 Hand-held control bracket.....................................................125 4 Starting/turning off the engine for driving................................................129 4.1 Starting the engine from the driver's cab............................................129 4.1.1 CHECKLIST: Starting the engine.................................................129 4.1.2 CHECKLIST: At low temperatures.................................................132 4.1.3 Ladders and access ladders.....................................................133 Ladders..........................................................................133 Access ladders...................................................................134 4.1.4 Refuel.........................................................................135 Fuel tank........................................................................135 DEF tank.........................................................................136 4.1.5 Checks before starting the engine..............................................137 On hydraulic tank................................................................137 Battery master switch............................................................137 Checking hand- held control......................................................138 4.1.6 Switching on the ignition......................................................138 4.1.7 Lamp test/equalisation of the switching states.................................139 Lamp test........................................................................139 Equalisation of the switching states.............................................140 4.1.8 Display – setting the brightness...............................................141 4.1.9 Starting the engine............................................................142 Without flame start system.......................................................143 With flame start system..........................................................144 4.1.10 Checks after starting the engine..............................................145 4.1.11 Monitoring elements...........................................................146 Instrument panel.................................................................146 ECOS display.....................................................................147 Display driving mode............................................................147 4.1.12 Setting idling speed..........................................................148 4.2 Turning off the engine...............................................................149 4.2.1 On the ignition lock/with hand-held control....................................149 After turning off................................................................149 4.2.2 Using the emergency stop switches..............................................150 Resetting the emergency stop switch..............................................150 4.3 Air intake inhibitor.................................................................151 Releasing the air intake inhibitor...................................................151 5 Driving....................................................................................155 5.1 Before driving.......................................................................155 5.1.1 CHECKLIST: Checks before on-road driving.......................................155 5.1.2 Checking the condition of the truck crane......................................161 Electrical system................................................................161 Adjusting the mirrors............................................................161 Adjusting the reverse camera.....................................................162 Warning plates for vehicle width.................................................163 Displaying vehicle height........................................................163 Supply pressure..................................................................164 Parking brake....................................................................165 5.1.3 Adjusting the seat and the steering column.....................................166 Driver's seat....................................................................166 Passenger's seat.................................................................167 Adjusting the steering column....................................................167 5.1.4 Switching the suspension on/off................................................168 Opening the submenu..............................................................168 Switching on the suspension......................................................169 Switching off the suspension.....................................................169 5.1.5 Setting the tachograph.........................................................170 Prerequisites....................................................................170 In the event of malfunctions.....................................................170 Setting the tachograph...........................................................171 Additional displays..............................................................174 5.1.6 Displaying the operating hours.................................................175 5.1.7 Settings/displays with the on-board computer...................................176 Operation........................................................................176 Overview.........................................................................177 Monitoring information...........................................................177 Error information................................................................178 Alarm clock......................................................................179 Language.........................................................................179 Settings.........................................................................180 Diagnostics......................................................................180 5.2 Operating the transmission...........................................................183 5.2.1 Switching on...................................................................183 5.2.2 Switching the transmission to neutral position.................................184 5.2.3 Changing the operating mode....................................................184 Change to automatic mode.........................................................184 Change to manual mode............................................................185 5.2.4 Display of the selected gears..................................................185 5.2.5 Selecting the direction of travel and starting gear............................187 Selecting the driving direction..................................................187 Selecting the starting gear......................................................188 5.2.6 Starting.......................................................................189 5.2.7 Driving and changing gears.....................................................190 In automatic operating mode......................................................190 In manual operating mode.........................................................191 5.2.8 Changing the driving direction.................................................192 Quick change of gear.............................................................192 5.2.9 Stopping.......................................................................193 Stopping for a long period of time...............................................193 5.2.10 On the roller type dynamometer................................................193 5.3 Driving and turning off the truck crane..............................................195 5.3.1 Checks while driving...........................................................195 Immediately after you start to move..............................................195 While driving....................................................................196 5.3.2 Tempomat.......................................................................198 Switching on.....................................................................198 Switching off....................................................................199 5.3.3 Temposet.......................................................................199 Switching on.....................................................................199 Switching off....................................................................200 5.3.4 Driving downhill...............................................................201 Starting.........................................................................201 Inspections when driving downhill................................................201 Downshifting.....................................................................202 Additional brakes................................................................203 5.3.5 Driving uphill.................................................................204 Starting.........................................................................204 Driving..........................................................................204 5.3.6 Warning submenu................................................................204 Meaning of the symbols...........................................................205 Exiting the submenu..............................................................206 5.3.7 Notes on torque reduction......................................................207 5.3.8 Error submenu..................................................................208 5.3.9 Messages on the on-board computer display......................................208 Information......................................................................209 Warning messages.................................................................210 Error messages...................................................................211 Information......................................................................213 5.3.10 Turning off the truck crane...................................................217 Securing against rolling away....................................................217 When stationary for more than 8hours............................................218 5.4 Off-road driving.....................................................................219 Adjustments to the transmission......................................................219 Connections..........................................................................219 Changing the vehicle level...........................................................219 Rocking the vehicle free and towing..................................................219 5.4.1 Transfer case – switching the off-road gear on/off.............................220 Neutral position.................................................................220 5.4.2 Longitudinal and transverse differential locks.................................221 5.4.3 Operating the level adjustment system..........................................223 Opening the submenu..............................................................223 Setting the on-road level........................................................223 Pre-selecting suspension struts..................................................224 Changing the vehicle level.......................................................225 Viewing the current inclination..................................................225 Exiting the submenu..............................................................226 5.4.4 Freeing truck crane stuck in terrain...........................................227 Rocking the truck crane free.....................................................227 Towing free forwards.............................................................228 Towing free in reverse gear......................................................228 5.4.5 Separate steering..............................................................229 Switching to separate steering...................................................229 Steering.........................................................................230 Switching to normal steering mode................................................231 5.5 Heating and air-conditioning system..................................................233 5.5.1 Standard heating system........................................................233 Switching on.....................................................................233 Heating..........................................................................233 Air distribution.................................................................234 Examples.........................................................................235 Switching off....................................................................235 5.5.2 Air-conditioning system........................................................236 Information......................................................................236 Switching on/off.................................................................236 Cooling..........................................................................237 Drying...........................................................................237 5.5.3 Auxiliary air heater – Version A...............................................238 Switching on.....................................................................238 Temperature......................................................................239 Setting the day and time.........................................................239 Storing the heating start........................................................240 Setting the heating period.......................................................241 Switching the heating start on and off...........................................242 Switching off....................................................................242 Setting the remaining time.......................................................243 5.5.4 Auxiliary air heater – Version B...............................................245 Switching on.....................................................................245 Setting the heating level........................................................246 Setting the day and time.........................................................247 Setting the preselection time..................................................247 Deleting preselection times......................................................249 Switching off....................................................................249 5.5.5 Auxiliary water heater.........................................................250 Preheating the engine............................................................250 Preheating the driver's cab......................................................251 Switching on.....................................................................251 Setting the day and time.........................................................252 Storing the heating start........................................................253 Switching heating start on/off...................................................254 Switching off....................................................................255 Additional functions.............................................................255 5.6 Towing a trailer.....................................................................257 Effects on the axle loads............................................................257 Coupling the trailer.................................................................258 Connecting the supply lines..........................................................259 Removing the supply lines............................................................260 Uncoupling the trailer...............................................................260 Checking the braking force...........................................................262 6 Driving modes..............................................................................265 6.1 Driving modes........................................................................265 Information about the axle loads.....................................................265 6.1.1 Information on how to use the tables...........................................266 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs).............................267 For 14.00 R25 tyres..............................................................267 For 16.00 R25 tyres..............................................................268 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs)...........269 6.2 Rigging work for driving with a trailer..............................................271 6.2.1 Switching on the slewing gear freewheel........................................272 6.2.2 Switching on boom floating position............................................273 6.2.3 Switching on boom pre-tensioning...............................................274 6.2.4 Switching the superstructure driving lights on/off.............................276 Switching off....................................................................276 Switching on.....................................................................276 7 Malfunctions in driving mode...............................................................279 7.1 Emergency stop switch................................................................279 7.2 What to do when a malfunction occurs in road traffic.................................281 7.3 Towing the truck crane...............................................................283 7.3.1 Towing after engine/transmission damage........................................284 Compressed-air supply............................................................284 Electric power supply............................................................284 On the transmission..............................................................285 Axle drives......................................................................286 Transfer case....................................................................286 Parking brake....................................................................286 Towing the truck crane out of the danger area....................................287 7.3.2 Tow starting...................................................................288 7.4 Wheels and tyres.....................................................................289 7.4.1 Wheel change...................................................................289 Removing a damaged wheel.........................................................289 On the spare wheel holder........................................................290 Mounting a wheel.................................................................291 7.4.2 Inflating the tyres yourself...................................................293 Connecting the filling hose......................................................293 Inflating the tyres..............................................................294 Removing the filling hose........................................................294 7.5 Fuses on the carrier.................................................................295 Notes on changing fuses..............................................................295 7.5.1 Fuses in the driver's cab......................................................296 F1 to F 41.......................................................................296 A1 to A3.........................................................................298 7.5.2 Fuses in the battery box.......................................................300 7.6 Troubleshooting......................................................................301 7.6.1 Malfunctions on the engine.....................................................301 7.6.2 Malfunctions on the DEF system.................................................303 7.6.3 Malfunctions in the transmission...............................................304 7.6.4 Malfunctions of the service brake..............................................305 7.6.5 Malfunctions of the steering...................................................306 7.6.6 Malfunctions of transfer case..................................................306 7.6.7 Malfunctions in the differential locks.........................................307 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................307 7.6.9 Malfunctions on the suspension.................................................308 7.6.10 Malfunctions of the level adjustment system...................................308 7.6.11 Malfunctions of the reverse camera............................................308 7.6.12 Malfunctions on the ECOS carrier..............................................309 ECOS programme version...........................................................309 General malfunctions.............................................................309 Error messages...................................................................310 Exiting the submenu..............................................................311 On the control units.............................................................312 7.7 Procedure in the event of malfunctions...............................................313 7.7.1 Switching on emergency operation in coolant circuit............................313 7.7.2 Procedure in the event of malfunctions to the transmission and engine..........314 Engine...........................................................................314 Transmission.....................................................................315 Transmission emergency program submenu...........................................316 Emergency gear shift.............................................................319 Compressed air emergency switching...............................................320 Switching gears mechanically in emergency mode...................................322 ID number of the transmission....................................................325 7.8 Emergency operation..................................................................327 7.8.1 External starting socket.......................................................327 Performing a jump start..........................................................328 7.8.2 Battery charger................................................................328 8 Index......................................................................................331 A........................................................................................333 B........................................................................................333 C........................................................................................333 D........................................................................................335 E........................................................................................337 F........................................................................................339 H........................................................................................340 I........................................................................................341 K........................................................................................341 L........................................................................................341 M........................................................................................342 O........................................................................................343 P........................................................................................344 R........................................................................................344 S........................................................................................345 T........................................................................................346 V........................................................................................348 W........................................................................................348 Correction sheets ...........................................................................353 Round outrigger pads made of synthetic material .........................................353 9 Operating elements for crane operation.....................................................359 9.1 Overview of the operating elements...................................................359 9.1.1 Exterior of the truck crane....................................................360 9.1.2 Crane cab......................................................................364 9.1.3 Front panel....................................................................366 9.1.4 Side panel.....................................................................367 Bottom...........................................................................367 Top..............................................................................368 Console, rear....................................................................370 Standard heating system..........................................................371 Auxiliary water heater...........................................................372 Auxiliary air heater.............................................................373 9.1.5 Control panels.................................................................374 Left.............................................................................374 Right............................................................................375 9.1.6 Control lever configuration....................................................376 Version 1........................................................................376 Version 2........................................................................377 9.1.7 ECOS control unit..............................................................378 9.1.8 ECOS display – main menu.......................................................380 9.1.9 ECOS display – submenus........................................................382 Counterweight submenu............................................................382 Slewing gear/ Houselock submenu..................................................383 Outriggers submenu...............................................................384 Telescoping submenu..............................................................386 Power unit speeds submenu........................................................387 Monitoring submenu...............................................................388 Settings submenu.................................................................389 Operating hours submenu..........................................................390 Error submenu....................................................................391 Warning submenu..................................................................392 Working range limiter submenu...................................................394 Enter slewing angle submenu......................................................395 Enter objects submenu............................................................396 Driving submenu..................................................................397 9.1.10 RCL control unit..............................................................398 9.1.11 Hand-held control.............................................................402 Outriggers control panel........................................................403 9.1.12 Outrigger control units.......................................................404 Outrigger........................................................................405 Outrigger pressure display.......................................................405 Inclination indicator............................................................405 9.2 Short description of the operating elements..........................................407 9.2.1 Definition of direction information............................................407 Basic rule.......................................................................407 Switches.........................................................................407 9.2.2 General rules for buttons and symbols on the display...........................408 9.2.3 Engine for crane operation.....................................................409 Side panel.......................................................................409 Console, rear....................................................................410 ECOS display.....................................................................410 9.2.4 DEF system.....................................................................411 Instrument panel.................................................................411 ECOS display.....................................................................411 9.2.5 Engine for driving.............................................................413 Side panel.......................................................................413 Main menu........................................................................413 Outriggers submenu...............................................................414 9.2.6 Seat contact switch and dead man's switch......................................415 9.2.7 ECOS crane control.............................................................417 Control unit.....................................................................417 9.2.8 Outrigger......................................................................420 Hand-held control................................................................420 In the Outrigger submenu.........................................................421 In the Settings submenu..........................................................422 On the outrigger control units...................................................423 9.2.9 Inclination indicators.........................................................425 9.2.10 Outrigger pressure displays...................................................426 Outriggers submenu...............................................................426 Outrigger control units..........................................................426 9.2.11 Anemometer display............................................................426 9.2.12 Counterweight submenu.........................................................427 Counterweight submenu............................................................427 9.2.13 Main hoist....................................................................430 9.2.14 Auxiliary hoist...............................................................432 9.2.15 Slewing gear..................................................................433 Submenu..........................................................................434 9.2.16 Derricking gear...............................................................437 9.2.17 Telescoping mechanism.........................................................438 Control panels...................................................................438 Submenu..........................................................................439 In the Settings submenu..........................................................443 9.2.18 Hydraulic system..............................................................445 9.2.19 Houselock.....................................................................446 9.2.20 Rated capacity limiter (RCL)..................................................447 Input elements with displays.....................................................447 Display elements.................................................................450 RCL override.....................................................................453 External displays................................................................454 9.2.21 Electrical system.............................................................455 9.2.22 Lighting, windscreen wiper/washing system.....................................455 Lighting.........................................................................455 Windscreen wiper/washing system..................................................457 9.2.23 Hand-held control.............................................................458 Sockets for hand- held control...................................................458 Engine control panel.............................................................459 Horn.............................................................................459 Outrigger control panel..........................................................460 9.2.24 Diagnostics...................................................................462 9.2.25 Windows, doors, keys..........................................................462 Windscreen.......................................................................462 Rear window......................................................................463 Crane cab door...................................................................463 Keys.............................................................................464 9.3 Short description of the operating elements – driving from the crane cab.............465 9.3.1 Driving submenu................................................................465 9.3.2 Engine for driving.............................................................466 9.3.3 Transmission...................................................................467 9.3.4 Final drive....................................................................468 9.3.5 Brakes.........................................................................469 Side panel.......................................................................469 ECOS display.....................................................................469 9.3.6 Steering.......................................................................470 Normal steering..................................................................471 Separate steering................................................................471 10 Starting/turning off the engine – for crane operation.....................................475 10.1 Starting the engine – from the crane cab............................................475 10.1.1 CHECKLIST: Starting the engine................................................475 10.1.2 CHECKLIST: At low temperatures................................................478 10.1.3 Refuel........................................................................479 Fuel tank........................................................................479 DEF tank.........................................................................481 Tank – auxiliary heater..........................................................482 10.1.4 Checks before starting the engine.............................................483 On hydraulic tank................................................................483 Battery master switch............................................................483 Checking the hand-held control...................................................484 10.1.5 Switching on the ignition.....................................................484 10.1.6 Lamp test/switching state equalisation........................................485 Lamp test........................................................................485 Equalisation of the switching states.............................................486 10.1.7 Adjusting display brightness..................................................487 10.1.8 Starting the engine...........................................................488 Without flame start system.......................................................488 With flame start system..........................................................489 10.1.9 Checks after starting the engine..............................................490 10.1.10 Monitoring submenu...........................................................491 10.1.11 Setting idling speed.........................................................492 10.2 Starting the engine – with the hand-held control....................................493 Prerequisites........................................................................493 Starting the engine..................................................................493 10.3 Turning off the engine..............................................................495 10.3.1 During normal operation, with the ignition lock/with the handheld control....495 After turning off................................................................495 10.3.2 In emergencies, with the emergency stop switches..............................496 Resetting the emergency stop switch..............................................496 10.4 Air intake inhibitor................................................................497 Releasing the air intake inhibitor...................................................497 11 Crane operation...........................................................................501 11.1 Before operating the crane..........................................................501 11.1.1 CHECKLIST: Checks before operating the crane..................................501 11.1.2 Checking the condition of the truck crane.....................................505 Visual inspection................................................................505 Checking the position of the hoist ropes.........................................505 Checking the electrical system...................................................506 11.1.3 Adjusting the crane cab seat and front control panel..........................507 Crane cab seat...................................................................507 Front panel......................................................................508 11.1.4 Checking the safety equipment.................................................509 Rated capacity limiter...........................................................509 Lifting limit switch.............................................................509 Emergency stop switch............................................................510 Seat contact switch..............................................................511 11.1.5 Earthing the load.............................................................512 11.1.6 Preheating the hydraulic oil..................................................513 11.1.7 Switching the Houselock on/off................................................514 Switching on the Houselock.......................................................514 Switching off the Houselock......................................................516 11.2 Operation of the rated capacity limiter.............................................517 11.2.1 Switching on the RCL..........................................................518 Switching on.....................................................................518 Lamp test on the RCL.............................................................520 Brightness of the displays.......................................................520 11.2.2 Enter rigging mode............................................................521 Entering the RCL code............................................................522 Entering the reeving.............................................................525 Entering individual components...................................................526 11.2.3 Checks before operating the crane.............................................530 11.2.4 Displays during crane operation...............................................532 Continuous displays..............................................................532 Optional displays................................................................534 11.2.5 RCL early warning.............................................................536 11.2.6 RCL shutdown..................................................................536 Shutdown due to overload.........................................................536 11.2.7 Error message.................................................................538 11.2.8 RCL override – version A......................................................539 11.2.9 RCL override – version B......................................................540 Overview status display..........................................................540 When rigging.....................................................................541 To raise the boom................................................................542 In emergencies...................................................................543 11.2.10 Displaying and entering the time and date....................................544 Display..........................................................................544 11.3 Crane operation with main boom......................................................547 11.3.1 Checks during crane operation.................................................547 Horizontal alignment.............................................................547 Safe distances...................................................................547 Checking the wind speed..........................................................548 11.3.2 Permissible slewing ranges and working positions..............................549 360 slewing range...............................................................549 0 to the rear working position..................................................549 180 to the front rigging position...............................................550 Free-on-wheels working position..................................................550 11.3.3 Main hoist....................................................................551 Switching on the main hoist......................................................552 Lifting and lowering.............................................................552 Switching off the main hoist.....................................................553 11.3.4 Auxiliary hoist...............................................................555 Switching on the auxiliary hoist.................................................556 Lifting and lowering.............................................................556 Switching off the auxiliary hoist................................................557 11.3.5 Lifting limit switch, lowering limit switch, height contact switch............559 Lifting limit switch.............................................................559 Lowering limit switch............................................................561 11.3.6 Derricking gear...............................................................561 Switching on the derricking gear.................................................562 Raising and lowering.............................................................562 Re-enable raising function.......................................................563 Switching off the derricking gear................................................564 Lowering the main boom to a horizontal position..................................564 11.3.7 Telescoping mechanism.........................................................565 Overview.........................................................................566 Telescoping process..............................................................566 Assignment for display...........................................................568 Fixed length, intermediate length, telescoping length............................570 Telescoping......................................................................571 Telescoping sequence.............................................................571 Checks before starting work......................................................572 Switching on the telescoping mechanism...........................................572 Function of the control lever....................................................573 Switching off the telescoping mechanism..........................................575 Manual telescoping...............................................................575 Checking the initial position....................................................576 Unlocking the telescoping cylinder...............................................578 Extending/ retracting the telescoping cylinder...................................580 Lock telescoping cylinder........................................................581 Unlocking the telescopic section.................................................582 Telescoping the telescopic section...............................................584 Locking the telescopic section...................................................585 Locking the telescopic section for on-road driving...............................586 Telescoping with teleautomation..................................................587 Telescoping the main boom when horizontal........................................591 11.3.8 High-speed mode...............................................................592 Switch on function...............................................................592 Derricking gear/ telescoping mechanism...........................................592 Hoist............................................................................593 11.3.9 Slewing gear..................................................................594 Slewing gear brake...............................................................594 Switching on the slewing gear....................................................595 Releasing the slewing gear brake.................................................595 Engaging the slewing gear brake..................................................595 Slew.............................................................................596 Braking the slewing movement.....................................................598 Slewing gear freewheel...........................................................598 Switching off the slewing gear...................................................599 11.3.10 Possible movement combinations...............................................600 11.3.11 Hydraulic oil cooling........................................................600 11.4 Settings and displays for crane operation...........................................601 11.4.1 Inclining the crane cab.......................................................601 11.4.2 Setting idling speed..........................................................602 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................602 11.4.4 Limiting the power unit speeds................................................603 11.4.5 Setting the characteristic curves for the control levers......................604 11.4.6 Critical load control.........................................................605 Function.........................................................................605 Switching on and off.............................................................605 11.4.7 Using the slewable spotlights.................................................606 11.4.8 Displaying the operating hours................................................607 11.4.9 Warning submenu...............................................................608 Meaning of the symbols...........................................................608 Exiting the submenu..............................................................611 11.4.10 Notes on torque reduction....................................................612 11.4.11 Error submenu................................................................613 11.5 Working range limiter...............................................................615 11.5.1 Opening the working range limiter submenu.....................................616 11.5.2 Viewing current settings......................................................617 11.5.3 Entering limit values.........................................................619 Overall height/ working radius...................................................619 Slewing angle....................................................................620 Entering objects.................................................................622 11.5.4 Entering limit values/objects manually........................................625 Limit values.....................................................................625 Objects..........................................................................626 11.5.5 Switching monitoring functions on/off.........................................627 11.5.6 Shutdown by working range limiter.............................................628 11.6 Work break..........................................................................629 11.6.1 In case of short work breaks..................................................629 11.6.2 In case of work breaks of more than 8 hours...................................630 To secure the truck crane........................................................630 11.7 Heating and air-conditioning system.................................................631 11.7.1 Standard heating system.......................................................631 Switching on.....................................................................631 Heating..........................................................................631 Air distribution.................................................................632 Switching off....................................................................633 11.7.2 Air-conditioning system.......................................................635 Information......................................................................635 Switching on/off.................................................................636 Cooling..........................................................................636 Drying the air...................................................................637 11.7.3 Auxiliary water heater........................................................637 Preheating the engine............................................................638 Preheating the crane cab.........................................................638 Switching on.....................................................................639 Setting the day and time.........................................................640 Storing the heating start........................................................641 Setting the heating period.......................................................642 Switching heating start on/off...................................................643 Switching off....................................................................643 Setting the remaining time.......................................................644 11.7.4 Auxiliary air heater..........................................................645 Switching on.....................................................................645 Temperature......................................................................646 Switching off....................................................................646 Other functions.................................................................646 11.8 CraneSTAR system....................................................................647 11.8.1 Overview......................................................................647 11.8.2 Position of the components....................................................647 12 Rigging work..............................................................................651 12.1 Rigging work checklists for crane operation with the main boom......................651 12.1.1 CHECKLIST: Rigging............................................................651 12.1.2 CHECKLIST: Unrigging..........................................................657 12.2 Choosing a suitable site............................................................661 12.2.1 Determining the required ground bearing area..................................661 12.2.2 Safe distance from slopes and pits............................................664 12.2.3 Earthing the truck crane......................................................665 12.2.4 Safe distance from electrical cables..........................................666 12.3 Rigging work after driving with a trailer...........................................669 12.3.1 Switching off the boom floating position......................................669 12.3.2 Switching off the slewing gear freewheel......................................670 Before slewing...................................................................670 12.3.3 Switching off boom pre-tensioning.............................................671 12.4 Connecting/disconnecting the hand-held control......................................673 12.5 Starting the engine for driving for rigging work....................................675 12.5.1 Starting/turning off the engine with the hand-held control....................675 Prerequisites....................................................................675 Starting the engine..............................................................676 Turning off the engine...........................................................676 12.5.2 Starting/turning off the engine from the crane cab............................677 Prerequisites....................................................................677 Starting the engine..............................................................677 After starting the engine........................................................678 Turning off the engine...........................................................678 12.6 Outrigger...........................................................................679 12.6.1 CHECKLIST: Extending the outriggers...........................................679 12.6.2 CHECKLIST: Retracting the outriggers..........................................681 12.6.3 Permissible outrigger spans...................................................682 12.6.4 Preparing the truck crane.....................................................683 In the driver's cab..............................................................683 Outrigger control units..........................................................683 12.6.5 Setting the outrigger spans...................................................684 For on-road driving..............................................................685 12.6.6 Extending/retracting outrigger beams..........................................686 From the control units...........................................................686 With the hand- held control......................................................687 From the crane cab...............................................................689 12.6.7 Moving the outrigger pads into working/driving position.......................691 12.6.8 Enlarging the ground bearing area.............................................692 12.6.9 Extending/retracting supporting cylinders.....................................693 From the control units...........................................................694 With the hand- held control......................................................695 From the crane cab...............................................................696 12.6.10 Level the truck crane on outriggers..........................................698 Inclination indicators...........................................................698 Prerequisites....................................................................699 Manual alignment.................................................................700 Automatic alignment..............................................................701 12.6.11 Levelling the free-on-wheels truck crane.....................................703 12.6.12 Outrigger pressure display...................................................705 12.7 Rigging/unrigging the counterweight.................................................707 12.7.1 Counterweight sections........................................................707 Version A........................................................................707 Version B........................................................................708 Version C........................................................................708 12.7.2 Identification................................................................709 12.7.3 Slinging points on the counterweight sections.................................710 12.7.4 CHECKLIST: Rigging the counterweight..........................................711 12.7.5 CHECKLIST: Unrigging the counterweight........................................712 12.7.6 Assembling counterweight versions – on the turntable..........................714 12.7.7 Assembling counterweight versions – on the counterweight platform.............715 Setting down the 2.2t base plate................................................715 Version..........................................................................716 Notes on the different versions..................................................717 With version A...................................................................720 With version B...................................................................722 With version C...................................................................724 12.7.8 Counterweight hoist unit......................................................728 Counterweight submenu............................................................728 Extending/ retracting the lifting cylinders......................................729 Automatic mode rigging..........................................................730 Automatic mode unrigging........................................................731 Cancel automatic mode............................................................733 12.7.9 Removing/installing the counterweight on the turntable........................734 Installing.......................................................................735 Removing.........................................................................736 12.7.10 Setting down counterweight for driving the truck crane.......................737 12.7.11 Slewing with rigged counterweight............................................740 12.8 Rigging work on the main boom.......................................................743 12.8.1 Hook block on the bumper......................................................743 Picking up the hook block........................................................743 Attaching the hook block.........................................................744 12.8.2 Hook block on a separate vehicle..............................................745 Picking up the hook block........................................................746 Setting down the hook block......................................................746 12.8.3 Reeving and unreeving the hoist rope..........................................748 Pocket lock......................................................................748 Fork.............................................................................749 Rope end clamp...................................................................750 Reeving the hoist rope...........................................................751 Unreeving the hoist rope.........................................................755 12.8.4 Possible reeving methods on the main boom.....................................757 With 7 head sheaves..............................................................757 With 8 head sheaves..............................................................760 12.8.5 Installing/removing the lifting limit switch..................................763 Installing the lifting limit switch..............................................763 Removing the lifting limit switch................................................766 12.8.6 Locking/unlocking the lifting limit switch....................................767 Locking..........................................................................767 Releasing locking................................................................768 12.8.7 Anemometer and air traffic control light......................................769 Installing.......................................................................769 Removing.........................................................................770 12.9 Other rigging work..................................................................771 12.9.1 Rigging in free on wheels working position....................................771 12.9.2 Railings on the turntable.....................................................775 12.9.3 Mirror for crane operation....................................................776 12.9.4 Cameras for crane operation...................................................777 Cameras on the hoists............................................................777 Camera on main boom..............................................................777 Turning the monitor on/off and switching.........................................780 13 Driving with rigged truck crane...........................................................783 13.1 Safety instructions.................................................................783 13.2 Driving distance....................................................................785 13.3 Before driving the rigged truck crane...............................................785 13.3.1 Check the tyre pressure and the wind speed....................................785 13.4 Permissible rigging modes and axle loads............................................787 13.4.1 Axle loads....................................................................787 13.4.2 To drive without a load.......................................................787 13.4.3 To drive with a load..........................................................788 13.5 Driving from the driver's cab.......................................................789 13.5.1 Preparing to drive............................................................789 Transmission.....................................................................789 Switching on separate steering...................................................789 Connections......................................................................789 13.5.2 While driving.................................................................790 13.6 Driving from the crane cab..........................................................791 13.6.1 Preparing to drive............................................................791 13.6.2 Opening/closing the Driving mode submenu......................................792 Automatic........................................................................792 Manual...........................................................................794 Closing..........................................................................794 13.6.3 Starting/turning off the engine for driving...................................795 Start the engine.................................................................795 Turning off the engine...........................................................796 13.6.4 Steering system...............................................................796 Switching on.....................................................................796 Adjusting the steering direction.................................................796 Displays when steering...........................................................797 Normal steering..................................................................797 Separate steering................................................................798 13.6.5 Operating the transmission....................................................799 Driving direction................................................................800 Selecting the transmission mode..................................................800 13.6.6 Camera system for driving from the crane cab..................................801 13.6.7 Starting......................................................................802 13.6.8 While driving.................................................................802 13.6.9 Warning messages..............................................................803 13.6.10 Possible connections.........................................................804 Longitudinal/ transverse differential locks......................................805 13.6.11 After driving................................................................806 13.7 Driving in combined operation.......................................................807 13.7.1 Switching combined operation on/off...........................................807 Prerequisites....................................................................807 Switching on.....................................................................808 Switching off....................................................................808 13.7.2 Starting/turning off the engine...............................................809 13.7.3 Preparing to drive............................................................810 Transmission.....................................................................810 Switching on separate steering...................................................810 Connections......................................................................810 13.7.4 While driving.................................................................811 Without load.....................................................................811 With load........................................................................812 14 Malfunctions during crane operation.......................................................815 14.1 Emergency stop switch...............................................................815 14.2 What to do when malfunctions occur during crane operation...........................817 Load can be lowered..................................................................817 Load cannot be lowered...............................................................817 14.3 Fuses on the superstructure.........................................................819 Notes on changing fuses..............................................................819 14.3.1 Fuses on the turntable........................................................820 Fuse groups F1/F2................................................................820 Fuses on the circuit board.......................................................821 14.3.2 Fuses in the crane cab........................................................822 14.3.3 Fuses in the battery box......................................................824 14.3.4 RCL fuses.....................................................................825 14.4 Finding and eliminating malfunctions................................................827 14.4.1 Malfunctions on the engine for crane operation................................827 14.4.2 Malfunctions on the DEF system................................................829 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................830 14.4.4 Malfunctions in the hoist cameras.............................................831 14.4.5 Malfunctions in the main boom camera..........................................831 14.4.6 Malfunctions on the derricking gear...........................................832 14.4.7 Malfunctions in the telescoping mechanism.....................................833 Telescoping mechanism error messages.............................................835 14.4.8 Malfunctions on the slewing gear..............................................836 14.4.9 Malfunctions on the counterweight hoist unit..................................837 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................838 14.4.11 Malfunctions when inclining the crane cab....................................838 14.4.12 Malfunctions when operating with the hand-held control.......................838 14.4.13 Malfunctions when driving from the crane cab.................................839 14.4.14 Malfunctions of the outriggers...............................................840 14.4.15 Troubleshooting the RCL......................................................841 General malfunctions.............................................................841 Error messages...................................................................842 Table of error codes.............................................................844 Switching off the sensor/tachogenerator.........................................847 14.4.16 Malfunctions ECOS – superstructure...........................................848 ECOS programme version...........................................................848 General malfunctions.............................................................848 Error messages...................................................................849 Exiting the submenu..............................................................850 14.4.17 Malfunctions on CraneSTAR system.............................................851 14.5 Emergency operations and programmes.................................................855 14.5.1 Mechanical emergency activation for retracting................................856 Prior to the emergency activation, check.........................................856 Procedure........................................................................856 Mechanical emergency activation..................................................857 14.5.2 Telescoping emergency programme...............................................859 Start the emergency program......................................................859 Determining the error type.......................................................860 Error on length indicator........................................................861 If there is an error at a proximity switch.......................................864 Terminating the emergency program................................................866 Tables for approaching the locking points........................................867 14.5.3 Entering the current telescoping..............................................869 14.5.4 Emergency operation with the hand-held control................................871 Preparations.....................................................................871 Operating a power unit...........................................................872 Stopping movements...............................................................874 Stopping movements in emergencies................................................874 Turning off the engine...........................................................874 14.5.5 Switching on emergency operation in coolant circuit...........................875 14.6 Hydraulic emergency operation.......................................................877 14.6.1 Operating principle...........................................................877 14.6.2 Connecting/disconnecting hoses................................................879 Establishing connections.........................................................879 Disconnecting....................................................................880 14.6.3 Switching emergency operation on/off..........................................881 14.6.4 Establishing the hydraulic circuits required..................................882 Switching over valves............................................................882 For lifting/ lowering............................................................884 For slewing......................................................................885 14.6.5 Performing emergency operation................................................886 Slew.............................................................................886 Derricking.......................................................................887 Lifting/lowering.................................................................887 14.6.6 After emergency operation.....................................................888 Switching off emergency operation................................................888 Switching over to crane operation................................................888 Disconnecting the hoses..........................................................888 14.6.7 Emergency supply of another crane.............................................889 For emergency supply.............................................................889 After emergency supply...........................................................889 14.7 Other emergency operations..........................................................891 14.7.1 External starting socket......................................................891 Performing a jump start..........................................................892 14.7.2 Battery charger...............................................................892 15 Index.....................................................................................895 A........................................................................................897 B........................................................................................897 C........................................................................................897 D........................................................................................899 E........................................................................................901 F........................................................................................903 H........................................................................................904 I........................................................................................905 K........................................................................................905 L........................................................................................905 M........................................................................................906 O........................................................................................907 P........................................................................................908 R........................................................................................908 S........................................................................................909 T........................................................................................910 V........................................................................................912 W........................................................................................912
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