Manitowoc Grove Crane GMK4080-2 Operating Manual 3302660 PDF

Description

Manitowoc Grove Crane GMK4080-2 Operating Manual 3302660 – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove Crane GMK4080-2 Operating Manual 3302660 – PDF DOWNLOAD

Language : English
Pages :980
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitowoc Grove Crane GMK4080-2 Operating Manual 3302660 – PDF DOWNLOAD

Operating manual 1
Additional pages 5
MAXbase 3
Additional outrigger spans 3
Hook blocks 5
Change 5
Telescoping emergency programe 7
Mounting counterweight on the turntable 9
Crane cab heating and air-conditioning system 11
Operation from the driver’s cab 11
Driving from the crane cab 13
Table of contents 17
General 47
1 Overview 47
1 1 Accidents 47
1 2 Branch offices 49
1 2 1 Manitowoc Crane Care 49
1 2 2 Dealer list 49
1 3 Warranty specifications 49
1 4 Terms used 50
1 5 Technical data 53
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 53
1 5 2 Maximum lifting capacity (ASME B 30 5) 53
1 5 3 Dimensions and weights of the truck crane, axle loads 54
Dimensions 55
Weight and axle loads 55
1 5 4 Dimensions and weights of removable parts 56
Spare wheel 56
Outrigger 56
Hook blocks and hook tackle 57
Counterweight parts 60
Auxiliary hoist 60
1 5 5 Carrier 61
Engine 61
Transmission 61
Transfer case 61
Axle lines 61
Steering 62
Tyres 62
Turning turning radii 62
Outrigger 63
Electrical system 64
Tool 64
Towing couplings 64
Driving speeds 64
Climbing ability 64
1 5 6 Superstructure 65
Main hoist 65
Auxiliary hoist 65
Slewing gear 65
Derricking gear 65
Main boom 66
Lattice extension 66
Operating speeds 66
Noise emission 66
1 6 Documentation supplied 67
1 6 1 Questions on documentation 68
1 7 Notes on the operating manual 69
1 7 1 What do the symbols used mean? 69
1 7 2 How is the operating manual structured? 71
Division 71
Structure of the chapters 71
Structure of the pages 72
1 7 3 How do I find the information I need? 73
Cross-references example 74
1 7 4 What information is available for operations planning? 76
1 8 Conversion table for US measuring units 77
1 9 Training – Information 79
1 10 Identification 80
1 11 EC Declaration of Conformity 82
1 12 Notes on the engine data card 83
2 Basic safety instructions 85
2 1 Intended use 85
2 1 1 Improper use 86
2 2 Organisational measures 87
2 3 Personnel qualifications 89
2 4 Safety instructions for driving the truck crane 90
2 5 Safety instructions for crane operation 91
2 6 Instructions on transporting persons 94
Equipment for lifting persons 94
Personnel 94
Operation 95
Truck crane 96
Driving 97
3 Operating elements for driving 97
3 1 Overview of the operating elements 97
3 1 1 On the outside of the truck crane 98
3 1 2 Driver’s cab 102
Front overview 102
Rear overview 104
Behind the cover 105
3 1 3 Steering column/steering wheel 106
3 1 4 Instrument panel 107
Left/right 107
Middle 108
3 1 5 Transmission operating elements 110
3 1 6 On-board computer 111
3 1 7 Tachograph 112
3 1 8 Heating and air-conditioning system 113
Standard 113
Auxiliary water heating system 114
Auxiliary air heater 115
3 1 9 CCS control unit 117
3 1 10 CCS – menu-dependent displays 118
3 1 11 CCS – Start menu 119
3 1 12 CCS – Overview menu groups 120
3 1 13 Carrier menu group 122
Suspension/level adjustment menu 123
Driving menu 124
3 1 14 Menu group, settings 125
Set display brightness and date/ time menu 126
Switch units menu 127
3 1 15 Menu group Information 128
Operating hours menu 129
Engine/transmission error menu 130
Crane operation error menu 131
3 1 16 Various controls menu group 132
3 1 17 Emergency operations menu group 133
3 1 18 Outrigger control units 134
3 2 Short description of the operating elements 135
3 2 1 Definition of information relating to directions of movement 136
Basic rule 136
3 2 2 General rules for buttons and symbols on the display 137
3 2 3 Engine 138
Steering column 138
On the steering wheel 138
Instrument panel 139
3 2 4 AdBlue system 140
Instrument panel 140
CCS display 141
3 2 5 Battery master switch 141
3 2 6 Electrical system 142
3 2 7 Crane control CCS 143
3 2 8 Transmission 145
Transmission control unit 145
Driving position display 147
3 2 9 Reverse camera 148
3 2 10 BirdView system 270° 149
3 2 11 Transfer case 151
3 2 12 Final drive 152
3 2 13 Brakes 153
Service brake 153
Additional brakes 153
Parking brake 154
3 2 14 Steering/separate steering 155
Instrument panel 155
CCS display 157
3 2 15 Suspension 159
CCS display 159
3 2 16 Lighting/windscreen wipers/horn 160
Steering column 160
Steering wheel 160
Instrument panel 160
CCS display 162
Roof 162
3 2 17 Level adjustment system 163
3 2 18 Trip recorder/speedometer 165
Tachograph 165
Cover 165
Speedometer 165
3 2 19 Diagnostics 166
3 2 20 Push-up roof 166
3 2 21 On-board computer 167
3 2 22 Front flap 168
3 2 23 Windows and doors 169
Window winder 169
Doors 170
3 2 24 Access ladders and ladders 171
4 Starting the engine for driving – switching it off 175
4 1 Starting the engine from the driver’s cab 175
4 1 1 CHECKLIST: Starting the engine 175
4 1 2 CHECKLIST: At low temperatures 178
4 1 3 Filling up 179
Fuel tank 179
AdBlue tank 181
4 1 4 Checks before starting the engine 182
At the hydraulic tank 182
Battery master switch 183
Checking the hand-held control 183
4 1 5 Switching the ignition on 183
4 1 6 Lamp test/equalisation of the switching states 185
Lamp test 185
Switching the switching state 185
4 1 7 Display – setting the brightness 186
4 1 8 Starting the engine 188
4 1 9 Checks after starting the engine 190
Start menu and on-board computer 190
Instrument panel 191
4 1 10 Setting the idling speed 192
4 2 Switch off the engine 193
4 2 1 At the ignition lock and with the outrigger control units 193
After switching off 193
4 2 2 Using the emergency stop switches 194
Emergency stop switch, resetting 194
4 3 Air intake inhibitor 195
Opening the air intake inhibitor 195
5 Driving 197
5 1 Before driving 197
5 1 1 CHECKLIST: Checks before on-road driving 197
5 1 2 Check the condition of the truck crane 203
Electrical system 203
Mirror, adjusting 203
Warning plates for vehicle width 204
Checking the vehicle height 205
Supply pressure 206
Parking brake 207
5 1 3 Adjusting the seat and the steering column 209
Adjusting the driver’s seat 209
Adjusting the passenger seat 210
Adjusting the steering column 211
5 1 4 Switching the suspension on/off 212
Opening the menu 212
Switching the suspension on 213
Switching the suspension off 213
5 1 5 Setting the tachograph 214
Prerequisites 214
In the event of malfunctions 214
Setting the tachograph 215
5 1 6 Time, setting 219
5 1 7 Displaying and resetting operating hours 220
5 2 Operating the transmission 221
5 2 1 Switching on 221
5 2 2 Switching the transmission to the neutral position 222
5 2 3 Selecting the direction of travel and starting gear 223
Selecting the driving direction 223
Selecting the starting gear 224
5 2 4 Changing operating mode 225
Changing to automatic mode 225
Change to manual mode 225
5 2 5 Starting 226
5 2 6 Driving and changing gears 227
In automatic operating mode 227
In manual operating mode 228
5 2 7 Changing the driving direction 229
5 2 8 Stopping 229
Stopping for longer periods 229
5 2 9 On the roller type dynamometer 230
5 2 10 Preheating transmission 230
5 3 Driving the truck crane and switching it off 231
5 3 1 Checks whilst driving 231
Brakes 231
ABS system 231
Steering 232
Warning messages 232
Monitoring elements 233
5 3 2 Cruise control 234
Switching on 234
Switching off 235
5 3 3 Temposet 236
Switching on 236
Switching off 236
5 3 4 Driving downhill 237
Starting 237
Checks when driving downhill 238
Downshifting 238
Additional brakes 239
5 3 5 Driving uphill 240
Starting 240
Driving 240
5 3 6 Overriding torque reduction 241
5 3 7 Switching the truck crane off 242
Secure it against rolling away 242
When stationary for more than 8 hours 243
5 3 8 Fold-up berth 244
5 4 Off-road driving 245
Adjustments to the transmission 245
Connections 245
Changing the vehicle level 245
Rocking the vehicle free and towing 245
5 4 1 Transfer case – switching the off-road gear on/off 246
5 4 2 Longitudinal and transverse differential locks 247
5 4 3 Operating the level adjustment system 249
Opening the menu 249
Setting the on- road level 250
Pre-selecting suspension struts 250
Changing the vehicle level 251
Viewing the current inclination 252
Exiting the menu 252
5 4 4 Freeing truck crane stuck in terrain 253
Rocking the truck crane free 253
Towing free forwards 254
Towing free to the rear 254
5 5 Separate steering 255
5 5 1 Switching to separate steering 256
5 5 2 Switching to normal steering mode 259
5 5 3 Switching units of measure 260
5 6 Radio 260
5 7 Heating and air-conditioning system 261
5 7 1 Standard heating system 261
Switching on 261
Heating 261
Air distribution 262
Examples 263
Switching off 263
5 7 2 Air-conditioning system 264
Notes 264
Switching on/off 264
Cooling 265
Drying 265
5 7 3 Auxiliary water heating system 266
Preheating the engine 266
Preheating the driver’s cab 267
Switching on 267
Setting the date and time 269
Storing the heating start 270
5 7 4 Auxiliary air heater 272
Switching on 272
Setting the heating level 273
Setting the day and time 274
Setting the preselection time 274
Preselection times Delete 276
Switching off 276
5 8 Towing a trailer 277
Effects on the axle loads 277
Coupling the trailer 278
Connecting the supply lines 279
Removing supply lines 280
Uncoupling the trailer 280
Checking the braking force 282
6 Driving modes 283
6 1 Driving modes 283
Information about the axle loads 283
6 1 1 Information on how to use the tables 284
6 1 2 Table for maximum axle load 12 t (26 500 lbs) 285
Tyres 385/95 R25 285
Tyres 445/95 R25 286
Tyres 525/80 R25 287
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) 288
6 2 Weighing the truck crane 289
Axle groups 290
Weighing procedure 291
Evaluation 292
6 3 Rigging work for driving with a dolly 293
6 3 1 Switching on the slewing gear freewheel 294
6 3 2 Switching on the boom floating position 295
6 3 3 Switching on boom pre-tensioning 296
6 4 Installing/removing the outrigger beams 297
6 4 1 CHECKLIST: Removing the outrigger beams 298
6 4 2 CHECKLIST: Installing the outrigger beams 300
6 4 3 Centre of gravity data 302
6 4 4 Preparations – for removal 302
6 4 5 Preparations – on the truck crane 303
Prerequisites 303
6 4 6 Removing/attaching outrigger pads 304
Removing the outrigger pads 304
Attaching the outrigger pads 305
6 4 7 Disconnecting/establishing hydraulic connection 306
6 4 8 Disconnecting/establishing the electrical connection 307
6 4 9 Unscrewing/screwing in the spacers 308
Unscrewing 308
Screwing in 309
6 4 10 Disconnecting/establishing the connections to the supporting box 310
6 4 11 Pulling out/Inserting the outrigger beam 310
Extending the outrigger beam 310
Inserting the outrigger beam 312
6 4 12 Transporting the outrigger beams 314
6 4 13 Note on error messages with removed outrigger beams 314
7 Transport 315
7 1 Transport with transport vehicle 315
7 1 1 CHECKLIST: Checks before transport 316
7 1 2 Drive the truck crane on to the transport vehicle 318
Driving on 319
Lashing 319
7 2 Transport by ship 320
8 Malfunctions in driving mode 321
8 1 Emergency stop switch 321
8 2 Procedure during malfunctions 322
8 2 1 What to do when a malfunction occurs in road traffic 322
8 2 2 Procedure during engine malfunctions 323
8 2 3 Procedure during transmission malfunctions 324
8 3 Warning and error messages 325
8 3 1 Warning or malfunction messages on the instrument panel 325
Meaning of the lamps 325
8 3 2 Warning and malfunction messages on the on-board computer display 329
Messages 329
Symbols 330
8 3 3 Warning messages on the CCS display 333
Symbols in the display area 333
8 3 4 Error messages on the CCS display 337
Exiting the menu 338
Special error messages 338
8 4 Troubleshooting 339
8 4 1 Malfunctions on the engine 339
When operating with the dual tank 341
8 4 2 Faults on the Adblue system 341
8 4 3 Differential lock malfunctions 342
8 4 4 Transfer case malfunctions 342
8 4 5 Malfunctions in the transmission 343
8 4 6 Malfunctions of the steering 344
8 4 7 Malfunctions of the service brake 345
8 4 9 Malfunctions of the level adjustment system 346
8 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 346
8 4 11 Malfunction in the CCS control unit 346
8 5 Emergency operation and breakdown assistance 347
8 5 1 Starting the truck crane externally 347
8 5 2 Battery charger 348
Prerequisites 348
8 5 3 Towing the truck crane 349
In the case of engine/transmission damage 349
Longer towing distances 352
Tow starting 352
8 5 4 Wheel change 353
Removing a damaged wheel 354
On the spare wheel holder 354
Mounting a wheel 355
8 5 5 Inflating the tyres yourself 357
Connecting the filling hose 357
Inflating the tyres 358
Remove the filling hose 358
8 5 6 Emergency operation, steering 3rd axle line 359
Performing emergency operation 359
After emergency operation 361
8 6 Tilting/lowering the driver’s cab 363
8 6 1 Prerequisites and information on tilting 363
8 6 2 Tilting and lowering the driver’s cab 364
Operating the hand pump 364
Tilting the driver’s cab 365
Lowering the driver’s cab 366
8 7 Fuses on the carrier 369
Information on changing fuses 369
8 7 1 Fuses in the driver’s cab 370
8 7 2 Fuses in the battery box 376
Crane operation 377
9 Operating elements for crane operation 377
9 1 Overview of the operating elements 377
9 1 1 Exterior of the truck crane 378
9 1 2 Crane cab 382
Side panel 384
Crane cab, rear 386
9 1 3 Control panels 388
Left 388
Right 389
9 1 4 Control lever assignment 390
Version 1 390
Version 2 391
9 1 5 CCS control unit 392
9 1 6 Menu-independent displays 394
9 1 7 CCS – Start menu 395
RCL display 396
Display Slewing ranges/working radii 397
9 1 8 CCS – Overview menu groups 398
9 1 9 Superstructure menu group 402
Superstructure lock sub-menu 403
Counterweight menu 404
9 1 10 Menu group outrigger/driving 405
Outrigger menu 406
Outrigger cylinders menu 408
Driving menu 410
9 1 11 RCL/Telescoping menu group 413
Menu enter rigging mode/ telescope 414
Pre-selection telescoping menu 418
Lifting capacity tables menu 420
Telescoping semi- automation menu 421
Manual telescoping menu 422
9 1 12 Active working range limiter menu group 423
Overall height menu 424
Working radius menu 425
Slewing angle menu 426
Hoist rope travel limitation menu 427
9 1 13 Information 1 menu group 428
Hydraulic pressure and fuel consumption menu 429
9 1 14 Heating/Engine/Additional equipment menu group 431
Economy menu 432
Remote control menu 433
Heating/air- conditioning menu 434
Spotlights menu 435
9 1 15 Telescoping emergency program menu group 436
Telescoping emergency program menu 437
Unknown telescoping menu 438
9 1 16 Settings menu group 439
Crane cab menu 440
Set display brightness and date/time menu 441
Switch units menu 442
Set control lever characteristic curve menu 443
Power unit speeds menu 444
9 1 17 Information 2 menu group 445
Operating hours menu 446
Engine/ transmission error menu 447
Crane operation error menu 448
Program version menu 449
9 1 18 Various controls 450
9 1 19 RCL control unit 451
9 1 20 Menu-independent displays 453
9 1 21 RCL – menus 454
Monitoring menu 454
Lifting capacity tables menu 456
Datalogger menu 457
9 1 22 Hand-held control 458
9 1 23 Outriggers control units 459
Menu- independent buttons 459
Outrigger menu 460
Raise axle menu 462
9 2 Short description of the operating elements 463
9 2 1 Definition of information relating to directions of movement 463
Basic rule 463
9 2 2 General rules for buttons and symbols on the display 464
9 2 3 Engine 465
Side panel 465
Left control lever 465
Economy mode menu 466
9 2 4 AdBlue system 466
CCS display 466
9 2 5 Seat contact switch and dead man’s switch 468
9 2 6 Crane control CCS 469
9 2 7 Outrigger – crane cab 474
Control panels 474
CCS display 475
9 2 8 Outrigger control units 477
General information 477
Outrigger menu 478
9 2 9 Raise axle 480
9 2 10 Inclination indicators 482
9 2 11 Outrigger pressure displays 483
Outriggers submenu 483
Outriggers control units 483
9 2 12 Anemometer displays 483
9 2 13 Counterweight menu 484
Counterweight submenu 484
9 2 14 Main hoist 488
Control panels 488
CCS display 488
9 2 15 Auxiliary hoist 490
Control panels 490
CCS display 491
9 2 16 Slewing gear 492
Control panels 492
CCS display 493
9 2 17 Derricking gear 494
Control panels 494
CCS display 495
Side panel 495
9 2 18 Telescoping mechanism 496
Control panels 496
CCS display 497
Telescoping semi- automation menu 497
Manual telescoping menu 499
9 2 19 Hydraulic system 502
9 2 20 Superstructure lock menu 503
Turntable locking 503
Houselock 505
9 2 21 Remote control 506
9 2 22 Rated capacity limiter (RCL) 507
CCS display 507
RCL display 516
RCL override – version A 517
RCL override – version B 518
9 2 23 Electrical system 519
9 2 24 Lighting, windscreen wiper/washing system 520
Lighting 520
Windscreen wiper/washing system 522
Horn 523
9 2 25 Hand-held control 524
Sockets for hand- held control 524
Engine control panel 525
Horn 525
9 2 26 Windows and doors 528
Window 528
Rear window 528
Crane cab door 529
9 2 27 Diagnostics 530
9 2 28 Other 530
9 3 Short description of the operating elements – driving from the crane cab 531
9 3 1 Driving menu 531
9 3 2 Transmission 533
9 3 3 Final drive 535
9 3 4 Brakes 536
CCS display 536
Side panel from above 536
9 3 5 Steering 537
CCS display 538
Control panels 540
10 Starting/switching off the engine – for crane operation 541
10 1 When starting the engine for the first time in the day 541
10 2 Starting the engine – from the crane cab 543
10 2 1 Check the fuel level and AdBlue level 543
Fuel 543
AdBlue 543
10 2 2 Checks before starting the engine 544
Checks on the carrier 544
Checking the hand-held control 544
At the hydraulic tank 544
10 2 3 Switching the ignition on 545
10 2 4 Comparison of switching states 546
10 2 5 Display – setting the brightness 546
10 2 6 Starting the engine 547
10 2 7 Checks after starting the engine 548
10 2 8 Setting the idling speed 549
10 3 Starting the engine – with the hand-held control 550
10 4 Switch off the engine 551
10 4 1 At the ignition lock and with hand-held control 551
After switching off 551
10 4 2 With the idling button 551
10 4 3 Using the emergency stop switches 552
Emergency stop switch, resetting 552
11 Crane operation 553
11 1 Before operating the crane 553
11 1 1 CHECKLIST: Checks before operating the crane 553
11 1 2 Check the condition of the truck crane 557
Fuel tank auxiliary heater 557
Visual inspection 557
Checking the position of the hoist ropes 558
Checking the electrical system 559
11 1 3 Adjusting the crane cab seat and front control panel 560
Crane cab seat 560
Front control panel 561
11 1 4 Checking the safety equipment 561
Rated capacity limiter 561
Lifting limit switch 562
Emergency stop switch 562
Seat contact switch 563
11 1 5 Earthing the load 564
11 1 6 Preheating hydraulic oil 565
Prerequisites 565
Preheating 565
11 1 7 Locking/unlocking the superstructure 566
Locking points 566
Locking the turntable 567
Unlocking the turntable 567
11 1 8 Switching the houselock on/off 568
Switching on the houselock 568
Switching off the houselock 570
11 2 Standard slewing range type 571
11 2 1 Permissible slewing ranges and working positions 571
360° slewing range 571
Working position 0° to the rear 571
180° to the front rigging position 571
11 3 MAXbase slewing range type 573
11 3 1 Specifications in the lifting capacity tables 574
11 3 2 Enabled slewing ranges 575
11 3 3 Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables 578
11 4 Operation of the rated capacity limiter 579
11 4 1 Switch on the RCL 580
Switching on 580
11 4 2 Enter rigging mode 582
Notes on Input 582
Enter the slewing range type 583
Entering individual components 584
Entering the RCL code 590
11 4 3 Pre-selecting telescoping 590
11 4 4 Confirm the rigging mode and lifting capacity table 591
Slewing range type Standard 591
Slewing range type MAXbase 593
11 4 5 Checks before operating the crane 595
Monitoring menu 595
Checking the rigging mode 595
Hoist checking 597
11 4 6 Display during the crane operation 599
On the RCL dislay 599
On the CCSdisplay 603
11 4 7 RCL early warning 607
11 4 8 RCL shutdown 607
Shutdown due to overload 607
11 4 9 Displaying the lifting capacity tables 609
Slewing range type Standard 609
Slewing range type MAXbase 611
11 4 10 RCL override – version A 613
Overview status display 613
When rigging 614
To raise the boom 615
In emergencies 616
11 4 11 RCL override – version B 617
11 4 12 Datalogger 618
Export data 618
Display the data 619
11 5 Crane operation with main boom 623
11 5 1 Checks during crane operation 623
Horizontal alignment 623
Safe distances 623
Checking the wind speed 624
Deformation of the main boom due to direct sunlight 625
11 5 2 Main hoist 626
Switching on the main hoist 627
Lifting and lowering 627
Maximum permissible hoist rope speed 628
Switching off the main hoist 629
11 5 3 Auxiliary hoist 630
Switching on the auxiliary hoist 630
Lifting and lowering 631
Maximum permissible hoist rope speed 632
Switching off the auxiliary hoist 632
11 5 4 Lifting limit switch and lowering limit switch 633
Lifting limit switch 633
Lowering limit switch 635
11 5 5 Derricking gear 636
Switching on the derricking gear 636
Raising and lowering 637
Maximum derricking speed 638
Re-enable raising function 638
Switching off the derricking gear 639
Lowering the main boom to a horizontal position 639
11 5 6 Telescoping mechanism 640
Overview 641
Telescoping process 642
Assignment for display 644
Fixed length, intermediate length, telescoping length 645
Telescoping 646
Telescoping sequence 646
Inspections prior to starting operations 647
Switching on the telescoping mechanism 648
Function of the control lever 648
Switching off the telescoping mechanism 650
Manual telescoping 651
Checking the initial position 651
Unlocking the telescoping cylinder 653
Extending/retracting the telescoping cylinder 655
Lock telescoping cylinder 656
Unlocking the telescopic section 657
Telescoping the telescopic section 658
Locking the telescopic section 659
Locking the telescopic section for on-road driving 660
Telescoping with semi-automaton 660
Telescoping with pre-selection 662
11 5 7 High-speed mode 663
Derricking gear telescoping mechanism 663
Hoists 663
11 5 8 Slewing gear 665
Slewing gear brake 665
Switching on the slewing gear 666
Releasing the slewing gear brake 666
Applying the slewing gear brake 666
Releasing locked slewing gear 666
Slewing 667
Permissible slewing speed 668
Braking the slewing movement 669
Slewing gear freewheel 669
Switching off the slewing gear 670
11 5 9 Switching the reduction of slewing speed on and off 671
Switching reduction off 671
11 5 10 Possible movement combinations 672
11 6 Settings and displays for crane operation 673
11 6 1 Inclining the crane cab 673
11 6 2 Setting the idling speed 674
11 6 3 Adjusting the wiper stroke interval of the windscreen wiper 674
11 6 4 Limiting the power unit speeds 675
11 6 5 Economy mode 676
Switching on 676
Ending/switching off 678
11 6 6 Switching units of measure 678
11 6 7 Setting the characteristic curves for the control levers 679
11 6 8 Using the slewable spotlights 680
Manually swinging 681
Automatic load tracking 681
11 6 9 Overriding torque reduction 682
11 6 10 Displaying the operating hours 683
11 7 Working range limiter 685
11 7 1 Viewing current settings 686
On the RCL dislay 686
In the CCS Start menu 687
11 7 2 Opening the working range limiter menu 687
11 7 3 Enter limit values – for the overall height 688
11 7 4 Enter limit values – for the working radius 690
11 7 5 Enter limit values – for the slewing range 692
11 7 6 Enter limit values – for the hoist rope travel 695
11 7 7 Shutdown by working range limiter 697
11 8 Work break 699
11 8 1 In case of short work breaks 699
11 8 2 In case of work breaks of more than 8 hours 700
To secure the truck crane 700
11 9 Heating and air-conditioning system 701
11 9 1 Standard heating system 701
Switching on 701
Heating 701
Air distribution 702
Switching off 702
11 9 2 Air-conditioning system 703
Notes 703
Switching on/off 703
Cooling, automatic 704
Cooling, maximum 704
11 9 3 Auxiliary heater 705
Switching on 705
Setting the temperature 706
Setting the heating start/heating duration 706
Switching heating start on/off 707
11 10 CraneSTAR system 708
11 10 1 Overview 708
11 10 2 Position of the components 708
12 Rigging work 709
12 1 Rigging work checklists for crane operation with the main boom 709
12 1 1 CHECKLIST: Rigging 709
12 1 2 CHECKLIST: Unrigging 715
12 2 Choice of a suitable positioning site 719
12 2 1 Determining the required load-bearing area 719
12 2 2 Safe distance from slopes and pits 722
12 2 3 Earthing the truck crane 723
12 2 4 Safe distance from overhead power lines 724
12 3 Rigging work after driving with a dolly 727
12 3 1 Switching off the boom floating position 727
12 3 2 Switching off the slewing gear freewheel 728
Before slewing 728
12 3 3 Switching off boom pre-tensioning 729
12 4 Connecting/disconnecting the hand-held control 731
12 5 Starting the engine for rigging 735
12 5 1 Starting/shutoff the engine – with the hand-held control 735
Prerequisites 735
Starting the engine 736
Turning off the engine 736
12 5 2 Starting/shutoff the engine – from the outrigger control units 737
Prerequisites 737
Starting the engine 737
Turning off the engine 737
12 6 Slewing range – only with the Standard slewing range type 739
12 6 1 Representation in the lifting capacity tables 739
12 6 2 Enabled outrigger spans 740
12 7 Outriggers – Overview – MAXbase slewing range type 741
12 7 1 Definitions 741
12 7 2 Representation in the lifting capacity tables 743
12 7 3 Enabled outrigger spans 744
12 8 Outrigger operation 749
12 8 1 CHECKLIST: Extending the outriggers 749
12 8 2 CHECKLIST: Retracting the outriggers 751
12 8 3 Preparing the truck crane 752
Driver’s cab 752
Crane cab 752
12 8 4 Setting the outrigger spans 754
For on-road driving 757
12 8 5 Extending/retracting outrigger beams 757
From the control units 758
From the crane cab 759
12 8 6 Moving the outrigger pads into operating/driving position 761
12 8 7 Enlarging the load-bearing area 763
12 8 8 Extending/retracting supporting cylinders 764
From the control units 765
From the crane cab 766
12 8 9 Levelling the truck crane on outriggers horizontally 768
Inclination indicators 768
Prerequisites 769
Manual alignment 770
Automatic alignment 770
12 8 10 Levelling the free-standing truck crane 772
12 8 11 Operating the axle raising system 774
12 8 12 Outrigger pressure display 776
12 9 Rigging/unrigging the counterweight 779
12 9 1 Information on rigging 779
When rigging 779
When unrigging 780
12 9 2 Counterweight sections 781
12 9 3 Identification 783
12 9 4 Slinging points on the counterweight sections 784
12 9 5 CHECKLIST: Rigging the counterweight 785
12 9 6 CHECKLIST: Unrigging the counterweight 787
12 9 7 Assembling counterweight combination 788
Setting down the top counterweight section 789
12 9 8 Removing/installing the counterweight on the turntable 792
Removing 792
Installing 794
Other combinations 796
12 9 9 Counterweight hoist unit 800
Counterweight menu 800
Extending/retracting the lifting cylinders 801
Automatic mode rigging 803
Automatic mode unrigging 805
Cancel automatic mode 806
12 9 10 Setting down counterweight for driving 807
12 9 11 Slewing with rigged counterweight 0
12 10 Rigging work on the main boom 809
12 10 1 Hook block on the bumper 809
Picking up the hook block 809
Attaching the hook block 810
12 10 2 Hook block on a separate vehicle 811
Picking up the hook block 812
Setting down the hook block 812
12 10 3 Hook block, separable 814
Rigging for on- road driving 814
Rigging for crane operation 815
12 10 4 Hook block with ballast plates 816
Removing 816
Installing 817
Information on crane operation 817
12 10 5 Reeving and unreeving the hoist rope 818
Hoist rope, reeving 819
Unreeving hoist rope 823
12 10 6 Rigging aid for the hoist rope 824
With 6 head sheaves 826
With 7 head sheaves 829
With 8 head sheaves 831
12 10 8 Installing/removing the lifting limit switch 832
Installing the lifting limit switch 832
Removing the lifting limit switch 835
12 10 9 Locking/unlocking the lifting limit switch 837
Locking 837
Removing the lock 837
12 10 10 Anemometer and air traffic control light 838
Installing 838
Switching on/off 839
Removing 839
12 11 Other rigging work 841
12 11 1 Railings on the turntable 841
12 11 2 Open/close coverings at the turntable 842
12 11 3 Folding the mirrors in and out, and adjusting them 843
12 11 4 Cameras for crane operation 844
Camera on main boom 844
Camera on the hoists 847
Camera on the driver’s cab 847
Operating the camera 848
12 11 5 Step at the crane cab 849
12 11 6 Storage compartments 851
12 11 7 Slinging points for personal protective equipment 852
13 Driving with a rigged truck crane 853
13 1 Driving distance 853
13 2 Permissible rigging modes and axle loads 854
Axle load table 854
13 2 1 To drive without a load 857
13 2 2 To drive with a load 857
13 2 3 Axle loads 857
13 3 Before driving the rigged truck crane 858
13 3 1 Check the tyre pressures and wind speed 858
13 3 2 Secure the superstructure against slewing 858
13 3 3 Putting the truck crane on the wheels – with Raise axle function 859
13 3 4 Putting the truck crane on the wheels – with the outriggers 861
13 4 Driving from the driver’s cab 863
13 4 1 Preparing to drive 863
Transmission 863
Switching on separate steering 863
Connections 863
13 4 2 Whilst driving 864
13 4 3 After driving 865
13 5 Driving from the crane cab 867
13 5 1 Preparing to drive 868
13 5 2 Opening/closing the driving menu 868
Opening the menu 868
Selecting the operating mode 869
Crane’s hydraulic system Driving mode 871
Closing menu 871
13 5 3 Steering 872
Switching on 872
Display and steering direction 872
Switching the steering direction 873
Displays when steering 873
Separate steering 874
Normal steering mode 877
13 5 4 Operating the transmission 878
Selecting the transmission mode 878
13 5 5 Whilst driving 879
DM and RM transmission mode 879
Transmission mode D 879
Warning messages 879
13 5 6 Possible connections 880
Longitudinal/ transverse differential locks 880
13 5 7 After driving 882
14 Malfunctions during crane operation 883
14 1 Emergency stop switch 883
14 2 What to do when malfunctions occur during crane operation 884
The load can be set down 884
Load cannot be set down 884
14 3 Warning and error messages 885
Program version 885
14 3 1 Warning messages on the CCS display 885
Meaning of the symbols 886
14 3 2 Error messages on the CCS display 889
14 3 3 Warning messages on the RCL display 891
14 4 Troubleshooting 895
14 4 1 Malfunctions on the engine 895
14 4 2 Malfunctions on the main hoist/auxiliary hoist 895
14 4 3 Malfunctions in the hoist cameras 897
14 4 4 Malfunctions in the main boom camera 897
14 4 5 Malfunctions on the derricking gear 898
14 4 6 Malfunctions in the telescoping mechanism 899
14 4 7 Malfunctions on the slewing gear 900
14 4 8 Malfunctions on the counterweight hoist unit 902
14 4 9 Malfunctions in the hydraulic system/hydraulic oil cooler 902
14 4 10 Malfunctions when operating with the hand-held control 903
14 4 11 Malfunctions when inclining the crane cab 903
14 4 12 Malfunctions of the outriggers 904
14 4 13 Malfunctions when raising the axles 904
14 4 14 Malfunctions on the CCS/RCL control units 905
14 4 15 Malfunctions when driving from the crane cab 905
14 4 16 Malfunctions on the turntable lock 906
14 4 17 Malfunctions on the CraneSTAR system 906
14 5 Emergency operations and programs 909
14 5 1 Mechanical emergency activation for retracting 910
Prior to the emergency operation, check 910
Procedure 910
Mechanical emergency activation 911
14 5 2 Telescoping emergency program 913
Open the Emergency program submenu 913
Determining the type of error 914
Error at the length indicator 915
Tables for approaching the locking points 919
14 5 3 Entering the current telescoping 921
14 5 4 Emergency operation with the hand-held control 923
To pre-select a power unit 924
Operating a power unit 924
Stopping movements 925
Stopping movements in emergencies 926
Switch off the engine 926
14 5 5 Notes on slewing in emergency operation 926
For the Standard slewing range type 926
For the MAXbase slewing range type 928
14 5 6 Rotate for overridden slewing gear shutdown 929
14 6 Hydraulic emergency operation with the hand pump 931
14 6 2 Switching over the crane’s hydraulic system 932
14 6 3 Establishing the required hydraulic circuits 933
Releasing/securing valves 933
Switching over valves 934
For lowering 935
14 6 4 Performing emergency activation 936
14 6 5 After emergency activation 936
14 7 Hydraulic emergency operation as per BGR 159 938
14 7 1 Applications and function 938
14 7 2 CHECKLIST: Emergency operation 940
14 7 3 CHECKLIST: After emergency operation 941
14 7 4 Connecting/removing transformer – for self-sufficiency 942
Connecting 942
Removing 943
14 7 5 Switching emergency operation on/off 944
14 7 6 Connecting/removing transformer – for external energy source 945
14 7 7 Establishing the required hydraulic circuits 946
Switching over valves 946
For lifting/ lowering 948
For slewing 949
14 7 8 Performing emergency operation 950
Slewing 950
Derricking 951
Lifting/lowering 951
14 7 9 Emergency supply of another crane 952
For emergency supply 952
After emergency supply 952
14 8 Fuses in the crane cab 953
Information on changing fuses 953
Index 959
A 961
B 961
C 961
D 964
E 966
F 967
H 968
I 969
L 969
M 970
O 971
P 972
R 972
S 974
T 975
V 977
W 977

Contact us: [email protected]

S.M