Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Manual 3112646

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Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Instructions Manual 3112646 – PDF DOWNLOAD

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Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Instructions Manual 3112646 – PDF DOWNLOAD

Language : English
Pages : 894
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Instructions Manual 3112646 – PDF DOWNLOAD

GMK 4100 1
Operating instructions Part 1 – Driving 1
Additional pages 3
Warning display STOP 3
New outriggers control units 5
New control unit 6
Old control unit 6
Outriggers 7
Outrigger pressure indicator 7
Inclination indicators 7
SLI override 11
1 Overview 27
1 1 Identification 27
1 2 EC Declaration of Conformity 31
1 3 Documentation supplied 32
1 4 Information about the operating instructions 33
1 4 1 What do the symbols used mean? 33
1 4 2 How are the operating instructions structured? 35
Division 35
Structure of the chapters 35
Structure of the pages 36
1 4 3 How do I find the information I need? 37
Cross-references example 38
1 4 4 What information is available for operations planning? 40
1 5 Conversion table for US measurements 41
2 Basic safety instructions 45
2 1 Intended use 45
2 1 1 Improper use 46
2 2 Organisational measures 47
2 3 Qualifications of the personnel 49
2 4 Safety instructions for driving the truck crane 50
2 5 Safety instructions for crane operation 50
2 6 Information on transporting persons 52
Equipment for lifting persons 52
Personnel 52
Operation 53
Truck crane 54
3 Operating elements for driving 57
3 1 Overview of the operating elements 57
3 1 1 On the outside of the truck crane 58
3 1 2 Driver’s cab 60
Overview 60
Behind the cover 62
3 1 3 Instrument panel 63
Left / right 63
Middle 64
3 1 4 Display, driver’s cab 66
3 1 5 Steering column / steering wheel 67
3 1 6 Transmission operating elements 68
3 1 7 Tachograph 69
3 1 8 ECOS control unit 70
3 1 9 ECOS display – main menu 72
3 1 10 ECOS display – submenus 74
Level adjustment system submenu 74
Settings submenu 76
Operating hours submenu 77
Warning submenu 77
Transmission emergency program submenu 78
Error submenu 79
3 1 11 Heating / Air-conditioning system 80
Standard heating system 80
Auxiliary air heater – Version A 81
Auxiliary air heater – Version B 82
Auxiliary water heater 83
3 1 12 Sockets for hand-held control 84
3 1 13 Outrigger control units 85
3 2 Short description of the operating elements 87
3 2 1 Definition of positional references 87
Basic rules 87
Switches and buttons 88
3 2 2 General information on the operating elements 88
3 2 3 General rules for buttons and symbols on the display 89
3 2 4 Engine 90
Steering column 90
Multipurpose switch 90
Instrument panel 91
Main menu 92
3 2 5 Electrical system 93
3 2 6 ECOS crane control 93
Control unit 93
3 2 7 Transmission 96
Transmission display 96
ECOS display 96
Operating elements 97
Instrument panel 98
3 2 8 Transfer case 99
Main menu 99
3 2 9 Final drive 100
3 2 10 Brakes 101
Service brake 101
Parking brake 102
Additional brakes 103
3 2 11 Steering / separate steering 104
ECOS display 104
Driver’s door 104
3 2 12 Suspension 105
3 2 13 Lighting / windscreen wipers / horn 106
Steering column 106
Instrument panel 106
Roof 108
3 2 14 Level adjustment system 108
3 2 15 Tachograph / speedometer 110
Tachograph 110
Speedometer 110
3 2 16 Diagnostics 111
Displays / submenu 111
3 2 17 On-board computer 112
3 2 18 Push-up roof 114
3 2 19 Windows, doors, keys 114
Window winder 114
Doors 115
Keys 115
3 2 20 Front flap 116
3 2 21 Storage compartment 116
4 Starting / turning off the engine for driving 119
4 1 Starting the engine from the driver’s cab 119
4 1 1 CHECKLIST: Starting the engine 119
4 1 2 CHECKLIST: if the temperature is low 122
4 1 3 Ladders and access ladders 123
Access ladders 123
Ladders 123
4 1 4 Refuelling 125
4 1 5 Checks before starting the engine 126
On the hydraulic tank 126
Battery master switch 126
Checking the hand-held control 127
4 1 6 Switching on the ignition 127
4 1 7 Lamp test / equalisation of the switching states 128
Lamp test 128
Equalisation of the switching states 129
4 1 8 Display – setting the brightness 130
4 1 9 To start the engine 131
Without flame start system 132
With flame start system 133
4 1 10 Checks after starting the engine 134
4 1 11 Control elements 135
Instrument panel 135
ECOS display 136
Display, driver’s cab 136
4 1 12 Setting the idling speed 137
4 2 Turning off the engine 139
4 2 1 On the ignition lock / with hand-held control 139
After turning off 139
4 2 2 With emergency stop switches 140
Resetting the emergency stop switch 140
4 3 Air intake inhibitor 141
Releasing the air intake inhibitor 141
5 Driving 145
5 1 Before driving 145
5 1 1 CHECKLIST: inspections before on-road driving 145
5 1 2 Checking the condition of the truck crane 150
Windscreen washing system 150
Electrical system 150
Adjusting the mirrors 151
Warning plates for vehicle width 152
Displaying the vehicle height 152
Supply pressure 153
Parking brake 154
5 1 3 Adjusting the seats and steering column 155
Driver’s seat 155
Passenger’s seat 156
Adjusting the steering column 157
5 1 4 Switching the suspension on / off 158
Opening the submenu 158
Switching on the suspension 159
To switch off the suspension 159
5 1 5 Adjusting the tachograph 160
Prerequisites 160
In the event of malfunctions 160
Adjusting the tachograph 161
Additional displays 164
5 1 6 Displaying the operating hours 165
5 1 7 Settings / displays with the on-board computer 166
Operation 166
Overview 167
Inspection information 167
Error information 168
Alarm clock 168
Language 169
Settings 169
Diagnostics 170
5 2 Operating the transmission 173
5 2 1 Switching on 173
5 2 2 Switching the transmission to neutral position 174
5 2 3 Changing the operating mode 174
Change-over to automatic mode 174
Change-over to manual mode 174
5 2 4 Display of the selected gears 175
5 2 5 Selecting the direction of travel and starting gear 175
Selecting the driving direction 175
Selecting the starting gear 176
5 2 6 Starting 177
5 2 7 Driving and changing gears 178
In automatic operating mode 178
In manual operating mode 179
5 2 8 Changing the driving direction 180
Quick change of gear 180
5 2 9 Stopping 181
Stopping for a long period of time 181
5 2 10 On the roller type dynamometer 181
5 3 Driving and turning off the truck crane 183
5 3 1 Inspections while driving 183
Immediately after you start to move 183
While driving 184
5 3 2 Tempomat 185
Switching on 185
Switching off 186
5 3 3 Temposet 187
Switching on 187
Switching off 187
5 3 4 Driving downhill 188
Starting 188
Inspections when driving downhill 188
Downshifting 189
Additional brakes 190
5 3 5 Driving uphill 191
Starting 191
Driving 191
5 3 6 Warning submenu 192
Meaning of the symbols 192
Exiting the submenu 193
5 3 7 Error submenu 194
5 3 8 Messages on the on-board computer display 194
Warnings 195
Warning messages 196
Error messages 197
Information 199
5 3 9 Turning off the truck crane 202
Secure against rolling away 202
When stationary for more than 8hours 203
5 4 Off-road driving 205
Adjustments to the transmission 205
Connections 205
Changing the vehicle level 205
Rocking the vehicle free and towing 205
5 4 1 Transfer case – off-road gear on / off 206
Neutral position 206
5 4 2 Longitudinal and transverse differential locks 207
5 4 3 Operation of the level adjustment system 209
Opening the submenu 209
Setting the on-road level 210
Pre-selecting suspension struts 210
Changing the vehicle level 211
Viewing the current inclination 211
Exiting the submenu 212
5 4 4 Freeing the truck crane stuck in terrain 213
Rocking the truck crane free 213
Towing free forwards 214
Towing free in reverse gear 214
5 4 5 Separate steering 215
Switching to separate steering 215
Steering 216
Switching to normal steering mode 217
5 5 Heating and air-conditioning system 219
5 5 1 Standard heating system 219
Switching on 219
Heating 219
Air distribution 220
Examples 221
Switching off 221
5 5 2 Air-conditioning system 222
Warnings 222
Switching on / off 222
Cooling 223
Drying 223
5 5 3 Auxiliary air heater – Version A 224
Switching on 224
Temperature 225
Setting the day and time 225
Storing the heating start 226
Setting the heating period 227
Switching the heating start on and off 227
Switching off 228
Setting the remaining time 228
5 5 4 Auxiliary air heater – Version B 229
Switching on 229
Setting the heating level 230
Setting the day and time 231
Setting the preselection time 231
Setting the heating period 233
Deleting preselection times 233
Switching off 233
5 5 5 Auxiliary water heater 234
Preheating the engine 234
Preheating the driver’s cab 235
Switching on 235
Setting the day and time 236
Storing the heating start 237
Setting the heating period 238
Switching heating start on / off 238
Switching off 239
Setting the remaining time 239
5 6 Towing a trailer 241
Effects on the axle loads 241
Coupling the trailer 242
Connecting the supply lines 243
Removing the supply lines 244
Uncoupling the trailer 244
Checking the braking force 246
6 Driving modes 249
6 1 Driving modes 249
Information on the axle loads 249
6 1 1 Information on how to use the tables 250
6 1 2 Table for a maximum axle load of 12 t (26500 lbs) 251
For 14 00 R25 tyres 251
For 16 00 R25 tyres 252
For 20 5 R25 tyres 253
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs) 254
6 2 Rigging work for driving with a trailer 255
6 2 1 Switching on the slewing gear freewheel 256
6 2 2 Switching on boom floating position 257
6 2 3 Switching on boom pre-tensioning 258
6 2 4 Switching the superstructure driving lights on / off 260
Switching off 260
Switching on 260
7 Malfunctions in driving mode 263
7 1 Emergency stop switch 263
7 2 What to do when a malfunction occurs in road traffic 265
7 3 Towing the truck crane 267
7 3 1 Towing in the event of engine or transmission damage 268
Compressed-air supply 268
Electric power supply 268
On the transmission 269
Axle drives 270
Transfer case 270
Parking brake 270
Towing the truck crane out of the danger area 271
7 3 2 Starting to tow 272
7 4 Wheels and tyres 273
7 4 1 Wheel change 273
Removing a damaged wheel 274
On the spare wheel holder 274
Mounting a wheel 275
7 4 2 Filling the tyres yourself 277
Connecting the filling hose 277
Filling the tyres 278
Removing the filling hose 278
7 5 Fuses 279
Notes on changing fuses 279
7 5 1 Fuses in the driver’s cab 280
F1 to F 41 280
A1 to A3 282
7 5 2 Fuses in the battery box 284
7 6 Finding and eliminating malfunctions 285
7 6 1 Malfunctions on the engine 285
7 6 2 Malfunctions on the transmission 287
7 6 3 Service brake malfunctions 288
7 6 4 Steering malfunctions 289
7 6 5 Transfer case malfunctions 289
7 6 6 Malfunctions in the differential locks 290
7 6 7 Malfunctions in the hydraulic system / hydraulic oil cooler 290
7 6 8 Malfunctions on the suspension 291
7 6 9 Malfunctions on the level adjustment system 291
7 6 10 Malfunctions on the ECOS carrier 292
ECOS program version 292
General malfunctions 292
Error messages 293
Exiting the submenu 294
On the control units 295
7 7 Procedure in the event of malfunctions 297
7 7 1 Switching on emergency operation in coolant circuit 297
7 7 2 Procedure in the event of malfunctions to the transmission and engine 298
Engine 298
Transmission 299
Transmission emergency program submenu 300
Emergency gear shift 303
Switching gears pneumatically in emergency mode 304
Switching gears mechanically in emergency mode 306
ID number of the transmission 309
8 Technical information on the carrier 313
8 1 Technical data 313
8 1 1 Dimensions and weights of the truck crane, axle loads 314
Dimensions 315
Weight and axle loads 315
8 1 2 Dimensions and weights of removable parts 316
Spare wheel 316
Outriggers 316
8 1 3 Carrier 317
Engine 317
Transmission 317
Transfer case 317
Axle lines 317
Steering 317
Tyres 317
Electrical system 318
Tools 318
Towing couplings 318
Outriggers 318
Driving speeds 319
Climbing ability 319
Turning circle radiuses 319
9 Index 323
A 325
B 325
C 326
D 327
E 329
F 331
H 331
I 332
K 333
L 333
M 334
O 334
P 335
R 335
S 336
T 338
V 340
W 340
Operating instructions Part 2 – Crane operation 343
Additional pages 345
SLI override 345
New outriggers control units 357
New control unit 358
Old control unit 358
Outriggers 359
Outrigger pressure indicator 359
Inclination indicators 359
Warning display STOP 363
10 Operating elements for crane operation 369
10 1 Overview of the operating elements 369
10 1 1 On the outside of the truck crane 370
10 1 2 Crane cab 372
10 1 3 Front panel 374
10 1 4 Side panel 375
Bottom 375
Top 376
Rear panel 378
Standard heating system 379
Auxiliary water heater 380
Auxiliary air heater 381
10 1 5 Control panels 382
Left 382
Right 383
10 1 6 Control lever assignment 384
Version 1 384
Version 2 385
10 1 7 ECOS control unit 386
10 1 8 ECOS display – main menu 388
10 1 9 ECOS display – submenus 390
Counterweight submenu 390
Slewing gear / Houselock submenu 391
Outriggers submenu 392
Telescoping submenu 394
Power unit speeds submenu 396
Monitoring submenu 397
Settings submenu 398
Operating hours submenu 400
Warning submenu 401
Error submenu 403
Working range limitation submenu 404
Driving submenu 406
10 1 10 SLI control unit 408
10 1 11 Hand-held control 412
Outriggers control panel 413
10 1 12 Outrigger control units 414
Outriggers 415
Outrigger pressure display 415
Inclination display 415
10 2 Short description of the operating elements 417
10 2 1 Definition of positional references 417
Basic rule 417
Switch 418
10 2 2 General rules for buttons and symbols on the display 418
10 2 3 Engine for crane operation 419
Side panel 419
Rear panel 420
ECOS display 420
10 2 4 Engine for driving 420
Side panel 420
Main menu 420
Outriggers submenu 421
10 2 5 Seat contact switch and dead man’s switch 422
10 2 6 ECOS crane control 423
Control unit 423
10 2 7 Outriggers 426
Hand-held control 426
In the outriggers submenu 427
In the settings submenu 428
On the outrigger control units 429
10 2 8 Inclination displays 431
10 2 9 Outrigger pressure displays 432
Outriggers submenu 432
Outrigger control units 432
10 2 10 Anemometer display 432
10 2 11 Counterweight submenu 433
Counterweight submenu 433
10 2 12 Main hoist 436
10 2 13 Auxiliary hoist 438
10 2 14 Slewing gear 439
Submenu 440
10 2 15 Derricking gear 443
10 2 16 Telescoping mechanism 444
Control panels 444
Submenu 445
In the settings submenu 449
10 2 17 Hydraulic system 451
10 2 18 Houselock 452
10 2 19 Safe load indicator (SLI) 453
Input elements with displays 453
Display elements 455
On the front panel 458
10 2 20 Electrical system 459
10 2 21 Lighting, windscreen wiper / washing system 459
Lighting 459
Windscreen wiper/ washing system 461
10 2 22 Hand-held control 462
Sockets for hand- held control 462
Engine control panel 463
Horn 463
Outriggers control panel 464
10 2 23 Diagnostics 466
10 2 24 Windows, doors, keys 467
Windows 467
Crane cab door 467
Keys 468
10 3 Short description of the operating elements – driving from the crane cab 469
10 3 1 Driving submenu 469
10 3 2 Engine for driving 470
10 3 3 Transmission 471
10 3 4 Final drive 472
10 3 5 Brakes 473
Side panel 473
ECOS display 473
10 3 6 Steering 474
Normal steering 475
Separate steering 475
11 Starting / turning off the engine – for crane operation 479
11 1 Starting the engine – from the crane cab 479
11 1 1 CHECKLIST: Starting the engine 479
11 1 2 CHECKLIST: If the temperature is low 482
11 1 3 Refuelling 483
For standard equipment 483
With additional equipment 484
11 1 4 Inspections before starting the engine 485
On the hydraulic tank 485
Battery master switch 485
Checking the hand-held control 486
11 1 5 Switch on the ignition 486
11 1 6 Lamp test / equalisation of the switching states 487
Lamp test 487
Equalisation of the switching states 488
11 1 7 Set brightness of display 489
11 1 8 To start the engine 490
Without flame start system 490
With flame start system 491
11 1 9 Inspections after starting the engine 492
11 1 10 Monitoring submenu 493
11 1 11 Setting the idling speed 494
11 2 Starting the engine – with the hand-held control 495
Prerequisites 495
To start the engine 495
11 3 Turning off the engine 497
11 3 1 During normal operation, with the ignition lock / with the hand- held control 497
After parking 497
11 3 2 In emergencies, with the emergency-stop switches 498
Resetting the emergency stop switch 498
11 4 Air intake inhibitor 499
Releasing the air intake inhibitor 499
12 Crane operation 503
12 1 Before crane operation 503
12 1 1 CHECKLIST: Inspections prior to crane operation 503
12 1 2 Checking the condition of the truck crane 507
Tank for windscreen washing system 507
Auxiliary heater – tank 507
Visual inspection 508
Checking the position of the hoist ropes 508
Checking the electrical system 509
12 1 3 Adjusting the crane cab seat and front panel 509
Crane cab seat 509
Front panel 510
12 1 4 Checking the safety devices 511
Safe load indicator 511
Lifting limit switch 511
Emergency stop switch 512
Seat contact switch 513
12 1 5 Earthing the load 514
12 1 6 Preheating the hydraulic oil 515
12 1 7 Switching the houselock on / off 516
Switching on the houselock 516
Switching off the houselock 518
12 2 Operation of the safe load indicator 519
12 2 1 Switching on the SLI 520
Switching on 520
Lamp test on the SLI 522
Brightness of the displays 522
12 2 2 Entering the rigging mode 523
Entering the SLI code 524
Entering the reeving 527
Entering individual components 528
12 2 3 Inspections prior to crane operation 531
12 2 4 Displays during crane operation 533
Continuous displays 533
Optional displays 535
12 2 5 SLI early warning 537
12 2 6 SLI shutdown 538
Shutdown due to overload 538
12 2 7 Error message 539
12 2 8 SLI override 540
12 2 9 Displaying and entering the time and date 541
Display 541
Input 542
12 3 Crane operation with main boom 543
12 3 1 Checks during crane operation 543
Horizontal alignment 543
Safe distances 543
Checking the wind speed 544
12 3 2 Permissible slewing ranges and working positions 545
360 slewing range 545
0 to the rear working position 545
180 to the front rigging position 546
Free-on-wheels working position 546
12 3 3 Main hoist 547
Switching on the main hoist 548
Lifting and lowering 548
Switching off the main hoist 549
12 3 4 Auxiliary hoist 550
Switching on the auxiliary hoist 550
Lifting and lowering 551
Switching off the auxiliary hoist 552
12 3 5 Lifting limit switch and lowering limit switch 553
Lifting limit switch 553
Lowering limit switch 555
12 3 6 Derricking gear 556
Switching on the derricking gear 556
Raising and lowering the boom 557
Switching off the derricking gear 558
Lowering the main boom to a horizontal position 558
12 3 7 Telescoping mechanism 559
Overview 560
Telescoping process 560
Assignment for display 562
Fixed length, intermediate length, telescoping length 564
Telescoping 565
Telescoping sequence 565
Inspections prior to starting operations 566
Switching on the telescoping mechanism 567
Function of the control lever 567
Switching off the telescoping mechanism 569
Manual telescoping 570
Checking the initial position 570
Unlocking the telescoping cylinder 573
Extending / retracting the telescoping cylinder 575
Locking the telescoping cylinder 576
Unlocking the telescopic section 577
Telescoping the telescopic section 579
Locking the telescopic section 580
Locking the telescopic section for on-road driving 581
Telescopic extension with teleautomation 582
Telescoping the main boom in horizontal position 586
12 3 8 High speed 587
Switch on function 587
Derricking gear / Telescoping mechanism 587
Hoists 588
12 3 9 Slewing gear 589
Slewing gear brake 589
Switching on the slewing gear 590
Releasing the slewing gear brake 590
Engaging the slewing gear brake 590
Slewing 591
Slewing to 0 or 180 593
Braking the slewing movement 594
Slewing gear freewheel 594
Switching off the slewing gear 595
12 3 10 Possible movement combinations 595
12 3 11 Hydraulic oil cooling 596
12 4 Settings and displays for crane operation 597
12 4 1 Inclining the crane cab 597
12 4 2 Setting the idling speed 597
12 4 3 Adjusting the stroke interval of the windscreen wiper 598
12 4 4 Limiting the power unit speeds 598
12 4 5 Setting the characteristic curve for the control levers 600
12 4 6 Critical load control 601
Function 601
Switching on and off 601
12 4 7 Operation of the directional spotlights 602
12 4 8 Displaying the operating hours 603
12 4 9 Warning submenu 604
Meaning of the symbols 604
Exiting the submenu 607
12 4 10 Error submenu 607
12 5 Working range limiter 609
12 5 1 Opening the Working range limiter submenu 610
12 5 2 Viewing current settings 610
12 5 3 Entering limit values 612
Overall height / Working radius 612
Slewing angle 613
Entering objects 615
12 5 4 Entering limit values / objects manually 618
Limit values 618
Objects 619
12 5 5 Switching monitoring functions on / off 620
12 5 6 Shutdown by working range limiter 621
12 6 Work break 623
12 6 1 Short work breaks 623
12 6 2 Work breaks of more than 8 hours 624
To secure the truck crane 624
12 7 Heating and air-conditioning system 625
12 7 1 Standard heating system 625
Switching on 625
Heating 625
Air distribution 626
Switching off 627
12 7 2 Air-conditioning system 627
Warnings 627
Switching on/off 628
Cooling 628
Drying the air 629
12 7 3 Auxiliary water heating system 629
Preheating the engine 630
Preheating the crane cab 630
Switching on 631
Setting the day and time 632
Storing the heating start 633
Setting the heating period 634
Switching heating start on/off 634
Switching off 635
Setting the remaining run time 635
12 7 4 Auxiliary air heater 636
Switching on 636
Temperature 637
Switching off 637
Other functions 637
12 8 CraneSTAR System 639
12 8 1 Overview 639
12 8 2 Position of the components 639
13 Rigging work 643
13 1 Rigging work checklists for crane operation with the main boom 643
13 1 1 CHECKLIST: Rigging 643
13 1 2 CHECKLIST: Unrigging 647
13 2 Choosing a suitable site 651
13 2 1 Determining the required ground bearing area 651
13 2 2 Safe distance from slopes and pits 654
13 2 3 Earthing the truck crane 655
13 2 4 Safe distance from electrical lines 656
13 3 Rigging work after driving with a trailer 659
13 3 1 Switching off the boom floating position 659
13 3 2 Switching off the slewing gear freewheel 660
Before slewing 660
13 3 3 Switching off boom pre-tensioning 661
13 4 Connecting / disconnecting the hand-held control 663
13 5 Starting the engine for driving for rigging work 665
13 5 1 Starting / turning off the engine with the hand-held control 665
Prerequisites 665
To start the engine 666
Turning off the engine 666
13 5 2 Starting / turning off the engine from the crane cab 667
Prerequisites 667
To start the engine 667
After starting the engine 668
Turning off the engine 668
13 6 Outriggers 669
13 6 1 CHECKLIST: Extending the outriggers 669
13 6 2 CHECKLIST: Retracting the outriggers 671
13 6 3 Permissible outrigger spans 672
13 6 4 Preparing the truck crane 673
In the driver’s cab 673
Control units (outrigger) 673
13 6 5 Setting the spans 674
For on-road driving 675
13 6 6 Extending / retracting outriggers 676
From the control units 677
With the hand- held control 678
From the crane cab 680
13 6 7 Moving the outrigger pads into working / driving position 682
13 6 8 Enlarging the ground bearing area 683
13 6 9 Extending / retracting supporting cylinders 685
From the control units 686
With the hand- held control 687
From the crane cab 688
13 6 10 Levelling the truck crane on outriggers 690
Inclination displays 690
Prerequisites 691
Manual alignment 692
Automatic alignment 693
13 6 11 Levelling the free-standing truck crane 695
13 6 12 Outrigger pressure display 697
13 7 Rigging / unrigging the counterweight 699
13 7 1 Counterweight parts 699
Version A 699
Version B 700
Version C 700
13 7 2 Identification 701
13 7 3 Slinging points 702
13 7 4 CHECKLIST: Rigging counterweight 703
13 7 5 CHECKLIST: Unrigging counterweight 704
13 7 6 Assembling counterweight versions 705
On the turntable 705
With the base plate 706
With version A 708
With version B 710
With version C 712
13 7 7 counterweight hoist unit 716
Counterweight submenu 716
Extending / retracting the lifting cylinders 717
Automatic mode, rigging 718
Automatic mode, unrigging 719
Cancel automatic mode 720
13 7 8 Removing / installing the counterweight on the turntable 721
Mounting 722
Removing 723
13 7 9 Setting down counterweight for driving the truck crane 724
13 7 10 Slewing with rigged counterweight 726
13 8 Rigging work on the main boom 729
13 8 1 Hook block on the bumper 729
Picking up the hook block 729
Attaching the hook block 730
13 8 2 Hook block on a separate vehicle 731
Hook block (picking up) 732
Hook block (setting down) 732
13 8 3 Reeving and unreeving the hoist rope 734
Fastening the rope end clamp 734
Reeving the hoist rope 736
Hoist rope (unreeving) 739
13 8 4 Possible reeving methods on the main boom 740
With 7 head sheaves 740
With 8 head sheaves 743
13 8 5 Installing / removing the lifting limit switch 746
Installing the lifting limit switch 746
Removing the lifting limit switch 749
13 8 6 Locking / Unlocking the lifting limit switch 750
Locking 750
Unlocking 751
13 8 7 Anemometer and air traffic control light 752
Mounting 752
Removing 753
13 9 Other rigging work 755
13 9 1 Rigging in free on wheels working position 755
13 9 2 Railings on the turntable 757
13 9 3 Mirror for crane operation 758
14 Driving the rigged truck crane 761
14 1 Safety instructions 761
14 2 Route 763
14 3 Before driving the rigged truck crane 763
14 3 1 Checking the tyre pressure and the wind speed 763
14 4 Permissible rigging modes and axle loads 765
14 4 1 Axle loads 765
14 4 2 To drive without a load 765
14 4 3 To drive with a load 766
14 5 Driving from the driver’s cab 767
14 5 1 Preparing to drive 767
Transmission 767
Switching on separate steering 767
Connections 767
14 5 2 While driving 768
14 6 Driving from the crane cab 769
14 6 1 Preparing to drive 769
14 6 2 Opening / closing the Driving mode submenu 770
Automatically 770
Manually 772
Closing 772
14 6 3 Starting / turning off the engine for driving 773
To start the engine 773
Turning off the engine 774
14 6 4 Steering 774
Switching on 774
Adapt steering direction 774
Displays when steering 775
Normal steering 775
Separate steering 776
14 6 5 Operating the transmission 777
Driving direction 778
Selecting the transmission mode 778
14 6 6 Starting 779
14 6 7 While driving 779
14 6 8 Warning messages 780
14 6 9 Possible connections 781
Longitudinal / transverse differential locks 782
14 6 10 After driving 783
14 7 Driving in combined operation 785
14 7 1 Switching combined operation on/off 785
Prerequisites 785
Switching on 786
Switching off 786
14 7 2 Starting/turning off the engine 787
14 7 3 Preparing to drive 788
Transmission 788
Switching on separate steering 788
Connections 788
14 7 4 While driving 789
Without load 789
With load 790
15 Malfunctions during crane operation 793
15 1 Emergency stop switch 793
15 2 What to do when a malfunction occurs during crane operation 795
Load can be lowered 795
Load cannot be lowered 795
15 3 Fuses 797
Notes on changing fuses 797
15 3 1 Fuses on the turntable 798
Fuse groups F1/F2 798
Fuses on the circuit board 799
15 3 2 Fuses in the crane cab 800
15 3 3 Fuses in the battery box 802
15 3 4 SLI fuses 803
15 4 Finding and eliminating malfunctions 805
15 4 1 Malfunctions on the engine 805
15 4 2 Malfunctions on the main hoist / auxiliary hoist 807
15 4 3 Malfunctions on the derricking gear 808
15 4 4 Malfunctions in the telescoping mechanism 809
Telescoping mechanism error messages 811
15 4 5 Malfunctions on the slewing gear 812
15 4 6 Malfunctions on the counterweight hoist unit 813
15 4 7 Malfunctions in the hydraulic system / hydraulic oil cooler 814
15 4 8 Malfunctions when inclining the crane cab 814
15 4 9 Malfunctions when operating with the hand-held control 814
15 4 10 Malfunctions when driving from the crane cab 815
15 4 11 Malfunctions on the outriggers 816
15 4 12 Troubleshooting on the SLI 817
General malfunctions 817
Error messages 818
Table of error codes 820
Switching off the sensor / tachogenerator 823
15 4 13 Malfunctions ECOS – superstructure 824
ECOS program version 824
General malfunctions 824
Error messages 825
Exiting the submenu 826
15 4 14 Troubleshooting at the CraneStar system 827
15 5 Emergency operations and programs 831
15 5 1 Mechanical emergency operation for retracting 832
Check prior to the emergency operation 832
Procedure 832
Mechanical emergency operation 833
15 5 2 Telescoping emergency program 835
Starting the emergency program 835
Determining the type of error 836
If there is an error on the length indicator 837
If there is an error on a proximity switch 841
Terminating the emergency program 842
Tables for approaching the locking points 843
15 5 3 Entering the current telescoping 845
15 5 4 Emergency operation with the hand-held control 847
Preparations 847
Operating a power unit 848
Stopping movements 850
Stopping movements in emergencies 850
Turning off the engine 850
15 5 5 Switching on emergency operation in coolant circuit 851
15 6 Hydraulic emergency operation 853
15 6 1 Operating principle 853
15 6 2 Connecting/disconnecting hoses 854
15 6 3 Activating/deactivating emergency operation 855
15 6 4 Establishing the required hydraulic circuits 856
Switching over valves 856
For lifting/ lowering 858
For slewing 859
15 6 5 Carrying out emergency operation 860
Slewing 860
Derricking 861
Lifting/lowering 861
15 6 6 After emergency operation 862
Switching offemergency operation 862
Switching to crane operation 862
Disconnecting the hoses 862
15 6 7 Emergency supply of another crane 863
Before emergency supply 863
After emergency supply 863
16 Technical information for the superstructure 867
16 1 Technical data 867
16 1 1 Maximum lifting capacity (DIN / ISO / EN) 867
16 1 2 Maximum lifting capacity (ANSI B 30 5) 867
16 1 3 Dimensions and weights of the truck crane, axle loads 868
16 1 4 Dimensions and weights of removable parts 868
Hook blocks and hook tackle 868
Counterweight parts 869
Counterweight versions 869
16 1 5 Superstructure 870
Engine 870
Hoists 870
Slewing gear 870
Derricking gear 870
Main boom 871
Lattice extension 871
Operating speeds 871
17 Index 875
A 877
B 877
C 878
D 879
E 881
F 883
H 883
I 884
K 885
L 885
M 886
O 886
P 887
R 887
S 888
T 890
V 892
W 892
Unbenannt 5

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