Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Manual 3113126

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Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Instructions Manual 3113126 – PDF DOWNLOAD

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Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Instructions Manual 3113126 – PDF DOWNLOAD

Language : English
Pages : 938
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane GMK4100 Part 1 Driving Operating Instructions Manual 3113126 – 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 (DIN/ISO/EN) 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 47
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 63
3 1 1 On the outside of the truck crane 64
3 1 2 Driver’s cab 66
Overview 66
Behind the cover 68
3 1 3 Instrument panel 69
Left/right 69
Middle 70
3 1 4 On-board computer 72
Display, driving mode 72
On-board computer time correction 73
3 1 5 Steering column/steering wheel 74
3 1 6 Transmission operating elements 75
3 1 7 Tachograph 77
3 1 8 ECOS control unit 78
3 1 9 ECOS display – main menu 80
3 1 10 ECOS display – submenus 82
Level adjustment system submenu 82
Settings submenu 83
Operating hours submenu 84
Warning submenu 85
Transmission emergency program submenu 86
Error submenu 87
3 1 11 Heating/Air-conditioning system 88
Standard heating system 88
Auxiliary air heater 89
Auxiliary water heater 91
3 1 12 Sockets for hand-held control 92
3 1 13 Outrigger control units 93
3 2 Short description of the operating elements 95
3 2 1 Definition of direction information 95
Basic rule 95
Switches and buttons 96
3 2 2 General rules for buttons and symbols on the display 96
3 2 3 Engine 97
Steering column 97
Multipurpose switch 97
Instrument panel 99
Main menu 99
3 2 4 DEF system 100
Instrument panel 100
3 2 5 Electrical system 101
3 2 6 ECOS crane control 102
Control unit 102
3 2 7 Transmission 105
Transmission display 105
ECOS display 105
Operating elements 106
Instrument panel 107
3 2 8 Transfer case 108
Main menu 108
3 2 9 Final drive 109
3 2 10 Reverse camera 110
3 2 11 Brakes 111
Service brake 111
Parking brake 112
Additional brakes 113
3 2 12 Steering/separate steering 114
ECOS display 114
Driver’s door 115
3 2 13 Suspension 115
3 2 14 Lighting/windscreen wipers/horn 116
Steering column 116
Instrument panel 116
Roof 118
3 2 15 Level adjustment system 118
3 2 16 Tachograph/speedometer 120
Tachograph 120
Speedometer 120
3 2 17 Diagnostics 121
Displays/ submenu 121
3 2 18 On-board computer 122
3 2 19 Push-up roof 124
3 2 20 Windows, doors, keys 124
Window winder 124
Doors 125
Keys 125
3 2 21 Front flap 126
3 2 22 Storage compartment 126
3 2 23 Hand-held control bracket 127
4 Starting/turning off the engine for driving 131
4 1 Starting the engine from the driver’s cab 131
4 1 1 CHECKLIST: Starting the engine 131
4 1 2 CHECKLIST: At low temperatures 134
4 1 3 Ladders and access ladders 135
Ladders 135
Access ladders 136
4 1 4 Refuel 137
Fuel tank 137
DEF tank 138
4 1 5 Checks before starting the engine 139
On hydraulic tank 139
Battery master switch 139
Checking hand- held control 140
4 1 6 Switching on the ignition 140
4 1 7 Lamp test/equalisation of the switching states 141
Lamp test 141
Equalisation of the switching states 142
4 1 8 Display – setting the brightness 143
4 1 9 Starting the engine 144
Without flame start system 145
With flame start system 146
4 1 10 Checks after starting the engine 147
4 1 11 Monitoring elements 148
Instrument panel 148
ECOS display 149
Display driving mode 149
4 1 12 Setting idling speed 150
4 2 Turning off the engine 151
4 2 1 On the ignition lock/with hand-held control 151
After turning off 151
4 2 2 Using the emergency stop switches 152
Resetting the emergency stop switch 152
4 3 Air intake inhibitor 153
Releasing the air intake inhibitor 153
5 Driving 157
5 1 Before driving 157
5 1 1 CHECKLIST: Checks before on-road driving 157
5 1 2 Checking the condition of the truck crane 163
Electrical system 163
Adjusting the mirrors 163
Adjusting the reverse camera 164
Warning plates for vehicle width 165
Displaying vehicle height 165
Supply pressure 166
Parking brake 167
5 1 3 Adjusting the seat and the steering column 168
Driver’s seat 168
Passenger’s seat 169
Adjusting the steering column 169
5 1 4 Switching the suspension on/off 170
Opening the submenu 170
Switching on the suspension 171
Switching off the suspension 171
5 1 5 Setting the tachograph 172
Prerequisites 172
In the event of malfunctions 172
Setting the tachograph 173
Additional displays 176
5 1 6 Displaying the operating hours 177
5 1 7 Settings/displays with the on-board computer 178
Operation 178
Overview 179
Monitoring information 179
Error information 180
Alarm clock 181
Language 181
Settings 182
Diagnostics 182
5 2 Operating the transmission 185
5 2 1 Switching on 185
5 2 2 Switching the transmission to neutral position 186
5 2 3 Changing the operating mode 186
Change to automatic mode 186
Change to manual mode 187
5 2 4 Display of the selected gears 187
5 2 5 Selecting the direction of travel and starting gear 189
Selecting the driving direction 189
Selecting the starting gear 190
5 2 6 Starting 191
5 2 7 Driving and changing gears 192
In automatic operating mode 192
In manual operating mode 193
5 2 8 Changing the driving direction 194
Quick change of gear 194
5 2 9 Stopping 195
Stopping for a long period of time 195
5 2 10 On the roller type dynamometer 195
5 3 Driving and turning off the truck crane 197
5 3 1 Checks while driving 197
Immediately after you start to move 197
While driving 198
5 3 2 Tempomat 200
Switching on 200
Switching off 201
5 3 3 Temposet 201
Switching on 201
Switching off 202
5 3 4 Driving downhill 203
Starting 203
Inspections when driving downhill 203
Downshifting 204
Additional brakes 205
5 3 5 Driving uphill 206
Starting 206
Driving 206
5 3 6 Warning submenu 206
Meaning of the symbols 207
Exiting the submenu 208
5 3 7 Notes on torque reduction 209
5 3 8 Error submenu 210
5 3 9 Messages on the on-board computer display 210
Information 211
Warning messages 212
Error messages 213
Information 215
5 3 10 Turning off the truck crane 219
Securing against rolling away 219
When stationary for more than 8hours 220
5 4 Off-road driving 221
Adjustments to the transmission 221
Connections 221
Changing the vehicle level 221
Rocking the vehicle free and towing 221
5 4 1 Transfer case – switching the off-road gear on/off 222
Neutral position 222
5 4 2 Longitudinal and transverse differential locks 223
5 4 3 Operating the level adjustment system 225
Opening the submenu 225
Setting the on-road level 225
Pre-selecting suspension struts 226
Changing the vehicle level 227
Viewing the current inclination 227
Exiting the submenu 228
5 4 4 Freeing truck crane stuck in terrain 229
Rocking the truck crane free 229
Towing free forwards 230
Towing free in reverse gear 230
5 4 5 Separate steering 231
Switching to separate steering 231
Steering 232
Switching to normal steering mode 233
5 5 Heating and air-conditioning system 235
5 5 1 Standard heating system 235
Switching on 235
Heating 235
Air distribution 236
Examples 237
Switching off 237
5 5 2 Air-conditioning system 238
Information 238
Switching on/off 238
Cooling 239
Drying 239
5 5 3 Auxiliary air heater – Version A 240
Switching on 240
Temperature 241
Setting the day and time 241
Storing the heating start 242
Setting the heating period 243
Switching the heating start on and off 244
Switching off 244
Setting the remaining time 245
5 5 4 Auxiliary air heater – Version B 247
Switching on 247
Setting the heating level 248
Setting the day and time 249
Setting the preselection time 249
Deleting preselection times 251
Switching off 251
5 5 5 Auxiliary water heater 252
Preheating the engine 252
Preheating the driver’s cab 253
Switching on 253
Setting the day and time 254
Storing the heating start 255
Switching heating start on/off 256
Switching off 257
Additional functions 257
5 6 Towing a trailer 259
Effects on the axle loads 259
Coupling the trailer 260
Connecting the supply lines 261
Removing the supply lines 262
Uncoupling the trailer 262
Checking the braking force 264
6 Driving modes 267
6 1 Driving modes 267
Information about the axle loads 267
6 1 1 Information on how to use the tables 268
6 1 2 Table for a maximum axle load of 12 t 269
For 14 00 R25 tyres 269
For 16 00 R25 tyres 270
For 20 5 R25 tyres 271
6 1 3 Maximum permitted speeds with an axle load of over 12 t 272
6 2 Rigging work for driving with a trailer 273
6 2 1 Switching on the slewing gear freewheel 274
6 2 2 Switching on boom floating position 275
6 2 3 Switching on boom pre-tensioning 276
6 2 4 Switching the superstructure driving lights on/off 278
Switching off 278
Switching on 278
7 Malfunctions in driving mode 281
7 1 Emergency stop switch 281
7 2 What to do when a malfunction occurs in road traffic 283
7 3 Towing the truck crane 285
7 3 1 Towing after engine/transmission damage 286
Compressed-air supply 286
Electric power supply 286
On the transmission 287
Axle drives 288
Transfer case 288
Parking brake 288
Towing the truck crane out of the danger area 289
7 3 2 Tow starting 290
7 4 Wheels and tyres 291
7 4 1 Wheel change 291
Removing a damaged wheel 291
On the spare wheel holder 292
Mounting a wheel 293
7 4 2 Inflating the tyres yourself 295
Connecting the filling hose 295
Inflating the tyres 296
Removing the filling hose 296
7 5 Fuses on the carrier 297
Notes on changing fuses 297
7 5 1 Fuses in the driver’s cab 298
F1 to F 41 298
A1 to A3 300
7 5 2 Fuses in the battery box 302
7 6 Troubleshooting 303
7 6 1 Malfunctions on the engine 303
7 6 2 Malfunctions on the DEF system 305
7 6 3 Malfunctions in the transmission 306
7 6 4 Malfunctions of the service brake 307
7 6 5 Malfunctions of the steering 308
7 6 6 Malfunctions of transfer case 308
7 6 7 Malfunctions in the differential locks 309
7 6 8 Malfunctions in the hydraulic system/hydraulic oil cooler 309
7 6 9 Malfunctions on the suspension 310
7 6 10 Malfunctions of the level adjustment system 310
7 6 11 Malfunctions of the reverse camera 310
7 6 12 Malfunctions on the ECOS carrier 311
ECOS programme version 311
General malfunctions 311
Error messages 312
Exiting the submenu 313
On the control units 314
7 7 Procedure in the event of malfunctions 315
7 7 1 Switching on emergency operation in coolant circuit 315
7 7 2 Procedure in the event of malfunctions to the transmission and engine 316
Engine 316
Transmission 317
Transmission emergency program submenu 318
Emergency gear shift 321
Compressed air emergency switching 322
Switching gears mechanically in emergency mode 324
ID number of the transmission 327
7 8 Emergency operation 329
7 8 1 External starting socket 329
Performing a jump start 330
7 8 2 Battery charger 330
8 Index 333
A 335
B 335
C 335
D 337
E 339
F 341
H 342
I 343
K 343
L 343
M 344
O 345
P 346
R 346
S 347
T 348
V 350
W 350
Corrections sheets 357
Round outrigger pads made of synthetic material 357
9 Operating elements for crane operation 363
9 1 Overview of the operating elements 365
9 1 1 Exterior of the truck crane 366
9 1 2 Crane cab 370
9 1 3 Front panel 372
9 1 4 Side panel 373
Bottom 373
Top 374
Console, rear 376
Standard heating system 377
Auxiliary water heater 378
Auxiliary air heater 379
9 1 5 Control panels 380
Left 380
Right 381
9 1 6 Control lever configuration 382
Version 1 382
Version 2 383
9 1 7 ECOS control unit 384
9 1 8 ECOS display – main menu 386
9 1 9 ECOS display – submenus 388
Counterweight submenu 388
Slewing gear/ Houselock submenu 389
Outriggers submenu 390
Telescoping submenu 392
Power unit speeds submenu 393
Monitoring submenu 394
Settings submenu 395
Operating hours submenu 396
Error submenu 397
Warning submenu 398
Working range limiter submenu 400
Enter slewing angle submenu 401
Enter objects submenu 402
Driving submenu 403
9 1 10 RCL control unit 404
9 1 11 RCL display – main menu 406
9 1 12 RCL display – submenus 407
Submenu Rigging mode entry 407
Monitoring submenu 408
Rigging mode monitoring submenu 410
Submenu Lifting capacity table 411
Working range submenu 412
Error submenu 413
Settings submenu 414
9 1 13 Hand-held control 415
Outriggers control panel 417
9 1 14 Outrigger control units 418
Outrigger 419
Outrigger pressure display 419
Inclination indicator 419
9 2 Short description of the operating elements 421
9 2 1 Definition of direction information 421
Basic rule 421
Switches 421
9 2 2 General rules for buttons and symbols on the display 422
9 2 3 Engine for crane operation 423
Side panel 423
Console, rear 424
ECOS display 424
9 2 4 DEF system 425
Instrument panel 425
ECOS display 425
9 2 5 Engine for driving 427
Side panel 427
Main menu 427
Outriggers submenu 428
9 2 6 Seat contact switch and dead man’s switch 429
9 2 7 ECOS crane control 431
Control unit 431
9 2 8 Outrigger 434
Hand-held control 434
In the Outrigger submenu 435
In the Settings submenu 436
On the outrigger control units 437
9 2 9 Inclination indicators 439
9 2 10 Outrigger pressure displays 440
Outriggers submenu 440
Outrigger control units 440
9 2 11 Anemometer display 440
9 2 12 Counterweight submenu 441
Counterweight submenu 441
9 2 13 Main hoist 444
9 2 14 Auxiliary hoist 446
9 2 15 Slewing gear 447
Submenu 448
9 2 16 Derricking gear 451
9 2 17 Telescoping mechanism 452
Control panels 452
Submenu 453
In the Settings submenu 457
9 2 18 Hydraulic system 459
9 2 19 Houselock 460
9 2 20 Rated capacity limiter (RCL) 461
Control unit 461
Main menu 463
Submenu Rigging mode entry 464
Monitoring submenu 467
Submenu Lifting capacity table 471
Working range submenu 472
RCL override 473
External displays 474
9 2 21 Electrical system 475
9 2 22 Lighting, windscreen wiper/washing system 475
Lighting 475
Windscreen wiper/washing system 477
9 2 23 Hand-held control 478
Sockets for hand- held control 478
Engine control panel 479
Horn 479
Outrigger control panel 480
9 2 24 Diagnostics 482
9 2 25 Windows, doors, keys 482
Windscreen 482
Rear window 483
Crane cab door 483
Keys 484
9 3 Short description of the operating elements – driving from the crane cab 485
9 3 1 Driving submenu 485
9 3 2 Engine for driving 486
9 3 3 Transmission 487
9 3 4 Final drive 488
9 3 5 Brakes 489
Side panel 489
ECOS display 489
9 3 6 Steering 490
Normal steering 491
Separate steering 491
10 Starting/turning off the engine – for crane operation 495
10 1 Starting the engine – from the crane cab 495
10 1 1 CHECKLIST: Starting the engine 495
10 1 2 CHECKLIST: At low temperatures 498
10 1 3 Refuel 499
Fuel tank 499
DEF tank 501
Tank – auxiliary heater 502
10 1 4 Checks before starting the engine 503
On hydraulic tank 503
Battery master switch 503
Checking the hand-held control 504
10 1 5 Switching on the ignition 504
10 1 6 Lamp test/switching state equalisation 505
Lamp test 505
Equalisation of the switching states 506
10 1 7 Adjusting display brightness 507
10 1 8 Starting the engine 508
Without flame start system 508
With flame start system 509
10 1 9 Checks after starting the engine 510
10 1 10 Monitoring submenu 511
10 1 11 Setting idling speed 512
10 2 Starting the engine – with the hand-held control 513
Prerequisites 513
Starting the engine 513
10 3 Turning off the engine 515
10 3 1 During normal operation, with the ignition lock/with the handheld control 515
After turning off 515
10 3 2 In emergencies, with the emergency stop switches 516
Resetting the emergency stop switch 516
10 4 Air intake inhibitor 517
Releasing the air intake inhibitor 517
11 Crane operation 521
11 1 Before operating the crane 521
11 1 1 CHECKLIST: Checks before operating the crane 521
11 1 2 Checking the condition of the truck crane 525
Visual inspection 525
Checking the position of the hoist ropes 525
Checking the electrical system 526
11 1 3 Adjusting the crane cab seat and front control panel 527
Crane cab seat 527
Front panel 528
11 1 4 Checking the safety equipment 529
Rated capacity limiter 529
Lifting limit switch 529
Emergency stop switch 530
Seat contact switch 531
11 1 5 Earthing the load 532
11 1 6 Preheating the hydraulic oil 533
11 1 7 Switching the Houselock on/off 534
Switching on the Houselock 534
Switching off the Houselock 536
11 2 Operation of the rated capacity limiter 537
11 2 1 Switching on the RCL 538
Switching on 538
Brightness of the displays 540
11 2 2 Enter rigging mode 541
Entering individual components 542
Entering the RCL code 546
Entering the reeving 547
Accepting the rigging mode 547
11 2 3 Checks before operating the crane 549
Opening the submenu 549
Checks 550
11 2 4 Displays during crane operation 553
11 2 5 RCL early warning 556
11 2 6 RCL shutdown 556
Shutdown due to overload 556
11 2 7 Display in the event of errors 558
11 2 8 RCL override – version A 559
11 2 9 RCL override – version B 561
Overview status display 561
When rigging 562
To raise the boom 563
In emergencies 564
11 2 10 Displaying the lifting capacity tables 565
11 2 11 Entering the time/date 567
11 3 Crane operation with main boom 569
11 3 1 Checks during crane operation 569
Horizontal alignment 569
Safe distances 569
Checking the wind speed 570
11 3 2 Permissible slewing ranges and working positions 571
360 slewing range 571
0 to the rear working position 571
180 to the front rigging position 572
Free-on-wheels working position 572
11 3 3 Main hoist 573
Switching on the main hoist 574
Lifting and lowering 574
Switching off the main hoist 575
11 3 4 Auxiliary hoist 577
Switching on the auxiliary hoist 578
Lifting and lowering 578
Switching off the auxiliary hoist 579
11 3 5 Lifting limit switch, lowering limit switch, height contact switch 581
Lifting limit switch 581
Lowering limit switch 583
11 3 6 Derricking gear 583
Switching on the derricking gear 584
Raising and lowering 584
Re-enable raising function 585
Switching off the derricking gear 586
Lowering the main boom to a horizontal position 586
11 3 7 Telescoping mechanism 587
Overview 588
Telescoping process 588
Assignment for display 590
Fixed length, intermediate length, telescoping length 592
Telescoping 593
Telescoping sequence 593
Checks before starting work 594
Switching on the telescoping mechanism 594
Function of the control lever 595
Switching off the telescoping mechanism 597
Manual telescoping 597
Checking the initial position 598
Unlocking the telescoping cylinder 600
Extending/ retracting the telescoping cylinder 602
Lock telescoping cylinder 603
Unlocking the telescopic section 604
Telescoping the telescopic section 606
Locking the telescopic section 607
Locking the telescopic section for on-road driving 608
Telescoping with teleautomation 609
Telescoping the main boom when horizontal 613
11 3 8 High-speed mode 614
Switch on function 614
Derricking gear/ telescoping mechanism 614
Hoist 615
11 3 9 Slewing gear 616
Slewing gear brake 616
Switching on the slewing gear 617
Releasing the slewing gear brake 617
Engaging the slewing gear brake 617
Slew 618
Braking the slewing movement 620
Slewing gear freewheel 620
Switching off the slewing gear 621
11 3 10 Possible movement combinations 622
11 3 11 Hydraulic oil cooling 622
11 4 Settings and displays for crane operation 623
11 4 1 Inclining the crane cab 623
11 4 2 Setting idling speed 624
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 624
11 4 4 Limiting the power unit speeds 625
11 4 5 Setting the characteristic curves for the control levers 626
11 4 6 Critical load control 627
Function 627
Switching on and off 627
11 4 7 Using the slewable spotlights 628
11 4 8 Displaying the operating hours 629
11 4 9 Warning submenu 630
Meaning of the symbols 630
Exiting the submenu 633
11 4 10 Notes on torque reduction 634
11 4 11 Error submenu 635
11 5 Working range limiter 637
11 5 1 Opening the working range limiter submenu 638
11 5 2 Viewing current settings 639
11 5 3 Entering limit values 641
Overall height/ working radius 641
Slewing angle 642
Entering objects 644
11 5 4 Entering limit values/objects manually 647
Limit values 647
Objects 648
11 5 5 Switching monitoring functions on/off 649
11 5 6 Shutdown by working range limiter 650
11 6 Work break 651
11 6 1 In case of short work breaks 651
11 6 2 In case of work breaks of more than 8 hours 652
To secure the truck crane 652
11 7 Heating and air-conditioning system 653
11 7 1 Standard heating system 653
Switching on 653
Heating 653
Air distribution 654
Switching off 655
11 7 2 Air-conditioning system 657
Information 657
Switching on/off 658
Cooling 658
Drying the air 659
11 7 3 Auxiliary water heater 659
Preheating the engine 660
Preheating the crane cab 660
Switching on 661
Setting the day and time 662
Storing the heating start 663
Setting the heating period 664
Switching heating start on/off 665
Switching off 665
Setting the remaining time 666
11 7 4 Auxiliary air heater 667
Switching on 667
Temperature 668
Switching off 668
Other functions 668
11 8 CraneSTAR system 669
11 8 1 Overview 669
11 8 2 Position of the components 669
12 Rigging work 673
12 1 Rigging work checklists for crane operation with the main boom 673
12 1 1 CHECKLIST: Rigging 673
12 1 2 CHECKLIST: Unrigging 679
12 2 Choosing a suitable site 683
12 2 1 Determining the required ground bearing area 683
12 2 2 Safe distance from slopes and pits 686
12 2 3 Earthing the truck crane 687
12 2 4 Safe distance from electrical cables 688
12 3 Rigging work after driving with a trailer 691
12 3 1 Switching off the boom floating position 691
12 3 2 Switching off the slewing gear freewheel 692
Before slewing 692
12 3 3 Switching off boom pre-tensioning 693
12 4 Connecting/disconnecting the hand-held control 695
12 5 Starting the engine for driving for rigging work 697
12 5 1 Starting/turning off the engine with the hand-held control 697
Prerequisites 697
Starting the engine 698
Turning off the engine 698
12 5 2 Starting/turning off the engine from the crane cab 699
Prerequisites 699
Starting the engine 699
After starting the engine 700
Turning off the engine 700
12 6 Outrigger 701
12 6 1 CHECKLIST: Extending the outriggers 701
12 6 2 CHECKLIST: Retracting the outriggers 703
12 6 3 Permissible outrigger spans 704
12 6 4 Preparing the truck crane 705
In the driver’s cab 705
Outrigger control units 705
12 6 5 Setting the outrigger spans 706
For on-road driving 707
12 6 6 Extending/retracting outrigger beams 708
From the control units 708
With the hand- held control 709
From the crane cab 711
12 6 7 Moving the outrigger pads into working/driving position 713
12 6 8 Enlarging the ground bearing area 714
12 6 9 Extending/retracting supporting cylinders 715
From the control units 716
With the hand- held control 717
From the crane cab 718
12 6 10 Level the truck crane on outriggers 720
Inclination indicators 720
Prerequisites 721
Manual alignment 722
Automatic alignment 723
12 6 11 Levelling the free-on-wheels truck crane 725
12 6 12 Outrigger pressure display 727
12 7 Rigging/unrigging the counterweight 729
12 7 1 Counterweight sections 729
Version A 729
Version B 730
Version C 730
12 7 2 Identification 731
12 7 3 Slinging points on the counterweight sections 732
12 7 4 CHECKLIST: Rigging the counterweight 733
12 7 5 CHECKLIST: Unrigging the counterweight 734
12 7 6 Assembling counterweight versions – on the turntable 736
12 7 7 Assembling counterweight versions – on the counterweight platform 737
Setting down the 2 2t base plate 737
Version 738
Notes on the different versions 739
With version A 742
With version B 744
With version C 746
12 7 8 Counterweight hoist unit 750
Counterweight submenu 750
Extending/ retracting the lifting cylinders 751
Automatic mode rigging 752
Automatic mode unrigging 753
Cancel automatic mode 755
12 7 9 Removing/installing the counterweight on the turntable 756
Installing 757
Removing 758
12 7 10 Setting down counterweight for driving the truck crane 759
12 7 11 Slewing with rigged counterweight 762
12 8 Rigging work on the main boom 763
12 8 1 Hook block on the bumper 763
Picking up the hook block 763
Attaching the hook block 764
12 8 2 Hook block on a separate vehicle 765
Picking up the hook block 766
Setting down the hook block 766
12 8 3 Reeving and unreeving the hoist rope 768
Pocket lock 768
Fork 769
Rope end clamp 770
Reeving the hoist rope 771
Unreeving the hoist rope 775
12 8 4 Possible reeving methods on the main boom 777
With 7 head sheaves 777
With 8 head sheaves 780
12 8 5 Installing/removing the lifting limit switch 783
Installing the lifting limit switch 783
Removing the lifting limit switch 786
12 8 6 Locking/unlocking the lifting limit switch 787
Locking 787
Releasing locking 788
12 8 7 Anemometer and air traffic control light 789
Installing 789
Removing 790
12 9 Other rigging work 791
12 9 1 Rigging in free on wheels working position 791
12 9 2 Railings on the turntable 795
12 9 3 Mirror for crane operation 796
12 9 4 Cameras for crane operation 797
Cameras on the hoists 797
Camera on main boom 797
Turning the monitor on/off and switching 800
13 Driving with rigged truck crane 803
13 1 Safety instructions 803
13 2 Driving distance 805
13 3 Before driving the rigged truck crane 805
13 3 1 Check the tyre pressure and the wind speed 805
13 4 Permissible rigging modes and axle loads 807
13 4 1 Axle loads 807
13 4 2 To drive without a load 807
13 4 3 To drive with a load 808
13 5 Driving from the driver’s cab 809
13 5 1 Preparing to drive 809
Transmission 809
Switching on separate steering 809
Connections 809
13 5 2 While driving 810
13 6 Driving from the crane cab 811
13 6 1 Preparing to drive 811
13 6 2 Opening/closing the Driving mode submenu 812
Automatic 812
Manual 814
Closing 814
13 6 3 Starting/turning off the engine for driving 815
Start the engine 815
Turning off the engine 816
13 6 4 Steering system 816
Switching on 816
Adjusting the steering direction 816
Displays when steering 817
Normal steering 817
Separate steering 818
13 6 5 Operating the transmission 819
Driving direction 820
Selecting the transmission mode 820
13 6 6 Camera system for driving from the crane cab 821
13 6 7 Starting 822
13 6 8 While driving 822
13 6 9 Warning messages 823
13 6 10 Possible connections 824
Longitudinal/ transverse differential locks 825
13 6 11 After driving 826
13 7 Driving in combined operation 827
13 7 1 Switching combined operation on/off 827
Prerequisites 827
Switching on 828
Switching off 828
13 7 2 Starting/turning off the engine 829
13 7 3 Preparing to drive 830
Transmission 830
Switching on separate steering 830
Connections 830
13 7 4 While driving 831
Without load 831
With load 832
14 Malfunctions during crane operation 835
14 1 Emergency stop switch 835
14 2 What to do when malfunctions occur during crane operation 837
Load can be lowered 837
Load cannot be lowered 837
14 3 Fuses on the superstructure 839
Notes on changing fuses 839
14 3 1 Fuses on the turntable 840
Fuse groups F1/F2 840
Fuses on the circuit board 841
14 3 2 Fuses in the crane cab 842
14 3 3 Fuses in the battery box 844
14 3 4 RCL fuses 845
14 4 Finding and eliminating malfunctions 847
14 4 1 Malfunctions on the engine for crane operation 847
14 4 2 Malfunctions on the DEF system 849
14 4 3 Malfunctions on the main hoist/auxiliary hoist 850
14 4 4 Malfunctions in the hoist cameras 851
14 4 5 Malfunctions in the main boom camera 851
14 4 6 Malfunctions on the derricking gear 852
14 4 7 Malfunctions in the telescoping mechanism 853
Telescoping mechanism error messages 855
14 4 8 Malfunctions on the slewing gear 856
14 4 9 Malfunctions on the counterweight hoist unit 857
14 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 858
14 4 11 Malfunctions when inclining the crane cab 858
14 4 12 Malfunctions when operating with the hand-held control 858
14 4 13 Malfunctions when driving from the crane cab 859
14 4 14 Malfunctions of the outriggers 860
14 4 15 Troubleshooting the RCL 861
General malfunctions 861
Error messages in the Monitoring submenu 862
Displays in the Error submenu 864
Table of error codes 866
Switching off the sensor/tachogenerator 869
14 4 16 Malfunctions ECOS – superstructure 870
ECOS programme version 870
General malfunctions 870
Error messages 871
Exiting the submenu 872
14 4 17 Malfunctions on CraneSTAR system 873
14 5 Emergency operations and programmes 877
14 5 1 Mechanical emergency activation for retracting 878
Prior to the emergency activation, check 878
Procedure 878
Mechanical emergency activation 879
14 5 2 Telescoping emergency programme 881
Start the emergency program 881
Determining the error type 882
Error on length indicator 883
If there is an error at a proximity switch 886
Terminating the emergency program 888
Tables for approaching the locking points 889
14 5 3 Entering the current telescoping 891
14 5 4 Emergency operation with the hand-held control 893
Preparations 893
Operating a power unit 894
Stopping movements 896
Stopping movements in emergencies 896
Turning off the engine 896
14 5 5 Switching on emergency operation in coolant circuit 897
14 6 Hydraulic emergency operation 899
14 6 1 Operating principle 899
14 6 2 Connecting/disconnecting hoses 901
Establishing connections 901
Disconnecting 902
14 6 3 Switching emergency operation on/off 903
14 6 4 Establishing the hydraulic circuits required 904
Switching over valves 904
For lifting/ lowering 906
For slewing 907
14 6 5 Performing emergency operation 908
Slew 908
Derricking 909
Lifting/lowering 909
14 6 6 After emergency operation 910
Switching off emergency operation 910
Switching over to crane operation 910
Disconnecting the hoses 910
14 6 7 Emergency supply of another crane 911
For emergency supply 911
After emergency supply 911
14 7 Other emergency operations 913
14 7 1 External starting socket 913
Performing a jump start 914
14 7 2 Battery charger 914
15 Index 917
A 919
B 919
C 919
D 921
E 923
F 925
H 926
I 927
K 927
L 927
M 928
O 929
P 930
R 930
S 931
T 932
V 934
W 934

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