Manitowoc Grove Crane GMK6300L-1 Part 1-Driving Operation Manual 3302741

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Manitowoc Grove Crane GMK6300L-1 Part 1-Driving Operation Manual 3302741 – PDF DOWNLOAD

FILE DETAILS:

Manitowoc Grove Crane GMK6300L-1 Part 1-Driving Operation Manual 3302741 – PDF DOWNLOAD

Language : English
Pages :1000
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane GMK6300L-1 Part 1-Driving Operation Manual 3302741 – PDF DOWNLOAD

Driving 1
Additional pages 3
Possible reeving methods on the main boom 3
Counterweight version B 13
Information on weight specifications 13
1 Overview 19
1 1 Accidents 19
1 2 Branch offices 21
1 2 1 Manitowoc Crane Care 21
1 2 2 Dealer list 21
1 3 Warranty specifications 21
1 4 Terms used 22
1 5 Technical data 25
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 25
1 5 2 Maximum lifting capacity (ASME B 30 5) 25
1 5 3 Dimensions and weights of the truck crane, axle loads 26
Dimensions 27
Weight and axleloads 27
1 5 4 Dimensions and weights of removable parts 28
Spare wheel 28
Outriggers 28
Driver’s safety guard 29
Hose drum 29
Hook blocks and hook tackle 29
Auxiliary hoist 30
Main boom 30
Counterweight parts 30
1 5 5 Carrier 31
Engine 31
Transmission 31
Transfer case 31
Axle lines 31
Steering 32
Tyres 32
Outriggers 32
Auxiliary supports 33
Electrical system 33
Tool 33
Towing coupling 33
Driving speeds 33
Climbing ability 33
Turning radii 34
1 5 6 Superstructure 35
Engine 35
Main hoist 35
Auxiliary hoist 35
Slewing gears 36
Derricking gear 36
Main boom 36
Lattice extension 36
Operating speeds 37
1 6 Documentation supplied 39
1 6 1 Questions on documentation 40
1 7 Notes on the operating manual 41
1 7 1 What do the symbols used mean? 41
1 7 2 How is the operating manual structured? 43
Division 43
Structure of thechapters 43
Structure of thepages 44
1 7 3 How do I find the information I need? 45
Cross-references example 46
1 7 4 What information is available for operations planning? 48
1 8 Conversion table for US measuring units 49
1 9 Training – Information 51
1 10 Identification 52
1 11 EC Declaration of Conformity 54
2 Basic safety instructions 57
2 1 Intended use 57
2 1 1 Improper use 58
2 2 Organisational measures 59
2 3 Personnel qualifications 61
2 4 Safety instructions for driving the truck crane 63
2 5 Safety instructions for crane operation 65
2 6 Instructions on transporting persons 69
Equipment for lifting persons 69
Personnel 70
Operation 70
Truck crane 71
3 Operating elements for driving 75
3 1 Overview of the operating elements 75
3 1 1 On the outside of the truck crane 76
3 1 2 Driver’s cab 80
Front overview 80
Behind the cover 84
Rear overview 85
3 1 3 Instrument panel 86
Left/right 86
Middle 87
3 1 4 Display, driving mode 90
3 1 5 Steering column/steering wheel 91
3 1 6 Transmission operating elements 92
3 1 7 Tachograph, time correction 93
3 1 8 ECOS control unit 94
3 1 9 ECOS display – main menu 96
3 1 10 ECOS display – submenus 98
Level adjustment system submenu 98
Settings submenu 100
Monitoring submenu 101
Operating hours submenu 102
Warning submenu 102
Error submenu 103
3 1 11 Heating/Air-conditioning system 104
Standard heating system 104
Auxiliary water heating system 105
3 1 12 Outrigger control units 106
3 1 13 Rear supporting box control unit 107
3 2 Short description of the operating elements 109
3 2 1 Definition of direction information 109
Basic rule 109
Switches and buttons 110
3 2 2 General notes on the operating elements 110
3 2 3 General rules for buttons and symbols on the display 111
3 2 4 Engine 112
Steering column 112
Multipurpose switch 112
Instrument panel 113
Main menu 114
3 2 5 Carbamide system 115
Instrument panel 115
Display, driving mode 116
ECOS display 116
3 2 6 Electrical system 117
3 2 7 ECOS crane control 118
Control unit 118
3 2 8 Transmission 121
Instrument panel, middle 121
Display, driving mode 121
Transmission control unit 121
3 2 9 Reverse camera 125
Reverse camera on/off 125
3 2 10 Transfer case 126
3 2 11 Final drive 127
3 2 12 Brakes 128
Service brake 128
Additional brakes 128
Parking brake 129
3 2 13 Steering/separate steering 130
Instrument panel 130
ECOS display 131
Driver’s door 132
3 2 14 Suspension 133
3 2 15 Lighting/windscreen wipers/horn 134
Steering column 134
Instrument panel 134
Roof 137
3 2 16 Level adjustment system 138
3 2 17 Tachograph/speedometer 141
Tachograph 141
Speedometer 141
3 2 18 Rear supporting box control unit 142
3 2 19 Diagnostics 143
Displays/ submenu 143
3 2 20 Windows, doors, keys 144
Window winder 144
Doors 145
Keys 145
3 2 21 Front flap 146
4 Starting the engine for driving / switching it off 149
4 1 Starting the engine from the driver’s cab 149
4 1 1 CHECKLIST: Starting the engine 149
4 1 2 CHECKLIST: At low temperatures 152
4 1 3 Ladders and access ladders 152
Fixed ladders 152
Ladders 153
4 1 4 Refuel 155
Fuel 155
Carbamide 156
4 1 5 Checks before starting the engine 158
At the hydraulic tank 158
Battery master switch 158
Checking the hand-held control 159
4 1 6 Switch on the ignition 159
4 1 7 Lamp test/equalisation of the switching states 160
Lamp test 160
Switching state alignment 161
4 1 8 Display – setting the brightness 162
4 1 9 Starting the engine 163
Without flame start system 164
With flame start system 164
4 1 10 Checks after starting the engine 166
Checking in the main menu 166
Indicator lamps on the instrument panel 166
4 1 11 Monitoring elements 168
Instrument panel 168
4 1 12 Monitoring submenu 169
4 1 13 Setting idling speed 170
4 2 Switch the engine off 171
4 2 1 At the ignition lock and with the outrigger control units 171
After switching off 171
4 2 2 Using the emergency stop switches 172
Resetting the emergency stop switch 172
4 3 Air intake inhibitor 173
Releasing the air intake inhibitor 173
5 Driving 177
5 1 Before driving 177
5 1 1 CHECKLIST: Checks before on-road driving 177
5 1 2 Checking the condition of the truck crane 183
Windscreen washing system 183
Electrical system 183
Adjusting themirrors 184
Warning plates for vehicle width 185
Displaying vehicle height 185
Supply pressure 186
Parking brake 187
5 1 3 Adjusting the seats and steering column 189
Driver’s seat 189
Passenger’s seat 191
Adjusting the steering column 192
5 1 4 Switching the suspension on/off 193
Opening the submenu 193
Switching the suspension on 194
Switching the suspension off 194
5 1 5 Setting the tachograph 195
Prerequisites 195
In the event of malfunctions 195
Setting the tachograph 196
5 1 6 Displaying the operating hours 201
5 1 7 Settings/indications on the driving display 202
5 2 Operating the transmission 203
5 2 1 Switching on 203
5 2 2 Switching the transmission to the neutral position 204
While driving 204
5 2 3 Changing the driving mode 205
5 2 4 Selecting the driving direction 206
5 2 5 Changing highest gear/starting gear 208
5 2 6 Starting 208
5 2 7 Driving and changing gears 209
5 2 8 Changing the driving direction 210
5 2 9 Stopping 211
Stopping for longer periods 211
5 2 10 On the roller type dynamometer 211
5 2 11 Oil level gauge 212
5 3 Driving the truck crane and switching it off 215
5 3 1 Checks whilst driving 215
Immediately after you start to move 215
While driving 217
5 3 2 Cruise control 218
Switching on 218
Switching off 219
5 3 3 Temposet 219
Switching on 219
Switching off 219
5 3 4 Driving downhill 220
Starting 220
Checks when driving downhill 220
Shifting down from the highest gear 221
Additional brakes 222
5 3 5 Driving uphill 223
Starting 223
Driving 223
5 3 6 Warning submenu 224
Meaning of thesymbols 224
Exiting the submenu 226
5 3 7 Warning or malfunction messages on the instrument panel 227
Meaning of the lamps 227
5 3 8 Override torque reduction 229
5 3 9 Error submenu 230
5 3 10 Switching the truck crane off 230
Secure it against rolling away 230
When stationary for more than 8hours 231
5 3 11 Folding berth 233
5 4 Off-road driving 235
Adjustments to the transmission 235
Connections 235
Changing the vehicle level 235
Rocking the vehicle free andtowing 235
5 4 1 Transfer case – switching the off-road gear on/off 236
Prerequisites 236
Switching on 237
Switching off 237
Neutral position 237
5 4 2 Longitudinal and transverse differential locks 238
5 4 3 Operating the level adjustment system 240
Opening the submenu 240
Setting the on-road level 241
Pre-selecting suspension struts 241
Changing the vehicle level 242
Viewing the current inclination 242
Exiting the submenu 243
5 4 4 Freeing truck crane stuck in terrain 244
Rocking the truck crane free 244
Towing free to thefront 245
Towing free to therear 245
5 5 Separate steering 247
5 5 1 Switching to separate steering 247
Manual 248
Automatic 249
switching to normal steering mode 250
5 6 Heating and air-conditioning system 251
5 6 1 Standard heating system 251
Switching on 251
Heating 251
Air distribution 252
Examples 253
Switching off 253
5 6 2 Air-conditioning system 254
Information 254
Switching on/off 254
Cooling 255
Drying 255
5 6 3 Auxiliary water heater 256
Preheating theengine 256
Preheating the driver’s cab 257
Switching on the auxiliary heater 257
Switching off the auxiliary heater 258
Setting time andweekday 258
Saving automatic heating start 259
Setting the heating period 260
Switching the automatic heating start on and off 261
Setting the remaining run time 261
5 7 Towing a trailer 263
Effects on the axleloads 263
Coupling the trailer 264
Connecting the supply lines 265
Removing supply lines 266
Uncoupling thetrailer 266
Checking the braking force 268
6 Driving modes 271
6 1 Driving modes 271
Information about the axle loads 271
6 1 1 Information on how to use the tables 272
6 1 2 Tables for a maximum axle load of 12 t (26,500 lbs) 273
For tyres 385/95 R25 273
For tyres 445/95 R25 274
For tyres 525/80 R25 275
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) 276
6 2 Weighing the truck crane 277
Determining 277
Axle groups 278
Weighing procedure 279
Evaluation 280
6 3 Rigging work for driving with a trailer 281
6 3 1 Switching on the slewing gear freewheel 282
6 3 2 Switching on the boom floating position 283
6 3 3 Switching on boom pre-tensioning 284
6 3 4 Adjusting axle pressure 285
Preselecting the axle pair 285
Adjusting axle pressure 286
Driving with changed axle pressures 286
Adjusting axle pressure for on-road driving 286
6 3 5 Switching the superstructure driving lights on/off 287
Switching off 287
Switching on 287
6 4 Main boom, removing/installing 289
Additional equipment required 289
6 4 1 CHECKLIST: Removing the main boom 290
Prerequisites 290
Checklist 290
6 4 2 CHECKLIST: Mounting the main boom 293
Prerequisites 293
Checklist 293
6 4 3 Slinging the main boom 296
Marking 296
Installing the lifting gear 296
Removing the lifting gear 297
6 4 4 Removing/attaching the clamps 298
6 4 5 Switching the pressure relief on/off 299
6 4 6 Connecting/disconnecting the derricking cylinder from the boom 300
Retracting the derricking cylinder head axle 301
Fitting the derricking cylinder head axle 302
6 4 7 Extending/retracting the boom pivot pin 303
Before pulling itout 303
After pushing it in 303
Pulling out the pivot pin 304
Pushing the pivot pin in 305
6 4 8 Disconnecting/connecting hydraulics/electrical 306
Disconnecting 306
Connecting 307
6 4 9 Lifting the main boom off/on the turntable 308
Lifting from the turntable 308
Lifting on to the turntable 309
6 4 10 Aligning the connecting points 310
6 4 11 Securing/releasing the derricking cylinder 310
6 4 12 Transporting the main boom 311
6 4 13 Inspections after main boom mounting 312
6 4 14 Installing/removing the hose drum 313
Installing 313
Removing 314
6 5 Installing/removing outrigger beams 317
6 5 1 CHECKLIST: Removing the outrigger beams 318
6 5 2 CHECKLIST: Installing the outrigger beams 320
6 5 3 Preparing the truck crane 322
Prerequisites 322
For removal 322
6 5 4 Removing/attaching outrigger pads 323
Removing outrigger pads 323
Attaching outrigger pads 324
6 5 5 Disconnecting/establishing the hydraulic connection 325
6 5 6 Disconnecting/establishing the electrical connection 326
6 5 7 Unscrewing/screwing in the spacers 327
Unscrewing 327
Screwing in 328
6 5 8 Disconnecting/establishing the connections to the supporting box 329
6 5 9 Extending/retracting the outrigger beam 329
Extending the outrigger beam 329
Inserting the outrigger beam 331
6 5 10 Transporting the outrigger beams 333
6 6 Installing/removing the supporting box 335
6 6 1 CHECKLIST: Removing the supporting box 336
6 6 2 CHECKLIST: Installing the supporting box 339
6 6 3 Rig the outrigger span 7 98x8 50/1 00m (26 1x27 9/3 3ft) 341
Front outrigger 342
Auxiliary supports 342
6 6 4 Establishing/disconnecting the pneumatic connection 344
6 6 5 Disconnecting/establishing the electrical connection 345
6 6 6 Disconnecting/establishing the hydraulic connection 346
6 6 7 Attaching/raising the supporting box with the truck crane 347
Prerequisites: 347
Lifting 348
Hanging 349
6 6 8 Installing the reverse camera 350
6 6 9 Crane movements during installation and removal 351
Prerequisites 351
Before installation 351
After the removal 351
6 6 10 Slinging points on the supporting box 352
6 6 11 Locking/unlocking the supporting box 353
Locking 353
Unlocking 354
6 6 12 Transporting the supporting box on the separate vehicle 355
Lashing eyelets 355
6 6 13 Installing / removing the rear bumper 356
Prerequisites: 356
Installing 357
Removing 357
6 7 Rigging the auxiliary hoist 359
6 7 1 CHECKLIST: Auxiliary hoist, installing 359
Prerequisites 359
6 7 2 CHECKLIST: Auxiliary hoist, removing 361
Prerequisites 361
6 7 3 Slinging the auxiliary hoist 363
6 7 4 Installing/removing the rigging frame 364
Prerequisite 364
6 7 5 Setting down the auxiliary hoist 365
6 7 6 Making/breaking the hydraulic connection 366
6 7 7 Establishing/disconnecting the electrical connection 367
6 7 8 Creating the connection to the turntable 368
Establishing the connection 368
Separating the connection 370
6 7 9 Securing the hoist rope 371
6 7 10 Transporting the auxiliary hoist 372
6 7 11 Check that the auxiliary hoist is functioning properly 373
Slewing direction 373
Slewing indicator 373
7 Malfunctions in driving mode 377
7 1 Emergency stop switch 377
7 2 What to do when a malfunction occurs in road traffic 379
7 3 Towing the truck crane 381
7 3 1 Towing after engine/transmission damage 382
Compressed-air supply 382
Electric power supply 383
On the transmission 383
Axle drives 383
Transfer case 384
Parking brake 384
Towing the truck crane out of the danger area 385
7 3 2 Tow starting 385
7 3 3 External starting socket 386
Performing a jump start 386
7 3 4 Battery charger 387
Prerequisites 387
7 4 Wheels and tyres 389
7 4 1 Wheel change 389
Removing adamaged wheel 390
On the spare wheel holder 390
Mounting a wheel 391
7 4 2 Inflating the tyres yourself 393
Connecting the filling hose 393
Inflating the tyres 394
Removing the filling hose 394
7 5 Fuses 395
Information on replacing fuses 395
7 5 1 Fuses in the driver’s cab 396
Group F1 396
Group F2 397
Group F3 397
Group F4 398
Group F5 398
Group F6 399
Group F7 399
Group F8 399
Group F9 400
Group F10 400
7 5 2 Fuses in the battery box 401
7 6 Troubleshooting 403
7 6 1 Malfunctions on the engine 403
7 6 2 Malfunctions in the exhaust system 405
7 6 3 Malfunctions in the transmission 406
7 6 4 Transfer case malfunctions 407
7 6 5 Malfunctions of the service brake 407
7 6 6 Malfunctions of the steering 408
7 6 7 Differential lock malfunctions 409
7 6 8 Malfunctions in the hydraulic system/hydraulic oil cooler 409
7 6 9 Malfunctions on the suspension 410
7 6 10 Malfunctions of the level adjustment system 410
7 6 11 Malfunctions on the ECOS carrier 411
ECOS programme version 411
General malfunctions 411
Error messages 412
Exiting the submenu 413
7 7 Procedure in the event of malfunctions 414
7 7 1 Switching on emergency operation in coolant circuit 414
7 7 2 Procedure during engine malfunctions 415
7 7 3 Malfunctions in the transmission 416
General malfunctions 416
Transmission malfunction 416
Reading out error codes 418
8 Index 421
A 423
B 423
C 424
D 425
E 427
F 429
H 429
I 430
K 430
L 431
M 431
O 432
P 434
R 434
S 435
T 437
V 439
W 439
Crane operation 443
Additional pages 445
Possible reeving methods on the main boom 445
Counterweight version B 455
Information on weight specifications 455
9 Operating elements for crane operation 461
9 1 Overview of the operating elements 461
9 1 1 Exterior of the truck crane 462
9 1 2 Crane cab 466
9 1 3 Front panel 468
9 1 4 Side panel 469
Bottom 469
Top 470
Console, rear 472
Standard heating system 473
Auxiliary water heating system 474
Auxiliary air heater 475
9 1 5 Control panels 476
Left 476
Right 477
9 1 6 Control lever configuration 478
Version 1 478
Version 2 479
9 1 7 ECOS control unit 480
9 1 8 ECOS display – main menu 482
9 1 9 ECOS display – submenus 484
Counterweight submenu 484
Slewing gear/ houselock submenu 485
Outriggers submenu 486
Telescoping submenu 488
Power unit speeds submenu 490
Monitoring submenu 491
Settings submenu 492
Operating hours submenu 493
Submenu Warning 494
Error submenu 497
Working range limiter submenu 498
9 1 10 RCL control unit 500
9 1 11 RCL display – main menu 501
9 1 12 Display RCL – submenus 503
Enter rigging mode submenu 503
Monitoring submenu 504
Rigging mode monitoring submenu 506
Lifting capacity table submenu 507
Working range submenu 508
Error submenu 509
Settings submenu 510
9 1 13 Hand-held control 511
9 1 14 Outrigger control units 512
Button 512
Outrigger button 513
Inclination and outrigger pressure display 514
Raise axle display 515
9 2 Short description of the operating elements 517
9 2 1 Definition of direction information 517
Basic rule 517
Switches 518
9 2 2 General rules for buttons and symbols on the display 518
9 2 3 Engine for crane operation 519
Side panel 519
Console, rear 520
ECOS display 520
9 2 4 Engine for driving 520
Side panel 520
Main menu 520
Outriggers submenu 521
9 2 5 Seat contact switch and dead man’s switch 522
9 2 6 ECOS crane control 523
Control unit 523
9 2 7 Outriggers 526
In the Outriggers submenu 526
In the Settings submenu 527
On the outrigger control units 528
9 2 8 Inclination indicators 530
9 2 9 Raise axle 531
Outrigger control units 531
9 2 10 Outrigger pressure displays 533
Outriggers submenu 533
Outriggers controlunits 533
9 2 11 Anemometer display 533
9 2 12 Counterweight submenu 534
Counterweight submenu 534
9 2 13 Main hoist 538
9 2 14 Auxiliary hoist 540
9 2 15 Slewing gear 541
Submenu 542
9 2 16 Derricking gear 544
9 2 17 Telescoping mechanism 546
Control panels 546
Submenu 547
In the Settings submenu 552
9 2 18 Hydraulic system 553
9 2 19 House lock 554
9 2 20 Rated capacity limiter (RCL) 555
Control unit 555
Main menu 557
Submenu Rigging mode entry 558
Monitoring submenu 562
Submenu Lifting capacity table 566
Working range submenu 567
RCL override 568
External displays 569
9 2 21 Electrical system 570
9 2 22 Lighting, windscreen wiper/washing system 571
Lighting 571
Windscreen wiper/washing system 573
9 2 23 Hand-held control 574
Sockets for hand-held control 574
Engine control panel 575
Horn 575
9 2 24 Windows, doors, keys 578
Windscreen 578
Rear window 578
Crane cab door 579
Keys 580
9 2 25 Diagnostics 580
10 Starting/switching off the engine – for crane operation 583
10 1 Starting the engine – from the crane cab 583
10 1 1 CHECKLIST: Starting the engine 583
10 1 2 CHECKLIST: At low temperatures 586
10 1 3 Refuel 586
Fuel 586
Carbamide 588
10 1 4 Checks before starting the engine 589
At the hydraulic tank 589
Battery master switch 589
Checking the hand-held control 590
10 1 5 Switch on the ignition 590
10 1 6 Lamp test / switching state alignment 591
Lamp test 591
10 1 7 Adjusting display brightness 593
10 1 8 Starting the engine 594
Without flame start system 594
With flame start system 595
10 1 9 Checks after starting the engine 596
10 1 10 Monitoring submenu 597
10 1 11 Setting idling speed 598
10 1 12 Override torque reduction 599
10 2 Starting the engine – with the hand-held control 601
Prerequisites 601
Starting the engine 601
10 3 Switching off the engine 603
10 3 1 During normal operation, with the ignition lock/with the hand-held control 603
After switching off 603
10 3 2 In emergencies, with the emergency stop switches 604
Resetting the emergency stop switch 604
10 4 Air intake inhibitor 605
Releasing the air intake inhibitor 605
11 Crane operation 609
11 1 Before operating the crane 609
11 1 1 CHECKLIST: Checks before operating the crane 609
11 1 2 Checking the condition of the truck crane 613
Windscreen washing system – Tank 613
Visual inspection 613
Checking the position of the hoist ropes 614
Checking the electrical system 614
11 1 3 Adjusting the crane cab seat and front control panel 615
Crane cab seat 615
Front control panel 616
11 1 4 Checking the safety equipment 617
Rated capacity limiter 617
Lifting limit switch 617
Emergency stop switch 618
Seat contact switch 619
11 1 5 Earthing the load 620
11 1 6 Preheating the hydraulic oil 621
11 1 7 Locking/unlocking the turntable 622
Locking points 622
11 1 8 Switching the houselock on/off 623
Switching on the houselock 623
Switching off the houselock 625
11 2 Operation of the rated capacity limiter 627
11 2 1 Switch on the RCL 628
Switching on 628
Brightness of the displays 630
11 2 2 Enter rigging mode 631
Entering individual components 632
Entering the RCL code 636
Entering the reeving 637
Accepting the rigging mode 637
11 2 3 Checks before operating the crane 639
Opening the submenu 639
Checks 640
11 2 4 Displays during crane operation 642
11 2 5 RCL early warning 645
11 2 6 RCL shutdown 645
Shutdown due to overload 645
11 2 7 Display in the event of errors 647
11 2 8 RCL override 648
Table – error/ information codes 654
11 2 9 Displaying the lifting capacity tables 655
11 2 10 Entering the time/date 657
11 3 Crane operation with main boom 659
11 3 1 Checks during crane operation 659
Horizontal alignment 659
Safe distances 659
Checking the windspeed 660
11 3 2 Permissible slewing ranges and working positions 661
360 slewing range 661
Working position 0to the rear 661
180 to the front rigging position 661
11 3 3 Main hoist 662
Maximum permissible hoistrope speed 662
Switching on the main hoist 663
Lifting and lowering 663
Switching off the main hoist 664
11 3 4 Auxiliary hoist 665
Maximum permissible hoist rope speed 665
Switching on the auxiliary hoist 666
Lifting and lowering 667
Switching off the auxiliary hoist 667
11 3 5 Lifting limit switch and lowering limit switch 668
Lifting limit switch 668
Lowering limit switch 669
11 3 6 Derricking gear 670
Switching on the derricking gear 670
Maximum permissible derricking speed 670
raising and lowering 671
Re-enable raising function 672
Switching off the derricking gear 672
Lowering the main boom to ahorizontal position 673
11 3 7 Telescoping mechanism 674
Overview 675
Telescoping process 675
Assignment for display 677
Fixed length, intermediate length, telescoping length 679
Telescoping 680
Telescoping sequence 680
Checks before starting work 681
Switching on the telescoping mechanism 682
Function of the control lever 682
Telescoping with lattice extension folded at the side 684
Switching off the telescoping mechanism 684
Manual telescoping 685
Checking the initial position 685
Unlocking the telescoping cylinder 687
Extending/retracting the telescoping cylinder 690
Lock telescoping cylinder 691
Unlocking the telescopic section 692
Telescoping the telescopic section 694
Locking the telescopic section 695
Locking the telescopic section for on-road driving 696
Telescoping with teleautomation 697
Telescoping the main boom when horizontal 701
11 3 8 High-speed mode 702
Switch on function 702
Derricking gear/ telescoping mechanism 702
Hoists 703
11 3 9 Slewing gear 704
Maximum permissible slewing speed 704
Switching on the slewing gear 704
Releasing the slewing gear brake 705
Engaging the slewing gear brake 705
Turning 705
Braking the slewing movement 707
Slewing gear freewheel 708
Switching off the slewing gear 708
11 3 10 Possible movement combinations 709
11 3 11 Hydraulic oil cooling 709
11 4 Settings and displays for crane operation 711
11 4 1 Inclining the crane cab 711
11 4 2 Setting idling speed 711
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 712
11 4 4 Limiting the power unit speeds 713
11 4 5 Setting the characteristic curves for the control levers 714
11 4 6 Critical load control 715
Function 715
Switching on andoff 715
11 4 7 Using the pivoting spotlights 716
11 4 8 Displaying the operating hours 717
11 4 9 Warning submenu 718
Meaning of thesymbols 718
Exiting the submenu 722
11 4 10 Error submenu 722
11 5 Working range limiter 723
11 5 1 Opening the working range limiter submenu 724
11 5 2 Viewing current settings 724
11 5 3 Entering limit values 726
Overall height/ working radius 726
Slewing angle 727
Entering objects 729
11 5 4 Entering limit values/objects manually 732
Limit values 732
Objects 733
11 5 5 Switching monitoring functions on/off 734
11 5 6 Shutdown by working range limiter 735
11 6 Work break 737
11 6 1 In case of short work breaks 737
11 6 2 In case of work breaks of more than 8 hours 738
To secure the truck crane 738
11 7 Heating and air-conditioning system 739
11 7 1 Standard heating system 739
Switching on 739
Heating 739
Air distribution 740
Switching off 740
11 7 2 Air-conditioning system 741
Information 741
Switching on/off 741
Cooling 742
Drying the air 742
11 7 3 Auxiliary water heater 743
Preheating theengine 743
Preheating the crane cab 744
Switching on 745
Setting the day and time 746
Storing the heating start 746
Setting the heating period 747
Switching heating start on/off 748
Switching off 749
Setting the remaining run time 749
11 7 4 Auxiliary air heater 750
Switching on 750
Temperature 751
Switching off 751
Other functions 751
11 8 CraneSTAR system 752
11 8 1 Overview 752
11 8 2 Position of the components 752
12 Rigging work 755
12 1 Rigging work checklists for crane operation with the main boom 755
12 1 1 CHECKLIST: Rigging 755
12 1 2 CHECKLIST: Unrigging 760
12 2 Choice of a suitable positioning site 763
12 2 1 Determining the required load-bearing area 763
12 2 2 Safe distance from slopes and pits 766
12 2 3 Earthing the truck crane 767
12 2 4 Safe distance from overhead power lines 768
12 3 Rigging work after driving with a trailer 771
12 3 1 Switching off the boom floating position 771
12 3 2 Switching off the slewing gear freewheel 772
Before slewing 772
12 3 3 Switching off boom pre-tensioning 773
12 4 Connecting/disconnecting the hand-held control 775
12 5 Starting the engine for driving for rigging work 777
12 5 1 Starting/turning off the engine from the crane cab 777
Prerequisites 777
Starting the engine 777
After starting theengine 778
Switching off theengine 778
12 5 2 Starting/switching off the engine from the outrigger control units 780
Prerequisites 780
Starting the engine 780
Switch the engine off 780
12 6 Outriggers 781
12 6 1 CHECKLIST: Extending the outriggers 781
12 6 2 CHECKLIST: Retracting the outriggers 783
12 6 3 Permissible outrigger spans 784
12 6 4 Preparing the truck crane 785
In the driver’s cab 785
Outriggers control units 785
12 6 5 Setting the outrigger spans 786
For on-road driving 788
12 6 6 Extending/retracting outrigger beams 789
From the control units 790
From the cranecab 791
12 6 7 Moving the outrigger pads into working/driving position 793
12 6 8 Enlarging the load-bearing area 794
12 6 9 Extending/retracting supporting cylinders 795
From the control units 796
From the crane cab 797
12 6 10 Levelling the truck crane on outriggers 800
Inclination indicators 800
Prerequisites 801
Manual alignment 802
Automatic alignment 803
12 6 11 Levelling the free-on-wheels truck crane 804
12 6 12 Outrigger pressure display 806
12 7 Rigging/unrigging the counterweight 807
12 7 1 Counterweight sections 807
Version A 807
Version B 808
12 7 2 Identification 809
12 7 3 Slinging points on the counterweight sections 810
12 7 4 CHECKLIST: Rigging the counterweight 812
12 7 5 CHECKLIST: Unrigging the counterweight 814
12 7 6 Assembling counterweight combination 816
Combinations for the basic equipment in version A 817
Combinations for the additional equipment in version A 820
Combinations for the basic equipment in version B 822
Combinations for the additional equipment in version B 825
12 7 7 Counterweight hoist unit 829
Counterweight submenu 829
Extending/retracting the lifting cylinders 830
Automatic mode rigging 831
Automatic mode unrigging 832
Cancel automatic mode 834
12 7 8 Setting down counterweight for driving the truck crane 835
Version A 835
Version B 835
12 7 9 Slewing with rigged counterweight 837
12 8 Rigging work on the main boom 839
12 8 1 Hook block on the bumper 839
Picking up the hook block 839
Attaching the hook block 840
12 8 2 Hook block on a separate vehicle 841
Picking up the hook block 842
Setting down the hook block 842
12 8 3 Hook block, separable 844
Rigging for on-road driving 844
Rigging for crane operation 845
12 8 4 Reeving and unreeving the hoist rope 846
Rope end fitting 846
Reeving the hoist rope 847
Unreeving hoist rope 850
12 8 5 Possible reeving methods on the main boom 851
With 9 head sheaves 852
With 10 head sheaves 855
12 8 6 Installing/removing the lifting limit switch 860
Installing the lifting limit switch 860
Removing the lifting limit switch 863
12 8 7 Locking/unlocking the lifting limit switch 864
Locking 864
Removing the lock 865
12 8 8 Anemometer and air traffic control light 866
Installing 866
Removing 867
12 9 Other rigging work 869
12 9 1 Railings on the turntable 869
12 9 2 Cameras for crane operation 871
Cameras on the hoists 871
Camera on main boom 871
Turning the monitor on/off and switching 874
12 9 3 Ladder on the counterweight 875
12 9 4 Extendable step 876
12 9 5 Folding the mirrors in and out, and adjusting them 877
13 Driving with a rigged truck crane 881
13 1 Driving path 881
13 2 Permissible rigging modes and axle loads 882
Axle load table 882
13 3 Before driving 884
13 3 1 Securing the superstructure against slewing 884
13 3 2 Check the tyre pressure and the wind speed 884
13 3 3 Putting the truck crane on the wheels 885
13 3 4 Gears/connections 887
Transmission 887
Connections 887
13 4 Whilst driving 887
13 5 After driving 889
13 6 Driving in combined operation 890
13 6 1 Switching combined operation on/off 890
Prerequisites 890
Switching on 891
Switching off 891
13 6 2 Starting/turning off the engine 892
13 6 3 Preparing to drive 893
Transmission 893
Switching on separate steering 893
Connections 893
13 6 4 While driving 894
14 Malfunctions during crane operation 897
14 1 Emergency stop switch 897
14 2 What to do when malfunctions occur during crane operation 899
The load can be set down 899
Load cannot be setdown 899
14 3 Fuses 901
Information on replacing fuses 901
14 3 1 Fuses on the turntable 902
Fuse groups F1/F2/F3 902
Fuses on the circuit board 903
14 3 2 Fuses in the crane cab 905
14 3 3 Fuses in the battery box 907
14 3 4 RCL fuses 908
14 4 Finding and eliminating malfunctions 909
14 4 1 Malfunctions on the engine 909
14 4 2 Malfunctions in the exhaust system 910
14 4 3 Malfunctions on the main hoist/auxiliary hoist 911
14 4 4 Malfunctions in the hoist cameras 912
14 4 5 Malfunctions in the main boom camera 912
14 4 6 Malfunctions on the derricking gear 913
14 4 7 Malfunctions in the telescoping mechanism 914
Telescoping mechanism error messages 915
14 4 8 Malfunctions in the slewing gear 917
14 4 9 Malfunctions in the counterweight hoist unit 919
14 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 920
14 4 11 Malfunctions when inclining the crane cab 920
14 4 12 Malfunctions when operating with the hand-held control 920
14 4 13 Malfunctions of the outriggers 921
14 4 14 Troubleshooting the RCL 922
General malfunctions 922
Error messages in the Monitoring submenu 923
Displays in the Error submenu 925
Table of error codes 927
Switch off the sensor/ tachogenerator 930
14 4 15 Malfunctions ECOS – superstructure 931
ECOS programme version 931
General malfunctions 931
Error messages 932
Exiting the submenu 933
14 4 16 Malfunctions on CraneSTAR system 934
14 5 Emergency operations and programs 937
14 5 1 Mechanical emergency activation for retracting 938
Prior to the emergency activation, check 938
Procedure 938
Mechanical emergency activation 939
14 5 2 Telescoping emergency program 941
Swinging the swing-away lattice 942
Checks 943
Starting the emergency program 943
Determining the type of error 944
Error at the length indicator 945
If there is an error at a proximity switch 949
Terminating emergency programme 950
Tables for approaching the locking points 951
14 5 3 Entering the current telescoping 953
14 5 4 Emergency operation with the hand-held control 955
Preparations 955
Operating a power unit 956
Stopping movements 958
Stopping movements in emergencies 958
Switch the engineoff 958
14 5 5 Switching on emergency operation in coolant circuit 959
14 6 Hydraulic emergency operation 961
14 6 1 Operating principle 961
14 6 2 Connecting/disconnecting hoses 962
Establishing connections 962
Disconnecting connections 963
14 6 3 Switching emergency operation on/off 964
14 6 4 Establishing the hydraulic circuits required 965
Switching over valves 965
For lifting/ lowering 967
For slewing 968
14 6 5 Performing emergency operation 969
Turning 969
Derricking 970
Lifting/lowering 970
14 6 6 After emergency operation 971
Switching off emergency operation 971
Switching over to crane operation 971
Disconnecting thehoses 971
14 6 7 Emergency supply of another crane 972
For emergency supply 972
After emergency supply 972
14 7 Other emergency operations 973
14 7 1 External starting socket 973
Performing a jump start 974
14 7 2 Battery charger 975
Prerequisites 975
15 Index 979
A 981
B 981
C 982
D 983
E 985
F 987
H 987
I 988
K 988
L 989
M 989
O 990
P 992
R 992
S 993
T 995
V 997
W 997

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S.M