Manitowoc Grove Crane GMK6300L Operation Operating Manual PDF

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Manitowoc Grove Crane Operation Operating Manual 3302740  – PDF DOWNLOAD

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Manitowoc Grove Crane Operation Operating Manual 3302740  – PDF DOWNLOAD

Language : English
Pages :1002
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Manitowoc Grove Crane Operation Operating Manual 3302740  – PDF DOWNLOAD

Operating Manual 1
Driving 1
Additional pages 3
Possible reeving methods on the main boom 3
Counterweight version B 13
Information on weight specifications 13
Hydraulic emergency operation 15
Additional switches required 15
1 Overview 21
1 1 Accidents 21
1 2 Branch offices 23
1 2 1 Manitowoc Crane Care 23
1 2 2 Dealer list 23
1 3 Warranty specifications 23
1 4 Terms used 24
1 5 Technical data 27
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 27
1 5 2 Dimensions and weights of the truck crane, axle loads 28
Dimensions 29
Weight and axleloads 29
1 5 3 Dimensions and weights of removable parts 30
Spare wheel 30
Outriggers 30
Driver’s safety guard 31
Hose drum 31
Hook blocks and hook tackle 31
Auxiliary hoist 32
Main boom 32
Counterweight parts 32
1 5 4 Carrier 33
Engine 33
Transmission 33
Transfer case 33
Axle lines 33
Steering 34
Tyres 34
Outriggers 34
Auxiliary supports 35
Electrical system 35
Tool 35
Towing coupling 35
Driving speeds 35
Climbing ability 35
Turning radii 36
1 5 5 Superstructure 37
Engine 37
Main hoist 37
Auxiliary hoist 37
Slewing gears 38
Derricking gear 38
Main boom 38
Lattice extension 38
Operating speeds 39
1 6 Documentation supplied 41
1 6 1 Questions on documentation 42
1 7 Notes on the operating manual 43
1 7 1 What do the symbols used mean? 43
1 7 2 How is the operating manual structured? 45
Division 45
Structure of thechapters 45
Structure of thepages 46
1 7 3 How do I find the information I need? 47
Cross-references example 48
1 7 4 What information is available for operations planning? 50
1 8 Conversion table for US measuring units 51
1 9 Training – Information 53
1 10 Identification 54
1 11 EC Declaration of Conformity 56
2 Basic safety instructions 59
2 1 Intended use 59
2 1 1 Improper use 60
2 2 Organisational measures 61
2 3 Personnel qualifications 63
2 4 Safety instructions for driving the truck crane 65
2 5 Safety instructions for crane operation 67
2 6 Instructions on transporting persons 71
Equipment for lifting persons 71
Personnel 72
Operation 72
Truck crane 73
3 Operating elements for driving 77
3 1 Overview of the operating elements 77
3 1 1 On the outside of the truck crane 78
3 1 2 Driver’s cab 82
Front overview 82
Behind the cover 86
Rear overview 87
3 1 3 Instrument panel 88
Left/right 88
Middle 89
3 1 4 Display, driving mode 92
3 1 5 Steering column/steering wheel 93
3 1 6 Transmission operating elements 94
3 1 7 Tachograph, time correction 95
3 1 8 ECOS control unit 96
3 1 9 ECOS display – main menu 98
3 1 10 ECOS display – submenus 100
Level adjustment system submenu 100
Settings submenu 102
Monitoring submenu 103
Operating hours submenu 104
Warning submenu 104
Error submenu 105
3 1 11 Heating/Air-conditioning system 106
Standard heating system 106
Auxiliary water heating system 107
3 1 12 Outrigger control units 108
3 1 13 Rear supporting box control unit 109
3 2 Short description of the operating elements 111
3 2 1 Definition of direction information 111
Basic rule 111
Switches and buttons 112
3 2 2 General notes on the operating elements 112
3 2 3 General rules for buttons and symbols on the display 113
3 2 4 Engine 114
Steering column 114
Multipurpose switch 114
Instrument panel 115
Main menu 116
3 2 5 Carbamide system 117
Instrument panel 117
Display, driving mode 118
ECOS display 118
3 2 6 Electrical system 119
3 2 7 ECOS crane control 120
Control unit 120
3 2 8 Transmission 123
Instrument panel, middle 123
Display, driving mode 123
Transmission control unit 123
3 2 9 Reverse camera 127
Reverse camera on/off 127
3 2 10 Transfer case 128
3 2 11 Final drive 129
3 2 12 Brakes 130
Service brake 130
Additional brakes 130
Parking brake 131
3 2 13 Steering/separate steering 132
Instrument panel 132
ECOS display 133
Driver’s door 134
3 2 14 Suspension 135
3 2 15 Lighting/windscreen wipers/horn 136
Steering column 136
Instrument panel 136
Roof 139
3 2 16 Level adjustment system 140
3 2 17 Tachograph/speedometer 143
Tachograph 143
Speedometer 143
3 2 18 Rear supporting box control unit 144
3 2 19 Diagnostics 145
Displays/ submenu 145
3 2 20 Windows, doors, keys 146
Window winder 146
Doors 147
Keys 147
3 2 21 Front flap 148
4 Starting the engine for driving / switching it off 151
4 1 Starting the engine from the driver’s cab 151
4 1 1 CHECKLIST: Starting the engine 151
4 1 2 CHECKLIST: At low temperatures 154
4 1 3 Ladders and access ladders 154
Fixed ladders 154
Ladders 155
4 1 4 Refuel 157
Fuel 157
Carbamide 158
4 1 5 Checks before starting the engine 160
At the hydraulic tank 160
Battery master switch 160
Checking the hand-held control 161
4 1 6 Switch on the ignition 161
4 1 7 Lamp test/equalisation of the switching states 162
Lamp test 162
Switching state alignment 163
4 1 8 Display – setting the brightness 164
4 1 9 Starting the engine 165
Without flame start system 166
With flame start system 166
4 1 10 Checks after starting the engine 168
Checking in the main menu 168
Indicator lamps on the instrument panel 168
4 1 11 Monitoring elements 170
Instrument panel 170
4 1 12 Monitoring submenu 171
4 1 13 Setting idling speed 172
4 2 Switch the engine off 173
4 2 1 At the ignition lock and with the outrigger control units 173
After switching off 173
4 2 2 Using the emergency stop switches 174
Resetting the emergency stop switch 174
4 3 Air intake inhibitor 175
Releasing the air intake inhibitor 175
5 Driving 179
5 1 Before driving 179
5 1 1 CHECKLIST: Checks before on-road driving 179
5 1 2 Checking the condition of the truck crane 185
Windscreen washing system 185
Electrical system 185
Adjusting themirrors 186
Warning plates for vehicle width 187
Displaying vehicle height 187
Supply pressure 188
Parking brake 189
5 1 3 Adjusting the seats and steering column 191
Driver’s seat 191
Passenger’s seat 193
Adjusting the steering column 194
5 1 4 Switching the suspension on/off 195
Opening the submenu 195
Switching the suspension on 196
Switching the suspension off 196
5 1 5 Setting the tachograph 197
Prerequisites 197
In the event of malfunctions 197
Setting the tachograph 198
5 1 6 Displaying the operating hours 203
5 1 7 Settings/indications on the driving display 204
5 2 Operating the transmission 205
5 2 1 Switching on 205
5 2 2 Switching the transmission to the neutral position 206
While driving 206
5 2 3 Changing the driving mode 207
5 2 4 Selecting the driving direction 208
5 2 5 Changing highest gear/starting gear 210
5 2 6 Starting 210
5 2 7 Driving and changing gears 211
5 2 8 Changing the driving direction 212
5 2 9 Stopping 213
Stopping for longer periods 213
5 2 10 On the roller type dynamometer 213
5 2 11 Oil level gauge 214
5 3 Driving the truck crane and switching it off 217
5 3 1 Checks whilst driving 217
Immediately after you start to move 217
While driving 219
5 3 2 Cruise control 220
Switching on 220
Switching off 221
5 3 3 Temposet 221
Switching on 221
Switching off 221
5 3 4 Driving downhill 222
Starting 222
Checks when driving downhill 222
Shifting down from the highest gear 223
Additional brakes 224
5 3 5 Driving uphill 225
Starting 225
Driving 225
5 3 6 Warning submenu 226
Meaning of thesymbols 226
Exiting the submenu 228
5 3 7 Warning or malfunction messages on the instrument panel 229
Meaning of the lamps 229
5 3 8 Override torque reduction 231
5 3 9 Error submenu 232
5 3 10 Switching the truck crane off 232
Secure it against rolling away 232
When stationary for more than 8hours 233
5 3 11 Folding berth 235
5 4 Off-road driving 237
Adjustments to the transmission 237
Connections 237
Changing the vehicle level 237
Rocking the vehicle free andtowing 237
5 4 1 Transfer case – switching the off-road gear on/off 238
Prerequisites 238
Switching on 239
Switching off 239
Neutral position 239
5 4 2 Longitudinal and transverse differential locks 240
5 4 3 Operating the level adjustment system 242
Opening the submenu 242
Setting the on-road level 243
Pre-selecting suspension struts 243
Changing the vehicle level 244
Viewing the current inclination 244
Exiting the submenu 245
5 4 4 Freeing truck crane stuck in terrain 246
Rocking the truck crane free 246
Towing free to thefront 247
Towing free to therear 247
5 5 Separate steering 249
5 5 1 Switching to separate steering 249
Manual 250
Automatic 251
switching to normal steering mode 252
5 6 Heating and air-conditioning system 253
5 6 1 Standard heating system 253
Switching on 253
Heating 253
Air distribution 254
Examples 255
Switching off 255
5 6 2 Air-conditioning system 256
Information 256
Switching on/off 256
Cooling 257
Drying 257
5 6 3 Auxiliary water heater 258
Preheating theengine 258
Preheating the driver’s cab 259
Switching on the auxiliary heater 259
Switching off the auxiliary heater 260
Setting time andweekday 260
Saving automatic heating start 261
Setting the heating period 262
Switching the automatic heating start on and off 263
Setting the remaining run time 263
5 7 Towing a trailer 265
Effects on the axleloads 265
Coupling the trailer 266
Connecting the supply lines 267
Removing supply lines 268
Uncoupling thetrailer 268
Checking the braking force 270
6 Driving modes 273
6 1 Driving modes 273
Information about the axle loads 273
6 1 1 Information on how to use the tables 274
6 1 2 Tables for a maximum axle load of 12 t 275
For tyres 385/95 R25 275
For tyres 445/95 R25 276
For tyres 525/80 R25 277
6 1 3 Maximum permitted speeds with an axle load of over 12 t 278
6 2 Weighing the truck crane 279
Determining 279
Axle groups 280
Weighing procedure 281
Evaluation 282
6 3 Rigging work for driving with a trailer 283
6 3 1 Switching on the slewing gear freewheel 284
6 3 2 Switching on the boom floating position 285
6 3 3 Switching on boom pre-tensioning 286
6 3 4 Adjusting axle pressure 287
Preselecting the axle pair 287
Adjusting axle pressure 288
Driving with changed axle pressures 288
Adjusting axle pressure for on-road driving 288
6 3 5 Switching the superstructure driving lights on/off 289
Switching off 289
Switching on 289
6 4 Main boom, removing/installing 291
Additional equipment required 291
6 4 1 CHECKLIST: Removing the main boom 292
Prerequisites 292
Checklist 292
6 4 2 CHECKLIST: Mounting the main boom 295
Prerequisites 295
Checklist 295
6 4 3 Slinging the main boom 298
Marking 298
Installing the lifting gear 298
Removing the lifting gear 299
6 4 4 Removing/attaching the clamps 300
6 4 5 Switching the pressure relief on/off 301
6 4 6 Connecting/disconnecting the derricking cylinder from the boom 302
Retracting the derricking cylinder head axle 303
Fitting the derricking cylinder head axle 304
6 4 7 Extending/retracting the boom pivot pin 305
Before pulling itout 305
After pushing it in 305
Pulling out the pivot pin 306
Pushing the pivot pin in 307
6 4 8 Disconnecting/connecting hydraulics/electrical 308
Disconnecting 308
Connecting 309
6 4 9 Lifting the main boom off/on the turntable 310
Lifting from the turntable 310
Lifting on to the turntable 311
6 4 10 Aligning the connecting points 312
6 4 11 Securing/releasing the derricking cylinder 312
6 4 12 Transporting the main boom 313
6 4 13 Inspections after main boom mounting 314
6 4 14 Installing/removing the hose drum 315
Installing 315
Removing 316
6 5 Installing/removing outrigger beams 319
6 5 1 CHECKLIST: Removing the outrigger beams 320
6 5 2 CHECKLIST: Installing the outrigger beams 322
6 5 3 Preparing the truck crane 324
Prerequisites 324
For removal 324
6 5 4 Removing/attaching outrigger pads 325
Removing outrigger pads 325
Attaching outrigger pads 326
6 5 5 Disconnecting/establishing the hydraulic connection 327
6 5 6 Disconnecting/establishing the electrical connection 328
6 5 7 Unscrewing/screwing in the spacers 329
Unscrewing 329
Screwing in 330
6 5 8 Disconnecting/establishing the connections to the supporting box 331
6 5 9 Extending/retracting the outrigger beam 331
Extending the outrigger beam 331
Inserting the outrigger beam 333
6 5 10 Transporting the outrigger beams 335
6 6 Installing/removing the supporting box 337
6 6 1 CHECKLIST: Removing the supporting box 338
6 6 2 CHECKLIST: Installing the supporting box 341
6 6 3 Rig the outrigger span 7 98x8 50/1 00m 343
Front outrigger 344
Auxiliary supports 344
6 6 4 Establishing/disconnecting the pneumatic connection 346
6 6 5 Disconnecting/establishing the electrical connection 347
6 6 6 Disconnecting/establishing the hydraulic connection 348
6 6 7 Attaching/raising the supporting box with the truck crane 349
Prerequisites: 349
Lifting 350
Hanging 351
6 6 8 Installing the reverse camera 352
6 6 9 Crane movements during installation and removal 353
Prerequisites 353
Before installation 353
After the removal 353
6 6 10 Slinging points on the supporting box 354
6 6 11 Locking/unlocking the supporting box 355
Locking 355
Unlocking 356
6 6 12 Transporting the supporting box on the separate vehicle 357
Lashing eyelets 357
6 6 13 Installing / removing the rear bumper 358
Prerequisites: 358
Installing 359
Removing 359
6 7 Rigging the auxiliary hoist 361
6 7 1 CHECKLIST: Auxiliary hoist, installing 361
Prerequisites 361
6 7 2 CHECKLIST: Auxiliary hoist, removing 363
Prerequisites 363
6 7 3 Slinging the auxiliary hoist 365
6 7 4 Installing/removing the rigging frame 366
Prerequisite 366
6 7 5 Setting down the auxiliary hoist 367
6 7 6 Making/breaking the hydraulic connection 368
6 7 7 Establishing/disconnecting the electrical connection 369
6 7 8 Creating the connection to the turntable 370
Establishing the connection 370
Separating the connection 372
6 7 9 Securing the hoist rope 373
6 7 10 Transporting the auxiliary hoist 374
6 7 11 Check that the auxiliary hoist is functioning properly 375
Slewing direction 375
Slewing indicator 375
7 Malfunctions in driving mode 379
7 1 Emergency stop switch 379
7 2 What to do when a malfunction occurs in road traffic 381
7 3 Towing the truck crane 383
7 3 1 Towing after engine/transmission damage 384
Compressed-air supply 384
Electric power supply 385
On the transmission 385
Axle drives 385
Transfer case 386
Parking brake 386
Towing the truck crane out of the danger area 387
7 3 2 Tow starting 387
7 3 3 External starting socket 388
Performing a jump start 388
7 3 4 Battery charger 389
Prerequisites 389
7 4 Wheels and tyres 391
7 4 1 Wheel change 391
Removing adamaged wheel 392
On the spare wheel holder 392
Mounting a wheel 393
7 4 2 Inflating the tyres yourself 395
Connecting the filling hose 395
Inflating the tyres 396
Removing the filling hose 396
7 5 Fuses 397
Information on replacing fuses 397
7 5 1 Fuses in the driver’s cab 398
Group F1 398
Group F2 399
Group F3 399
Group F4 400
Group F5 400
Group F6 401
Group F7 401
Group F8 401
Group F9 402
Group F10 402
7 5 2 Fuses in the battery box 403
7 6 Troubleshooting 405
7 6 1 Malfunctions on the engine 405
7 6 2 Malfunctions in the exhaust system 407
7 6 3 Malfunctions in the transmission 408
7 6 4 Transfer case malfunctions 409
7 6 5 Malfunctions of the service brake 409
7 6 6 Malfunctions of the steering 410
7 6 7 Differential lock malfunctions 411
7 6 8 Malfunctions in the hydraulic system/hydraulic oil cooler 411
7 6 9 Malfunctions on the suspension 412
7 6 10 Malfunctions of the level adjustment system 412
7 6 11 Malfunctions on the ECOS carrier 413
ECOS programme version 413
General malfunctions 413
Error messages 414
Exiting the submenu 415
7 7 Procedure in the event of malfunctions 416
7 7 1 Switching on emergency operation in coolant circuit 416
7 7 2 Procedure during engine malfunctions 417
7 7 3 Malfunctions in the transmission 418
General malfunctions 418
Transmission malfunction 418
Reading out error codes 420
8 Index 423
Crane Operation 459
Additional pages 447
Possible reeving methods on the main boom 447
Counterweight version B 457
Information on weight specifications 457
9 Operating elements for crane operation 463
9 1 Overview of the operating elements 463
9 1 1 Exterior of the truck crane 464
9 1 2 Crane cab 468
9 1 3 Front panel 470
9 1 4 Side panel 471
Bottom 471
Top 472
Console, rear 474
Standard heating system 475
Auxiliary water heating system 476
Auxiliary air heater 477
9 1 5 Control panels 478
Left 478
Right 479
9 1 6 Control lever configuration 480
Version 1 480
Version 2 481
9 1 7 ECOS control unit 482
9 1 8 ECOS display – main menu 484
9 1 9 ECOS display – submenus 486
Counterweight submenu 486
Slewing gear/ houselock submenu 487
Outriggers submenu 488
Telescoping submenu 490
Power unit speeds submenu 492
Monitoring submenu 493
Settings submenu 494
Operating hours submenu 495
Submenu Warning 496
Error submenu 499
Working range limiter submenu 500
9 1 10 RCL control unit 502
9 1 11 RCL display – main menu 503
9 1 12 Display RCL – submenus 505
Enter rigging mode submenu 505
Monitoring submenu 506
Rigging mode monitoring submenu 508
Lifting capacity table submenu 509
Working range submenu 510
Error submenu 511
Settings submenu 512
9 1 13 Hand-held control 513
9 1 14 Outrigger control units 514
Button 514
Outrigger button 515
Inclination and outrigger pressure display 516
Raise axle display 517
9 2 Short description of the operating elements 519
9 2 1 Definition of direction information 519
Basic rule 519
Switches 520
9 2 2 General rules for buttons and symbols on the display 520
9 2 3 Engine for crane operation 521
Side panel 521
Console, rear 522
ECOS display 522
9 2 4 Engine for driving 522
Side panel 522
Main menu 522
Outriggers submenu 523
9 2 5 Seat contact switch and dead man’s switch 524
9 2 6 ECOS crane control 525
Control unit 525
9 2 7 Outriggers 528
In the Outriggers submenu 528
In the Settings submenu 529
On the outrigger control units 530
9 2 8 Inclination indicators 532
9 2 9 Raise axle 533
Outrigger control units 533
9 2 10 Outrigger pressure displays 535
Outriggers submenu 535
Outriggers controlunits 535
9 2 11 Anemometer display 535
9 2 12 Counterweight submenu 536
Counterweight submenu 536
9 2 13 Main hoist 540
9 2 14 Auxiliary hoist 542
9 2 15 Slewing gear 543
Submenu 544
9 2 16 Derricking gear 546
9 2 17 Telescoping mechanism 548
Control panels 548
Submenu 549
In the Settings submenu 554
9 2 18 Hydraulic system 555
9 2 19 House lock 556
9 2 20 Rated capacity limiter (RCL) 557
Control unit 557
Main menu 559
Submenu Rigging mode entry 560
Monitoring submenu 564
Submenu Lifting capacity table 568
Working range submenu 569
RCL override 570
External displays 571
9 2 21 Electrical system 572
9 2 22 Lighting, windscreen wiper/washing system 573
Lighting 573
Windscreen wiper/washing system 575
9 2 23 Hand-held control 576
Sockets for hand-held control 576
Engine control panel 577
Horn 577
9 2 24 Windows, doors, keys 580
Windscreen 580
Rear window 580
Crane cab door 581
Keys 582
9 2 25 Diagnostics 582
10 Starting/switching off the engine – for crane operation 585
10 1 Starting the engine – from the crane cab 585
10 1 1 CHECKLIST: Starting the engine 585
10 1 2 CHECKLIST: At low temperatures 588
10 1 3 Refuel 588
Fuel 588
Carbamide 590
10 1 4 Checks before starting the engine 591
At the hydraulic tank 591
Battery master switch 591
Checking the hand-held control 592
10 1 5 Switch on the ignition 592
10 1 6 Lamp test / switching state alignment 593
Lamp test 593
10 1 7 Adjusting display brightness 595
10 1 8 Starting the engine 596
Without flame start system 596
With flame start system 597
10 1 9 Checks after starting the engine 598
10 1 10 Monitoring submenu 599
10 1 11 Setting idling speed 600
10 1 12 Override torque reduction 601
10 2 Starting the engine – with the hand-held control 603
Prerequisites 603
Starting the engine 603
10 3 Switching off the engine 605
10 3 1 During normal operation, with the ignition lock/with the hand-held control 605
After switching off 605
10 3 2 In emergencies, with the emergency stop switches 606
Resetting the emergency stop switch 606
10 4 Air intake inhibitor 607
Releasing the air intake inhibitor 607
11 Crane operation 611
11 1 Before operating the crane 611
11 1 1 CHECKLIST: Checks before operating the crane 611
11 1 2 Checking the condition of the truck crane 615
Windscreen washing system – Tank 615
Visual inspection 615
Checking the position of the hoist ropes 616
Checking the electrical system 616
11 1 3 Adjusting the crane cab seat and front control panel 617
Crane cab seat 617
Front control panel 618
11 1 4 Checking the safety equipment 619
Rated capacity limiter 619
Lifting limit switch 619
Emergency stop switch 620
Seat contact switch 621
11 1 5 Earthing the load 622
11 1 6 Preheating the hydraulic oil 623
11 1 7 Locking/unlocking the turntable 624
Locking points 624
11 1 8 Switching the houselock on/off 625
Switching on the houselock 625
Switching off the houselock 627
11 2 Operation of the rated capacity limiter 629
11 2 1 Switch on the RCL 630
Switching on 630
Brightness of the displays 632
11 2 2 Enter rigging mode 633
Entering individual components 634
Entering the RCL code 638
Entering the reeving 639
Accepting the rigging mode 639
11 2 3 Checks before operating the crane 641
Opening the submenu 641
Checks 642
11 2 4 Displays during crane operation 644
11 2 5 RCL early warning 647
11 2 6 RCL shutdown 647
Shutdown due to overload 647
11 2 7 Display in the event of errors 649
11 2 8 RCL override 650
Table – error/ information codes 656
11 2 9 Displaying the lifting capacity tables 657
11 2 10 Entering the time/date 659
11 3 Crane operation with main boom 661
11 3 1 Checks during crane operation 661
Horizontal alignment 661
Safe distances 661
Checking the windspeed 662
11 3 2 Permissible slewing ranges and working positions 663
360 slewing range 663
Working position 0to the rear 663
180 to the front rigging position 663
11 3 3 Main hoist 664
Maximum permissible hoistrope speed 664
Switching on the main hoist 665
Lifting and lowering 665
Switching off the main hoist 666
11 3 4 Auxiliary hoist 667
Maximum permissible hoist rope speed 667
Switching on the auxiliary hoist 668
Lifting and lowering 669
Switching off the auxiliary hoist 669
11 3 5 Lifting limit switch and lowering limit switch 670
Lifting limit switch 670
Lowering limit switch 671
11 3 6 Derricking gear 672
Switching on the derricking gear 672
Maximum permissible derricking speed 672
raising and lowering 673
Re-enable raising function 674
Switching off the derricking gear 674
Lowering the main boom to ahorizontal position 675
11 3 7 Telescoping mechanism 676
Overview 677
Telescoping process 677
Assignment for display 679
Fixed length, intermediate length, telescoping length 681
Telescoping 682
Telescoping sequence 682
Checks before starting work 683
Switching on the telescoping mechanism 684
Function of the control lever 684
Telescoping with lattice extension folded at the side 686
Switching off the telescoping mechanism 686
Manual telescoping 687
Checking the initial position 687
Unlocking the telescoping cylinder 689
Extending/retracting the telescoping cylinder 692
Lock telescoping cylinder 693
Unlocking the telescopic section 694
Telescoping the telescopic section 696
Locking the telescopic section 697
Locking the telescopic section for on-road driving 698
Telescoping with teleautomation 699
Telescoping the main boom when horizontal 703
11 3 8 High-speed mode 704
Switch on function 704
Derricking gear/ telescoping mechanism 704
Hoists 705
11 3 9 Slewing gear 706
Maximum permissible slewing speed 706
Switching on the slewing gear 706
Releasing the slewing gear brake 707
Engaging the slewing gear brake 707
Turning 707
Braking the slewing movement 709
Slewing gear freewheel 710
Switching off the slewing gear 710
11 3 10 Possible movement combinations 711
11 3 11 Hydraulic oil cooling 711
11 4 Settings and displays for crane operation 713
11 4 1 Inclining the crane cab 713
11 4 2 Setting idling speed 713
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 714
11 4 4 Limiting the power unit speeds 715
11 4 5 Setting the characteristic curves for the control levers 716
11 4 6 Critical load control 717
Function 717
Switching on andoff 717
11 4 7 Using the pivoting spotlights 718
11 4 8 Displaying the operating hours 719
11 4 9 Warning submenu 720
Meaning of thesymbols 720
Exiting the submenu 724
11 4 10 Error submenu 724
11 5 Working range limiter 725
11 5 1 Opening the working range limiter submenu 726
11 5 2 Viewing current settings 726
11 5 3 Entering limit values 728
Overall height/ working radius 728
Slewing angle 729
Entering objects 731
11 5 4 Entering limit values/objects manually 734
Limit values 734
Objects 735
11 5 5 Switching monitoring functions on/off 736
11 5 6 Shutdown by working range limiter 737
11 6 Work break 739
11 6 1 In case of short work breaks 739
11 6 2 In case of work breaks of more than 8 hours 740
To secure the truck crane 740
11 7 Heating and air-conditioning system 741
11 7 1 Standard heating system 741
Switching on 741
Heating 741
Air distribution 742
Switching off 742
11 7 2 Air-conditioning system 743
Information 743
Switching on/off 743
Cooling 744
Drying the air 744
11 7 3 Auxiliary water heater 745
Preheating theengine 745
Preheating the crane cab 746
Switching on 747
Setting the day and time 748
Storing the heating start 748
Setting the heating period 749
Switching heating start on/off 750
Switching off 751
Setting the remaining run time 751
11 7 4 Auxiliary air heater 752
Switching on 752
Temperature 753
Switching off 753
Other functions 753
11 8 CraneSTAR system 754
11 8 1 Overview 754
11 8 2 Position of the components 754
12 Rigging work 757
12 1 Rigging work checklists for crane operation with the main boom 757
12 1 1 CHECKLIST: Rigging 757
12 1 2 CHECKLIST: Unrigging 762
12 2 Choice of a suitable positioning site 765
12 2 1 Determining the required load-bearing area 765
12 2 2 Safe distance from slopes and pits 768
12 2 3 Earthing the truck crane 769
12 2 4 Safe distance from overhead power lines 770
12 3 Rigging work after driving with a trailer 773
12 3 1 Switching off the boom floating position 773
12 3 2 Switching off the slewing gear freewheel 774
Before slewing 774
12 3 3 Switching off boom pre-tensioning 775
12 4 Connecting/disconnecting the hand-held control 777
12 5 Starting the engine for driving for rigging work 779
12 5 1 Starting/turning off the engine from the crane cab 779
Prerequisites 779
Starting the engine 779
After starting theengine 780
Switching off theengine 780
12 5 2 Starting/switching off the engine from the outrigger control units 782
Prerequisites 782
Starting the engine 782
Switch the engine off 782
12 6 Outriggers 783
12 6 1 CHECKLIST: Extending the outriggers 783
12 6 2 CHECKLIST: Retracting the outriggers 785
12 6 3 Permissible outrigger spans 786
12 6 4 Preparing the truck crane 787
In the driver’s cab 787
Outriggers control units 787
12 6 5 Setting the outrigger spans 788
For on-road driving 790
12 6 6 Extending/retracting outrigger beams 791
From the control units 792
From the cranecab 793
12 6 7 Moving the outrigger pads into working/driving position 795
12 6 8 Enlarging the load-bearing area 796
12 6 9 Extending/retracting supporting cylinders 797
From the control units 798
From the crane cab 799
12 6 10 Levelling the truck crane on outriggers 802
Inclination indicators 802
Prerequisites 803
Manual alignment 804
Automatic alignment 805
12 6 11 Levelling the free-on-wheels truck crane 806
12 6 12 Outrigger pressure display 808
12 7 Rigging/unrigging the counterweight 809
12 7 1 Counterweight sections 809
Version A 809
Version B 810
12 7 2 Identification 811
12 7 3 Slinging points on the counterweight sections 812
12 7 4 CHECKLIST: Rigging the counterweight 814
12 7 5 CHECKLIST: Unrigging the counterweight 816
12 7 6 Assembling counterweight combination 818
Combinations for the basic equipment in version A 819
Combinations for the additional equipment in version A 822
Combinations for the basic equipment in version B 824
Combinations for the additional equipment in version B 827
12 7 7 Counterweight hoist unit 831
Counterweight submenu 831
Extending/retracting the lifting cylinders 832
Automatic mode rigging 833
Automatic mode unrigging 834
Cancel automatic mode 836
12 7 8 Setting down counterweight for driving the truck crane 837
Version A 837
Version B 837
12 7 9 Slewing with rigged counterweight 839
12 8 Rigging work on the main boom 841
12 8 1 Hook block on the bumper 841
Picking up the hook block 841
Attaching the hook block 842
12 8 2 Hook block on a separate vehicle 843
Picking up the hook block 844
Setting down the hook block 844
12 8 3 Hook block, separable 846
Rigging for on-road driving 846
Rigging for crane operation 847
12 8 4 Reeving and unreeving the hoist rope 848
Rope end fitting 848
Reeving the hoist rope 849
Unreeving hoist rope 852
12 8 5 Possible reeving methods on the main boom 853
With 9 head sheaves 854
With 10 head sheaves 857
12 8 6 Installing/removing the lifting limit switch 862
Installing the lifting limit switch 862
Removing the lifting limit switch 865
12 8 7 Locking/unlocking the lifting limit switch 866
Locking 866
Removing the lock 867
12 8 8 Anemometer and air traffic control light 868
Installing 868
Removing 869
12 9 Other rigging work 871
12 9 1 Railings on the turntable 871
12 9 2 Cameras for crane operation 873
Cameras on the hoists 873
Camera on main boom 873
Turning the monitor on/off and switching 876
12 9 3 Ladder on the counterweight 877
12 9 4 Extendable step 878
12 9 5 Folding the mirrors in and out, and adjusting them 879
13 Driving with a rigged truck crane 883
13 1 Driving path 883
13 2 Permissible rigging modes and axle loads 884
Axle load table 884
13 3 Before driving 886
13 3 1 Securing the superstructure against slewing 886
13 3 2 Check the tyre pressure and the wind speed 886
13 3 3 Putting the truck crane on the wheels 887
13 3 4 Gears/connections 889
Transmission 889
Connections 889
13 4 Whilst driving 889
13 5 After driving 891
13 6 Driving in combined operation 892
13 6 1 Switching combined operation on/off 892
Prerequisites 892
Switching on 893
Switching off 893
13 6 2 Starting/turning off the engine 894
13 6 3 Preparing to drive 895
Transmission 895
Switching on separate steering 895
Connections 895
13 6 4 While driving 896
14 Malfunctions during crane operation 899
14 1 Emergency stop switch 899
14 2 What to do when malfunctions occur during crane operation 901
The load can be set down 901
Load cannot be setdown 901
14 3 Fuses 903
Information on replacing fuses 903
14 3 1 Fuses on the turntable 904
Fuse groups F1/F2/F3 904
Fuses on the circuit board 905
14 3 2 Fuses in the crane cab 907
14 3 3 Fuses in the battery box 909
14 3 4 RCL fuses 910
14 4 Finding and eliminating malfunctions 911
14 4 1 Malfunctions on the engine 911
14 4 2 Malfunctions in the exhaust system 912
14 4 3 Malfunctions on the main hoist/auxiliary hoist 913
14 4 4 Malfunctions in the hoist cameras 914
14 4 5 Malfunctions in the main boom camera 914
14 4 6 Malfunctions on the derricking gear 915
14 4 7 Malfunctions in the telescoping mechanism 916
Telescoping mechanism error messages 917
14 4 8 Malfunctions in the slewing gear 919
14 4 9 Malfunctions in the counterweight hoist unit 921
14 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 922
14 4 11 Malfunctions when inclining the crane cab 922
14 4 12 Malfunctions when operating with the hand-held control 922
14 4 13 Malfunctions of the outriggers 923
14 4 14 Troubleshooting the RCL 924
General malfunctions 924
Error messages in the Monitoring submenu 925
Displays in the Error submenu 927
Table of error codes 929
Switch off the sensor/ tachogenerator 932
14 4 15 Malfunctions ECOS – superstructure 933
ECOS programme version 933
General malfunctions 933
Error messages 934
Exiting the submenu 935
14 4 16 Malfunctions on CraneSTAR system 936
14 5 Emergency operations and programs 939
14 5 1 Mechanical emergency activation for retracting 940
Prior to the emergency activation, check 940
Procedure 940
Mechanical emergency activation 941
14 5 2 Telescoping emergency program 943
Swinging the swing-away lattice 944
Checks 945
Starting the emergency program 945
Determining the type of error 946
Error at the length indicator 947
If there is an error at a proximity switch 951
Terminating emergency programme 952
Tables for approaching the locking points 953
14 5 3 Entering the current telescoping 955
14 5 4 Emergency operation with the hand-held control 957
Preparations 957
Operating a power unit 958
Stopping movements 960
Stopping movements in emergencies 960
Switch the engineoff 960
14 5 5 Switching on emergency operation in coolant circuit 961
14 6 Hydraulic emergency operation 963
14 6 1 Operating principle 963
14 6 2 Connecting/disconnecting hoses 964
Establishing connections 964
Disconnecting connections 965
14 6 3 Switching emergency operation on/off 966
14 6 4 Establishing the hydraulic circuits required 967
Switching over valves 967
For lifting/ lowering 969
For slewing 970
14 6 5 Performing emergency operation 971
Turning 971
Derricking 972
Lifting/lowering 972
14 6 6 After emergency operation 973
Switching off emergency operation 973
Switching over to crane operation 973
Disconnecting thehoses 973
14 6 7 Emergency supply of another crane 974
For emergency supply 974
After emergency supply 974
14 7 Other emergency operations 975
14 7 1 External starting socket 975
Performing a jump start 976
14 7 2 Battery charger 977
Prerequisites 977
15 Index 981
A 983
B 983
C 984
D 985
E 987
F 989
H 989
I 990
K 990
L 991
M 991
O 992
P 994
R 994
S 995
T 997
V 999
W 999

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