Grove Crane Manitowoc GMK 3060i Part 1 – Driving Operating Manual 3302406 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane Manitowoc GMK 3060i Part 1 – Driving Operating Manual 3302406 – PDF DOWNLOAD
Language : English
Pages : 870
Downloadable : Yes
File Type : PDF
Size: 32.4 MB
DESCRIPTION:
Grove Crane Manitowoc GMK 3060i Part 1 – Driving Operating Manual 3302406 – PDF DOWNLOAD
Basic safety instructions:
Intended Use:
The GMK 3060i is an advanced truck crane designed in compliance with approved safety regulations. However, it is important to acknowledge that the operator or third parties can still be endangered, and there is a risk to the crane or other property during its operation.
- Modification of the truck crane is only permitted with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 3060i truck crane should only be used when it is in perfect technical condition, for its intended purpose, and with careful attention to safe operation and potential hazards.
- Any malfunctions that could compromise safety must be promptly addressed.
- The GMK 3060i truck crane may only be operated without the corresponding special equipment within the permitted temperature range (refer to Technical Data, p. 1-7).
- The GMK 3060i truck crane is exclusively designed for lifting loads that fall within the permitted GMK 3060i lifting capacities. The load must be slung as prescribed to a vertically positioned hook block before lifting.
Intended use also includes:
- Observing the entire crane documentation, including the operating instructions, lifting capacity table, outrigger pressure table, and safety manual.
- Adhering to the inspection and maintenance requirements specified in the maintenance manual.
- The GMK 3060i may only be operated with equipment parts approved by Manitowoc Crane Group Germany GmbH and labeled with the serial number of the GMK 3060i.
- The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK 3060i truck crane. The user alone assumes the associated risks.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane Manitowoc GMK 3060i Part 1 – Driving Operating Manual 3302406 – PDF DOWNLOAD
Part 1 – Driving 1
Additional page 3
CCS – Datalogger 3
Additional menu and program 3
Additional menu 3
Export data 4
Display the data 4
Outrigger spans 9
1 Overview 15
1 1 Accidents 15
1 2 Branch offices 17
1 2 1 Manitowoc Crane Care 17
1 2 2 Dealer list 17
1 3 Warranty specifications 17
1 4 Terms used 18
1 5 Technical data 21
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 21
1 5 2 Dimensions and weights of the truck crane, axle loads 22
Dimensions 23
Weight and axle loads 23
1 5 3 Dimensions and weights of removable parts 24
Spare wheel 24
Outriggers 24
Hook blocks and hook tackle 24
Counterweight parts 25
1 5 4 Carrier 26
Engine 26
Transmission 26
Transfer case 26
Axle lines 26
Steering 26
Tyres 27
Outriggers 27
Electrical system 28
Tool 28
Towing couplings 28
Driving speeds 28
Climbing ability 28
Turning radii 29
1 5 5 Superstructure 29
Main hoist 29
Auxiliary hoist 30
Slewing gears 30
Derricking gear 30
Main boom 30
Lattice extension 30
Operating speeds 31
1 6 Documentation supplied 33
1 6 1 Questions on documentation 34
1 7 Notes on the operating instructions 35
1 7 1 What do the symbols used mean? 35
1 7 2 How are the operating instructions structured? 37
Division 37
Structure of the chapters 37
Structure of the pages 38
1 7 3 How do I find the information I need? 39
Cross-references example 40
1 7 4 What information is available for operations planning? 42
1 8 Conversion table for US measuring units 43
1 9 Training – Information 45
1 10 Identification 46
1 11 EC Declaration of Conformity 48
2 Basic safety instructions 51
2 1 Intended use 51
2 1 1 Improper use 52
2 2 Organisational measures 53
2 3 Personnel qualifications 55
2 4 Safety instructions for driving the truck crane 56
2 5 Safety instructions for crane operation 56
2 6 Notes on transporting persons 59
Equipment for lifting persons 59
Personnel 59
Operation 60
Truck crane 61
3 Operating elements for driving 65
3 1 Overview of the operating elements 65
3 1 1 On the outside of the truck crane 66
3 1 2 Driver’s cab 68
Overview 68
Behind the cover 70
Page 71
Doors 72
Front 73
3 1 3 Instrument panel 74
Middle 74
Left/right 76
3 1 4 Transmission operating elements 77
3 1 5 Display, driving mode 78
3 1 6 Steering column/steering wheel 79
3 1 7 Tachograph 80
3 1 8 Standard heating 81
Auxiliary water heater 82
Auxiliary air heater 83
3 1 9 Control unit CCS 84
3 1 10 Display CCS – Start menu 86
3 1 11 CCS – Overview menu groups 87
Carrier menu group 88
Suspension/level adjustment menu 89
Driving menu 90
Settings menu group 91
Menu for setting the display brightness and date/ time 92
Information menu group 93
Operating hours menu 94
Engine/transmission error menu 95
Crane operation error menu 96
Operating additional equipment 97
3 1 12 Sockets for hand-held control 98
3 1 13 Outrigger control units 99
3 2 Short description of the operating elements 101
3 2 1 Definition of direction information 101
Basic rule 101
Switches and buttons 102
3 2 2 General notes on the operating elements 102
3 2 3 General rules for buttons and symbols on the display 103
3 2 4 Engine 104
Steering column 104
Multipurpose switch 104
Instrument panel 105
3 2 5 DEF system 107
Instrument panel 107
Display, driving mode 108
CCS display 108
3 2 6 Crane control CCS 108
3 2 7 Transmission 113
Transmission control unit 113
Display, driving mode 114
3 2 8 Reverse camera 116
3 2 9 Final drive 117
3 2 10 Brakes 119
Service brake 119
Additional brakes 120
Parking brake 121
3 2 11 Steering/separate steering 122
Instrument panel 122
Driver’s door 122
CCS display 123
3 2 12 Suspension 124
CCS display 124
3 2 13 Lighting/windscreen wipers/horn 125
Steering column 125
Instrument panel 125
CCS display 127
Roof 128
3 2 14 Level adjustment system 129
3 2 15 Tachograph/speedometer 131
Tachograph 131
3 2 16 Diagnostics 132
3 2 17 Windows, doors, keys 133
Window winder 133
Doors 134
Keys 135
3 2 18 Front flap 135
4 Starting/turning off the engine for driving 139
4 1 Starting the engine from the driver’s cab 139
4 1 1 CHECKLIST: Starting the engine 139
4 1 2 CHECKLIST: At low temperatures 142
4 1 3 Ladders 143
4 1 4 Refuel 146
Fuel tank 146
Filling DEF 148
Auxiliary heater tank 149
4 1 5 Checks before starting the engine 150
On hydraulic tank 150
Battery master switch 151
Checking hand- held control 151
4 1 6 Switching on the ignition 151
4 1 7 Lamp test/equalisation of the switching states 152
Lamp test 152
Equalisation of the switching states 152
4 1 8 Display – setting the brightness 153
4 1 9 Starting the engine 154
Without flame start system 155
With flame start system 156
4 1 10 Checks after starting the engine 157
Checking in the main menu 157
Indicator lamps on the instrument panel 157
4 1 11 Monitoring elements 158
Instrument panel 158
4 1 12 Start menu 159
4 1 13 Setting idling speed 160
4 2 Turning off the engine 161
4 2 1 On the ignition lock/with hand-held control/on the outrigger control units 161
After turning off 161
4 2 2 Using the emergency stop switches 162
Resetting the emergency stop switch 162
4 3 Air intake inhibitor 163
Releasing the air intake inhibitor 163
5 Driving 167
5 1 Before driving 167
5 1 1 CHECKLIST: Checks before on-road driving 167
5 1 2 Checking the condition of the truck crane 172
Electrical system 172
Adjusting the mirrors 172
Warning plates for vehicle width 174
Displaying vehicle height 174
Supply pressure 175
Parking brake 176
5 1 3 Adjusting the seat and the steering column 177
Adjusting the driver’s seat 177
Adjusting the passenger seat 178
Adjusting the steering column 179
Storage compartment under the driver’s seat 179
5 1 4 Switching the suspension on/off 180
Open menu 180
Switching on the suspension 181
Switching off the suspension 181
5 1 5 Setting the tachograph 182
Prerequisites 182
In the event of malfunctions 182
Setting the tachograph 183
5 1 6 Entering the time/date 187
5 1 7 Displaying and resetting operating hours 188
5 1 8 Settings/indications on the driving display 189
5 2 Operating the transmission 190
5 2 1 Switching on 190
5 2 2 Switching the transmission to neutral position 191
5 2 3 Selecting the direction of travel and starting gear 192
Selecting the driving direction 192
Selecting the starting gear 193
5 2 4 Changing the operating mode 194
Change to automatic mode 194
Change to manual mode 194
5 2 5 Starting 195
5 2 6 Driving and changing gears 197
In automatic operating mode 197
In manual operating mode 198
5 2 7 Changing the driving direction 199
5 2 8 Stopping 199
Stopping for a long period of time 199
5 2 9 DM and RM transmission mode 200
Switching on 200
Switching off 201
5 2 10 On the roller type dynamometer 202
5 2 11 Preheating transmission 202
5 3 Driving and turning off the truck crane 203
5 3 1 Checks while driving 203
Immediately after you start to move 203
While driving 205
5 3 2 Tempomat 206
Switching on 206
Switching off 207
5 3 3 Cruise control 207
Switching on 207
Switching off 207
5 3 4 Driving downhill 208
Starting 208
Inspections when driving downhill 209
Downshifting 209
Additional brakes 210
5 3 5 Driving uphill 211
Starting 211
Driving 211
5 3 6 Warning or malfunction messages on the instrument panel 212
Meaning of the lamps 212
5 3 7 Notes on torque reduction 214
5 3 8 Warning messages in the start menu 215
5 3 9 Turning off the truck crane 216
Securing against rolling away 216
When stationary for more than 8hours 217
5 3 10 Fold-up berth 218
5 4 Off-road driving 219
Adjustments to the transmission 219
Connections 219
Changing the vehicle level 219
Rocking the vehicle free and towing 219
5 4 1 Longitudinal and transverse differential locks 220
5 4 2 Operating the level adjustment system 222
Open menu 222
Setting the on-road level 223
Pre-selecting suspension struts 223
Changing the vehicle level 224
Viewing the current inclination 224
Exiting the menu 225
5 4 3 Freeing truck crane stuck in terrain 226
Rocking the truck crane free 226
Towing free forwards 227
Towing free in reverse gear 227
5 5 Separate steering 229
5 5 1 Switching to separate steering 229
Manual 230
Automatic 231
5 6 Heating and air-conditioning system 233
5 6 1 Standard heating system 233
Switching on 233
Temperature 233
Fan 233
Fresh air/recirculated air 234
Air distribution 234
Switching off 235
5 6 2 Auxiliary water heater 236
Preheating the engine 236
Preheating the driver’s cab 236
Switching on 237
Setting the day and time 238
Storing the heating start 238
Setting the heating period 240
Switching the heating start on and off 240
Switching off 241
Setting the remaining time 241
5 6 3 Auxiliary air heater 242
Switching on 242
Temperature 243
Other functions 243
Switching off 243
5 6 4 Air-conditioning system 244
Switching on 244
Operation 244
Drying the air 245
Switching off 245
5 7 Towing a trailer 247
Effects on the axle loads 247
Coupling the trailer 248
Connecting the supply lines 249
Removing the supply lines 250
Uncoupling the trailer 250
Checking the braking force 252
6 Driving modes 255
6 1 Driving modes 255
Information about the axle loads 255
6 1 1 Information on how to use the tables 256
6 1 2 Table for a maximum axle load of 12 t 257
For 385/95 R25 tyres 257
For 445/95 R25 tyres 258
For 525/80 R25 tyres 259
7 Malfunctions in driving mode 263
7 1 Emergency stop switch 263
7 2 What to do when a malfunction occurs in road traffic 265
7 3 Towing the truck crane 267
7 3 1 Towing after engine/transmission damage 268
Compressed-air supply 268
Electric power supply 268
On the transmission 269
Axle drives 269
Parking brake 269
Towing the truck crane out of the danger area 270
Longer towing distances 270
7 3 2 Tow starting 270
7 4 Other emergency operations 271
7 4 1 Externally starting the truck crane 271
7 4 2 Battery charger 272
7 5 Wheels and tyres 273
7 5 1 Wheel change 273
Removing a damaged wheel 274
On the spare wheel holder 274
Mounting a wheel 275
7 5 2 Inflating the tyres yourself 277
Connecting the filling hose 277
Inflating the tyres 278
Removing the filling hose 278
7 6 Tilting/lowering the driver’s cabin 279
7 6 1 Prerequisites and information on tilting 279
7 6 2 Tilting and lowering the driver’s cab 280
Operating the hand pump 280
Tilting the driver’s cab 281
Lowering the driver’s cab 282
7 7 Fuses on the carrier 283
Notes on changing fuses 283
7 7 1 Fuses in the driver’s cab 284
7 7 2 Fuses in the battery box 290
7 8 Troubleshooting 291
7 8 1 Malfunctions on the engine 291
When operating with the dual tank 293
7 8 2 Faults on the DEF system 293
7 8 3 Differential lock malfunctions 294
7 8 4 Malfunctions in the transmission 295
7 8 5 Malfunctions of the steering 296
7 8 6 Malfunctions of the service brake 297
7 8 7 Malfunctions on the suspension 297
7 8 8 Malfunctions of the level adjustment system 297
7 8 9 Malfunctions in the hydraulic system/hydraulic oil cooler 298
7 9 Warnings in the start menu 299
Symbols in the display area 299
7 9 1 Engine/transmission error menu 304
Open menu 304
Exiting the menu 304
7 10 Procedure in the event of malfunctions 305
7 10 1 Switching on emergency operation in coolant circuit 305
7 10 2 Procedure during transmission malfunctions 306
Error messages 306
Displaying error codes 308
8 Index 311
A 313
B 313
C 313
D 316
E 318
F 319
H 320
I 320
K 320
L 321
M 321
O 322
P 323
R 323
S 324
T 325
V 327
W 327
Part 2 – Crane operation 331
Additional page 333
CCS – Datalogger 333
Additional menu and program 333
Additional menu 333
Export data 334
Display the data 334
9 Operating elements for crane operation 343
9 1 Overview of the operating elements 343
9 1 1 Exterior of the truck crane 344
9 1 2 Crane cab 346
Side panel 348
Crane cab, rear 350
9 1 3 Control panels 352
Left 352
Right 353
9 1 4 Control lever configuration 354
Version 1 354
Version 2 355
9 1 5 Heating system 357
9 1 6 Control unit CCS 358
9 1 7 CCS – Start menu 361
9 1 8 CCS – overview of menu groups 362
Superstructure menu group 366
Superstructure lock menu 367
Counterweight menu 368
Outrigger menu 369
Outrigger support beam menu 371
Outrigger cylinders menu 372
Teleautomation menu group 374
Telescoping full automation menu 375
Telescoping semi- automation menu 376
Main boom configuration menu 377
Active working range limiter menu group 378
Overall height menu 379
Working radius menu 380
Slewing angle menu 381
Information menu group 382
Hydraulic pressure and fuel consumption menu 383
Driving menu group 385
Driving mode menu 386
Telescoping menu group 388
Manual telescoping menu 389
Telescoping emergency program menu 390
Unknown telescoping menu 391
Settings menu group 392
Adjust wiper stroke interval menu 393
Menu for setting the display brightness and date/time 394
Switch units menu 395
Set control lever characteristic curve menu 396
Power unit speeds menu 397
Menu group Information 399
Operating hours menu 400
Engine/transmission error menu 402
Crane operation error menu 403
Program version menu 404
Operating additional equipment 405
9 1 9 Control unit RCL 406
9 1 10 RCL – menu groups 408
Enter rigging mode menu 411
Monitoring menu 412
Lifting capacity table menu 414
9 1 11 Hand-held control 415
Outrigger control panel 417
9 1 12 Outrigger control units 418
Button 418
Outrigger button 419
Inclination and outrigger pressure display 420
9 1 13 For emergency hydraulic operation 421
9 2 Short description of the operating elements 423
9 2 1 Definition of direction information 423
Basic rule 423
Switches 423
9 2 2 General rules for buttons and symbols on the display 424
9 2 3 Engine 425
Side panel 425
CCS display 425
9 2 4 DEF system 426
CCS display 426
9 2 5 Seat contact switch and dead man’s switch 427
9 2 6 Crane control CCS 428
9 2 7 Outrigger 434
Hand-held control 434
Right-hand control panel 435
Left-hand control panel 435
In the Outrigger menu 436
On the outrigger control units 438
9 2 8 Inclination indicators 440
9 2 9 Anemometer displays 441
9 2 10 Counterweight menu 442
9 2 11 Superstructure lock/houselock menu 444
Superstructure lock 444
Houselock 445
9 2 12 Main hoist 447
Control panels 447
CCS display 448
9 2 13 Auxiliary hoist 449
Control panels 449
CCS display 450
9 2 14 Slewing gear 451
Control panels 451
CCS display 452
9 2 15 Derricking gear 453
Control panels 453
CCS display 454
9 2 16 Telescoping mechanism 455
Control panels 455
CCS display 455
Telescoping full automation menu 456
Telescoping semi- automation menu 457
Manual telescoping menu 459
Main boom configuration menu 462
9 2 17 Hydraulic system 463
9 2 18 Rated capacity limiter (RCL) 464
Control unit control console RCL 464
Display RCL 465
Enter rigging mode menu 467
Monitoring menu 470
Lifting capacity tables menu 473
RCL override 474
External displays 475
9 2 19 Electrical system 476
9 2 20 Lighting, windscreen wiper/washing system 476
Lighting 476
Windscreen wiper/washing system 478
9 2 21 Hand-held control 479
Sockets on truck crane 479
Engine control panel 480
Horn 480
Outriggers control panel 481
9 2 22 Diagnostics 483
9 2 23 Windows, doors, keys 484
Windscreen 484
Rear window 484
Crane cab door 485
Keys 486
9 3 Short description of the operating elements – driving from the crane cab 487
9 3 1 Driving mode menu 487
9 3 2 Transmission 488
9 3 3 Final drive 489
9 3 4 Brakes 490
CCS display 490
Side panel from above 491
9 3 5 Steering 492
CCS display 492
Steering modes 493
Separate steering 493
Control panels 494
10 Starting/stopping the engine – for crane operation 497
10 1 When starting the engine for the first time of the day 497
10 2 Starting the engine – from the crane cab 499
10 2 1 Checking the fuel level and DEF level 499
Fuel 499
DEF 499
10 2 2 Checks before starting the engine 500
Checks on the carrier 500
Checking hand- held control 500
10 2 3 Switching on the ignition 500
10 2 4 Lamp test/equalisation of the switching states 501
Lamp test 501
Equalisation of the switching states 501
10 2 5 Display – setting the brightness 502
10 2 6 Starting the engine 503
Without flame start system 503
With flame start system 504
10 2 7 Checks after starting the engine 505
10 2 8 Setting idling speed 506
10 3 Starting the engine – with the hand-held control 507
10 4 Turning off the engine 509
10 4 1 On the ignition lock/with hand-held control 509
After starting from the crane cab 509
After starting up with the hand- held control 509
After turning off 509
10 4 2 Using the emergency stop switches 510
Resetting the emergency stop switch 510
11 Crane operation 513
11 1 Before operating the crane 513
11 1 1 CHECKLIST: Checks before operating the crane 513
11 1 2 Checking the condition of the truck crane 517
Auxiliary heater – tank 517
Visual inspection 518
Checking the position of the hoist ropes 518
Checking the electrical system 519
11 1 3 Adjusting the crane cab seat and front control panel 520
Crane cab seat 520
Front panel 520
11 1 4 Checking the safety equipment 521
Rated capacity limiter 521
Lifting limit switch 521
Emergency stop switch 522
Seat contact switch 523
11 1 5 Earthing the load 524
11 1 6 Preheating the hydraulic oil 525
11 1 7 Locking/unlocking the superstructure 527
Locking points 527
Locking the superstructure 528
Unlocking the superstructure 528
11 1 8 Switching the houselock on/off 529
Switching on the houselock 529
Switching off the houselock 531
11 2 Operation of the rated capacity limiter 533
11 2 1 Switch on the RCL 534
Switching on 534
Brightness of the displays 536
Temperature on the display 536
11 2 2 Enter rigging mode 537
Entering individual components 538
Entering the RCL code 542
Entering the reeving 543
Accepting the rigging mode 543
11 2 3 Checks before operating the crane 545
Open menu 545
Checks 545
11 2 4 Displays during crane operation 548
11 2 5 RCL pre-warning 551
11 2 6 RCL switch-off 551
Shutdown due to overload 551
11 2 7 Display in the event of errors 553
11 2 8 RCL override 554
Overview status display 554
When rigging 555
To raise the boom 556
In emergencies 557
11 2 9 Displaying the lifting capacity tables 558
11 2 10 Setting the time/date 560
11 3 Crane operation with main boom 561
11 3 1 Checks during crane operation 561
Horizontal alignment 561
Safe distances 561
Checking the wind speed 562
11 3 2 Permissible slewing ranges and working positions 563
360 slewing range 563
0 to the rear working position 563
180 to the front rigging position 564
Free-on-wheels working position 564
11 3 3 Main hoist 565
Switching on the main hoist 566
Lifting and lowering 566
Switching off the main hoist 567
11 3 4 Auxiliary hoist 568
Switching on the auxiliary hoist 568
Lifting and lowering 569
Switching off the auxiliary hoist 570
11 3 5 Lifting limit switch and lowering limit switch 571
Lifting limit switch 571
Lowering limit switch 573
11 3 6 Derricking gear 574
Switching on the derricking gear 574
Raising and lowering 575
Re-enable raising function 576
Switching off the derricking gear 576
Lowering the main boom to ahorizontal position 577
11 3 7 Telescoping mechanism 578
Overview 579
Telescoping process 579
Assignment for display 582
Fixed length, intermediate length, telescoping length 583
Telescoping 584
Telescoping sequence 584
Checks before starting work 585
Switching on the telescoping mechanism 586
Function of the control lever 586
Switching off the telescoping mechanism 588
Manual telescoping 589
Checking the initial position 589
Unlocking the telescoping cylinder 591
Extending/ retracting the telescoping cylinder 593
Lock telescoping cylinder 594
Unlocking the telescopic section 595
Telescoping the telescopic section 596
Locking the telescopic section 597
Locking the telescopic section for on-road driving 598
Telescoping with semi-automation 598
Telescoping with full automation 601
Telescoping the main boom when horizontal 602
Telescoping with main boom configuration 602
11 3 8 High-speed mode 603
Derricking gear/ telescoping mechanism 603
Hoists 604
11 3 9 Slewing gear 605
Switching on the slewing gear 605
Slew 605
Braking the slewing movement 607
Engaging the slewing gear brake 607
Releasing the slewing gear brake 607
Slewing gear freewheel 608
Switching off the slewing gear 608
11 3 10 Possible movement combinations 609
11 4 Settings and displays for crane operation 611
11 4 1 Inclining the crane cab 611
11 4 2 Setting idling speed 612
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 612
11 4 4 Limiting the power unit speeds 613
11 4 5 Switching units 614
11 4 6 Setting the characteristic curves for the control levers 615
11 4 7 Using the slewable spotlights 616
11 4 8 Override torque reduction 617
11 4 9 Displaying the operating hours 618
11 4 10 Warnings in the start menu 619
Meaning of the symbols 619
11 5 Working range limiter 623
11 5 1 Viewing current settings 624
11 5 2 Opening the working range limiter menu 624
11 5 3 Entering limit values 627
Overall height 627
Working radius 628
Slewing angle 628
11 5 4 Entering limit values manually 630
Limit values 630
11 5 5 Switching monitoring functions on/off 632
11 5 6 Shutdown by working range limiter 633
11 6 Work break 635
11 6 1 In case of short work breaks 635
11 6 2 In case of work breaks of more than 8 hours 636
To secure the truck crane 636
11 7 Heating and ventilating the crane cab 637
11 7 1 Heating system 637
Switching on 638
Temperature 638
Fan 639
Fresh air/ recirculated air 639
Air distribution 639
Setting the day and time 641
Storing the heating start 642
Setting the heating period 643
Switching the heating start on and off 643
Switching off 644
Setting the remaining time 644
11 7 2 Air-conditioning system 645
Switching on 645
Operation 645
Drying the air 646
Switching off 646
11 8 CraneSTAR system 647
11 8 1 Overview 647
11 8 2 Position of the components 647
12 Rigging work 651
12 1 Rigging work checklists for crane operation with the main boom 651
12 1 1 CHECKLIST: Rigging 651
12 1 2 CHECKLIST: Unrigging 656
12 2 Choosing a suitable site 659
12 2 1 Determining the required ground bearing area 659
12 2 2 Safe distance from slopes and pits 662
12 2 3 Earthing the truck crane 663
12 2 4 Safe distance from electrical cables 664
12 3 Connecting/disconnecting the hand-held control 667
12 4 Starting the engine for rigging 669
12 4 1 Starting/turning off the engine with the hand-held control 669
Prerequisites 669
Starting the engine 670
Turning off the engine 670
12 4 2 Starting/turning off the engine from the outrigger control units 671
Prerequisites 671
Starting the engine 671
Turning off the engine 671
12 5 Outrigger 673
12 5 1 CHECKLIST: Extending the outriggers 673
12 5 2 CHECKLIST: Retracting the outriggers 675
12 5 3 Permissible outrigger spans 676
12 5 4 Preparing the truck crane 677
In the driver’s cab 677
Outrigger control units 677
12 5 5 Setting the outrigger spans 678
12 5 6 Extending/retracting outrigger beams 680
From the control units 681
With the hand- held control 682
From the crane cab 684
12 5 7 Moving the outrigger pads into working/driving position 686
12 5 8 Enlarging the ground bearing area 687
12 5 9 Extending/retracting supporting cylinders 689
From the control units 690
With the hand- held control 691
From the crane cab 692
12 5 10 Level the truck crane on outriggers 694
Inclination indicators 694
Prerequisites 695
Manual alignment 696
Automatic alignment 697
12 5 11 Levelling the free-on-wheels truck crane 699
12 5 12 Outrigger pressure display 701
12 6 Rigging/unrigging the counterweight 703
12 6 1 Counterweight sections and identification 703
Counterweight sections 703
Identification 704
12 6 2 Slinging points at the counterweight sections 705
12 6 3 CHECKLIST: Rigging the counterweight 706
12 6 4 CHECKLIST: Unrigging the counterweight 709
12 6 5 Assembling counterweight combination 711
Combinations mounted on the turntable 712
Other combinations 715
12 6 6 Counterweight hoist unit 717
Counterweight menu 717
Extending/ retracting the lifting cylinders 718
Locking/unlocking counterweight 720
12 6 7 Setting down counterweight for driving the truck crane 721
12 6 8 Slewing with rigged counterweight 722
12 7 Rigging work on the main boom 723
12 7 1 Hook block on the bumper 723
Picking up the hook block 723
Attaching the hook block 724
12 7 2 Hook block on a separate vehicle 725
Picking up the hook block 726
Setting down the hook block 726
12 7 3 Reeving and unreeving the hoist rope 728
Rope end fitting 728
Fastening the rope end clamp 729
Reeving the hoist rope 731
Unreeving the hoist rope 734
12 7 4 Possible reeving methods on the main boom 735
With 5 head sheaves 735
With 6 head sheaves 737
12 7 5 Installing/removing the lifting limit switch 740
Installing the lifting limit switch 740
Removing the lifting limit switch 743
12 7 6 Locking/unlocking the lifting limit switch 745
Locking 745
Removing the lock 745
12 7 7 Anemometer and air traffic control light 746
Installing 746
Switching the air traffic control light on and off 747
Removing 747
12 8 Other rigging work 749
12 8 1 Folding mirrors in/out and adjusting 749
12 8 2 Cameras for crane operation 750
Cameras on the hoists 750
Camera on main boom 750
Operating the camera 752
12 8 3 Stair tread on the crane cab 753
13 Driving with rigged truck crane 757
13 1 Driving distance 757
13 2 Permissible rigging modes and axle loads 758
13 2 1 To drive without a load 758
13 2 2 To drive with a load 758
13 2 3 Axle loads 759
13 3 Before driving the rigged truck crane 761
13 3 1 Check the tyre pressure and the wind speed 761
13 3 2 Securing the superstructure against slewing 761
13 3 3 Putting the truck crane on the wheels 762
13 4 Driving from the driver’s cab 765
13 4 1 Preparing to drive 765
Transmission 765
Switching on separate steering 765
Connections 765
13 4 2 While driving 766
13 5 Driving from the crane cab 767
13 5 1 Preparing to drive 768
13 5 2 Opening/closing the Driving mode menu 769
Opening 769
Closing 770
13 5 3 Steering system 771
Switching on 771
Adjusting the steering direction 771
Displays when steering 772
Normal steering 772
Separate steering 773
13 5 4 Operating the transmission 775
Driving direction 775
Crane hydraulic system on/off 775
Selecting the transmission mode 776
13 5 5 While driving 777
DMand RM transmission mode 777
Transmission mode D 777
Warning messages 777
13 5 6 Possible connections 778
Longitudinal/ transverse differential locks 778
13 5 7 After driving 780
14 Malfunctions during crane operation 783
14 1 Emergency stop switch 783
14 2 What to do when a malfunction occurs during crane operation 785
Load can be lowered 785
Load cannot be lowered 785
14 3 Fuses in the crane cab 787
Notes on changing fuses 787
14 4 Finding and eliminating malfunctions 792
14 4 1 Malfunctions on the engine 792
14 4 2 Malfunctions when operating with the hand-held control 792
14 4 3 Malfunctions on the turntable lock 793
14 4 4 Malfunctions when inclining the crane cab 793
14 4 5 Malfunctions on the main hoist 794
14 4 6 Malfunctions in the telescoping mechanism 795
14 4 7 Malfunctions in the hoist cameras 796
14 4 8 Malfunctions in the main boom camera 796
14 4 9 Malfunctions on the derricking gear 797
14 4 10 Malfunctions on the slewing gear 798
14 4 11 Malfunctions on the counterweight hoist unit 799
14 4 12 Malfunctions in the hydraulic system/hydraulic oil cooler 800
14 4 13 Malfunctions when driving from the crane cab 800
14 4 14 Malfunctions of the outriggers 801
14 4 15 Troubleshooting the crane control 802
General malfunctions 802
Symbols in the error or information display areas 803
Displays in the Error menu 807
14 4 16 Malfunctions in the CraneSTAR system 809
14 5 Emergency operations and programmes 813
14 5 1 Mechanical emergency activation for retracting 814
Prior to the emergency operation, check 814
Procedure 814
Mechanical emergency activation 815
14 5 2 Telescoping emergency programme 817
Open submenu Emergency program 817
Determining the error type 818
Error on length indicator 819
Tables for approaching the locking points 823
14 5 3 Entering the current telescoping 825
14 5 4 Emergency operation with the hand-held control 827
Preparations 827
To pre-select a power unit 828
Operating a power unit 828
Stopping movements 829
Stopping movements in emergencies 830
Turning off the engine 830
14 6 Hydraulic emergency operation 831
14 6 1 Connect/disconnect hoses 831
14 6 2 Establishing the required hydraulic circuits 832
Switching over valves 832
For lifting/lowering 834
14 6 3 Performing emergency operation 835
14 6 4 After the emergency activation 835
14 7 Hydraulic emergency operation BGR 159 837
14 7 1 Operating principle 837
14 7 2 Connecting/disconnecting hoses 838
For transformers 838
For the hand pump 839
14 7 3 Establishing the hydraulic circuits required 840
Switching positions of the valves 840
Switching over valves 840
For lifting/lowering 842
For slewing 843
14 7 4 Performing emergency operation 843
Derricking 844
Lifting/lowering 845
Slew 845
14 7 5 After emergency operation 846
Switching off emergency operation 846
Switching over to crane operation 846
Disconnecting the hoses 846
14 7 6 Emergency supply of another crane 847
After emergency supply 848
15 Index 851
A 853
B 853
C 853
D 856
E 858
F 859
H 860
I 860
K 860
L 861
M 861
O 862
P 863
R 863
S 864
T 865
V 867
W 867
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V