Grove GMK4100-L Driving & Crane Operation Operating Manual 3113129 – PDF DOWNLOAD
FILE DETAILS:
Grove GMK4100-L Driving & Crane Operation Operating Manual 3113129 – PDF DOWNLOAD
Language : English
Pages : 914
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove GMK4100-L Driving & Crane Operation Operating Manual 3113129 – PDF DOWNLOAD
Correction sheets 3
Round outrigger pads made of synthetic material 3
1 Overview 9
1 1 Accidents 9
1 2 Branch offices 11
1 2 1 Manitowoc Crane Care 11
1 2 2 Dealer list 11
1 3 Warranty specifications 11
1 4 Terms used 12
1 5 Technical data 15
1 5 1 Maximum lifting capacity (ASME B 30 5) 15
1 5 2 Dimensions and weights of the truck crane, axle loads 16
Dimensions 17
Weight and axle loads 17
1 5 3 Dimensions and weights of removable parts 18
Spare wheel 18
Outriggers 18
Counterweight combinations 18
Counterweight parts 19
Hook blocks and hook tackle 19
1 5 4 Carrier 21
Engine 21
Transmission 22
Transfer case 22
Axle lines 22
Steering 22
Tyres 22
Outriggers 23
Electrical system 23
Tool 23
Towing couplings 23
Driving speeds 24
Climbing ability 24
Turning radii 24
1 5 5 Superstructure 25
Engine 25
Main hoist 25
Auxiliary hoist 26
Slewing gear 26
Derricking gear 26
Main boom 27
Lattice extension 27
Operating speeds 27
1 6 Documentation supplied 29
1 6 1 Questions on documentation 30
1 7 Notes on the operating instructions 31
1 7 1 What do the symbols used mean? 31
1 7 2 How are the operating instructions structured? 33
Division 33
Structure of the chapters 33
Structure of the pages 34
1 7 3 How do I find the information I need? 35
Cross-references example 36
1 7 4 What information is available for operations planning? 38
1 8 Conversion table for US measuring units 39
1 9 Training – Information 41
1 10 Identification 42
1 11 EC Declaration of Conformity 44
2 Basic safety instructions 47
2 1 Intended use 47
2 1 1 Improper use 48
2 2 Organisational measures 49
2 3 Personnel qualifications 51
2 4 Safety instructions for driving the truck crane 52
2 5 Safety instructions for crane operation 53
2 6 Notes on transporting persons 55
Equipment for lifting persons 55
Personnel 55
Operation 56
Truck crane 57
3 Operating elements for driving 61
3 1 Overview of the operating elements 61
3 1 1 On the outside of the truck crane 62
3 1 2 Driver’s cab 64
Overview 64
Behind the cover 66
3 1 3 Instrument panel 67
Left/right 67
Middle 68
3 1 4 On-board computer 70
Display, driving mode 70
On-board computer time correction 71
3 1 5 Steering column/steering wheel 72
3 1 6 Transmission operating elements 73
3 1 7 Tachograph 75
3 1 8 ECOS control unit 76
3 1 9 ECOS display – main menu 78
3 1 10 ECOS display – submenus 80
Level adjustment system submenu 80
Settings submenu 81
Operating hours submenu 82
Warning submenu 83
Transmission emergency program submenu 84
Error submenu 85
3 1 11 Heating/Air-conditioning system 86
Standard heating system 86
Auxiliary air heater 87
Auxiliary water heater 89
3 1 12 Sockets for hand-held control 90
3 1 13 Outrigger control units 91
3 2 Short description of the operating elements 93
3 2 1 Definition of direction information 93
Basic rule 93
Switches and buttons 94
3 2 2 General rules for buttons and symbols on the display 94
3 2 3 Engine 95
Steering column 95
Multipurpose switch 95
Instrument panel 97
Main menu 97
3 2 4 DEF system 98
Instrument panel 98
3 2 5 Electrical system 99
3 2 6 ECOS crane control 100
Control unit 100
3 2 7 Transmission 103
Transmission display 103
ECOS display 103
Operating elements 104
Instrument panel 105
3 2 8 Transfer case 106
Main menu 106
3 2 9 Final drive 107
3 2 10 Reverse camera 108
3 2 11 Brakes 109
Service brake 109
Parking brake 110
Additional brakes 111
3 2 12 Steering/separate steering 112
ECOS display 112
Driver’s door 113
3 2 13 Suspension 113
3 2 14 Lighting/windscreen wipers/horn 114
Steering column 114
Instrument panel 114
Roof 116
3 2 15 Level adjustment system 116
3 2 16 Tachograph/speedometer 118
Tachograph 118
Speedometer 118
3 2 17 Diagnostics 119
Displays/ submenu 119
3 2 18 On-board computer 120
3 2 19 Push-up roof 122
3 2 20 Windows, doors, keys 122
Window winder 122
Doors 123
Keys 123
3 2 21 Front flap 124
3 2 22 Storage compartment 124
3 2 23 Hand-held control bracket 125
4 Starting/turning off the engine for driving 129
4 1 Starting the engine from the driver’s cab 129
4 1 1 CHECKLIST: Starting the engine 129
4 1 2 CHECKLIST: At low temperatures 132
4 1 3 Ladders and access ladders 133
Ladders 133
Access ladders 134
4 1 4 Refuel 135
Fuel tank 135
DEF tank 136
4 1 5 Checks before starting the engine 137
On hydraulic tank 137
Battery master switch 137
Checking hand- held control 138
4 1 6 Switching on the ignition 138
4 1 7 Lamp test/equalisation of the switching states 139
Lamp test 139
Equalisation of the switching states 140
4 1 8 Display – setting the brightness 141
4 1 9 Starting the engine 142
Without flame start system 143
With flame start system 144
4 1 10 Checks after starting the engine 145
4 1 11 Monitoring elements 146
Instrument panel 146
ECOS display 147
Display driving mode 147
4 1 12 Setting idling speed 148
4 2 Turning off the engine 149
4 2 1 On the ignition lock/with hand-held control 149
After turning off 149
4 2 2 Using the emergency stop switches 150
Resetting the emergency stop switch 150
4 3 Air intake inhibitor 151
Releasing the air intake inhibitor 151
5 Driving 155
5 1 Before driving 155
5 1 1 CHECKLIST: Checks before on-road driving 155
5 1 2 Checking the condition of the truck crane 161
Electrical system 161
Adjusting the mirrors 161
Adjusting the reverse camera 162
Warning plates for vehicle width 163
Displaying vehicle height 163
Supply pressure 164
Parking brake 165
5 1 3 Adjusting the seat and the steering column 166
Driver’s seat 166
Passenger’s seat 167
Adjusting the steering column 167
5 1 4 Switching the suspension on/off 168
Opening the submenu 168
Switching on the suspension 169
Switching off the suspension 169
5 1 5 Setting the tachograph 170
Prerequisites 170
In the event of malfunctions 170
Setting the tachograph 171
Additional displays 174
5 1 6 Displaying the operating hours 175
5 1 7 Settings/displays with the on-board computer 176
Operation 176
Overview 177
Monitoring information 177
Error information 178
Alarm clock 179
Language 179
Settings 180
Diagnostics 180
5 2 Operating the transmission 183
5 2 1 Switching on 183
5 2 2 Switching the transmission to neutral position 184
5 2 3 Changing the operating mode 184
Change to automatic mode 184
Change to manual mode 185
5 2 4 Display of the selected gears 185
5 2 5 Selecting the direction of travel and starting gear 187
Selecting the driving direction 187
Selecting the starting gear 188
5 2 6 Starting 189
5 2 7 Driving and changing gears 190
In automatic operating mode 190
In manual operating mode 191
5 2 8 Changing the driving direction 192
Quick change of gear 192
5 2 9 Stopping 193
Stopping for a long period of time 193
5 2 10 On the roller type dynamometer 193
5 3 Driving and turning off the truck crane 195
5 3 1 Checks while driving 195
Immediately after you start to move 195
While driving 196
5 3 2 Tempomat 198
Switching on 198
Switching off 199
5 3 3 Temposet 199
Switching on 199
Switching off 200
5 3 4 Driving downhill 201
Starting 201
Inspections when driving downhill 201
Downshifting 202
Additional brakes 203
5 3 5 Driving uphill 204
Starting 204
Driving 204
5 3 6 Warning submenu 204
Meaning of the symbols 205
Exiting the submenu 206
5 3 7 Notes on torque reduction 207
5 3 8 Error submenu 208
5 3 9 Messages on the on-board computer display 208
Information 209
Warning messages 210
Error messages 211
Information 213
5 3 10 Turning off the truck crane 217
Securing against rolling away 217
When stationary for more than 8hours 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 Transfer case – switching the off-road gear on/off 220
Neutral position 220
5 4 2 Longitudinal and transverse differential locks 221
5 4 3 Operating the level adjustment system 223
Opening the submenu 223
Setting the on-road level 223
Pre-selecting suspension struts 224
Changing the vehicle level 225
Viewing the current inclination 225
Exiting the submenu 226
5 4 4 Freeing truck crane stuck in terrain 227
Rocking the truck crane free 227
Towing free forwards 228
Towing free in reverse gear 228
5 4 5 Separate steering 229
Switching to separate steering 229
Steering 230
Switching to normal steering mode 231
5 5 Heating and air-conditioning system 233
5 5 1 Standard heating system 233
Switching on 233
Heating 233
Air distribution 234
Examples 235
Switching off 235
5 5 2 Air-conditioning system 236
Information 236
Switching on/off 236
Cooling 237
Drying 237
5 5 3 Auxiliary air heater – Version A 238
Switching on 238
Temperature 239
Setting the day and time 239
Storing the heating start 240
Setting the heating period 241
Switching the heating start on and off 242
Switching off 242
Setting the remaining time 243
5 5 4 Auxiliary air heater – Version B 245
Switching on 245
Setting the heating level 246
Setting the day and time 247
Setting the preselection time 247
Deleting preselection times 249
Switching off 249
5 5 5 Auxiliary water heater 250
Preheating the engine 250
Preheating the driver’s cab 251
Switching on 251
Setting the day and time 252
Storing the heating start 253
Switching heating start on/off 254
Switching off 255
Additional functions 255
5 6 Towing a trailer 257
Effects on the axle loads 257
Coupling the trailer 258
Connecting the supply lines 259
Removing the supply lines 260
Uncoupling the trailer 260
Checking the braking force 262
6 Driving modes 265
6 1 Driving modes 265
Information about the axle loads 265
6 1 1 Information on how to use the tables 266
6 1 2 Table for a maximum axle load of 12 t (26,500 lbs) 267
For 14 00 R25 tyres 267
For 16 00 R25 tyres 268
6 1 3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) 269
6 2 Rigging work for driving with a trailer 271
6 2 1 Switching on the slewing gear freewheel 272
6 2 2 Switching on boom floating position 273
6 2 3 Switching on boom pre-tensioning 274
6 2 4 Switching the superstructure driving lights on/off 276
Switching off 276
Switching on 276
7 Malfunctions in driving mode 279
7 1 Emergency stop switch 279
7 2 What to do when a malfunction occurs in road traffic 281
7 3 Towing the truck crane 283
7 3 1 Towing after engine/transmission damage 284
Compressed-air supply 284
Electric power supply 284
On the transmission 285
Axle drives 286
Transfer case 286
Parking brake 286
Towing the truck crane out of the danger area 287
7 3 2 Tow starting 288
7 4 Wheels and tyres 289
7 4 1 Wheel change 289
Removing a damaged wheel 289
On the spare wheel holder 290
Mounting a wheel 291
7 4 2 Inflating the tyres yourself 293
Connecting the filling hose 293
Inflating the tyres 294
Removing the filling hose 294
7 5 Fuses on the carrier 295
Notes on changing fuses 295
7 5 1 Fuses in the driver’s cab 296
F1 to F 41 296
A1 to A3 298
7 5 2 Fuses in the battery box 300
7 6 Troubleshooting 301
7 6 1 Malfunctions on the engine 301
7 6 2 Malfunctions on the DEF system 303
7 6 3 Malfunctions in the transmission 304
7 6 4 Malfunctions of the service brake 305
7 6 5 Malfunctions of the steering 306
7 6 6 Malfunctions of transfer case 306
7 6 7 Malfunctions in the differential locks 307
7 6 8 Malfunctions in the hydraulic system/hydraulic oil cooler 307
7 6 9 Malfunctions on the suspension 308
7 6 10 Malfunctions of the level adjustment system 308
7 6 11 Malfunctions of the reverse camera 308
7 6 12 Malfunctions on the ECOS carrier 309
ECOS programme version 309
General malfunctions 309
Error messages 310
Exiting the submenu 311
On the control units 312
7 7 Procedure in the event of malfunctions 313
7 7 1 Switching on emergency operation in coolant circuit 313
7 7 2 Procedure in the event of malfunctions to the transmission and engine 314
Engine 314
Transmission 315
Transmission emergency program submenu 316
Emergency gear shift 319
Compressed air emergency switching 320
Switching gears mechanically in emergency mode 322
ID number of the transmission 325
7 8 Emergency operation 327
7 8 1 External starting socket 327
Performing a jump start 328
7 8 2 Battery charger 328
8 Index 331
A 333
B 333
C 333
D 335
E 337
F 339
H 340
I 341
K 341
L 341
M 342
O 343
P 344
R 344
S 345
T 346
V 348
W 348
Correction sheets 353
Round outrigger pads made of synthetic material 353
9 Operating elements for crane operation 359
9 1 Overview of the operating elements 359
9 1 1 Exterior of the truck crane 360
9 1 2 Crane cab 364
9 1 3 Front panel 366
9 1 4 Side panel 367
Bottom 367
Top 368
Console, rear 370
Standard heating system 371
Auxiliary water heater 372
Auxiliary air heater 373
9 1 5 Control panels 374
Left 374
Right 375
9 1 6 Control lever configuration 376
Version 1 376
Version 2 377
9 1 7 ECOS control unit 378
9 1 8 ECOS display – main menu 380
9 1 9 ECOS display – submenus 382
Counterweight submenu 382
Slewing gear/ Houselock submenu 383
Outriggers submenu 384
Telescoping submenu 386
Power unit speeds submenu 387
Monitoring submenu 388
Settings submenu 389
Operating hours submenu 390
Error submenu 391
Warning submenu 392
Working range limiter submenu 394
Enter slewing angle submenu 395
Enter objects submenu 396
Driving submenu 397
9 1 10 RCL control unit 398
9 1 11 Hand-held control 402
Outriggers control panel 403
9 1 12 Outrigger control units 404
Outrigger 405
Outrigger pressure display 405
Inclination indicator 405
9 2 Short description of the operating elements 407
9 2 1 Definition of direction information 407
Basic rule 407
Switches 407
9 2 2 General rules for buttons and symbols on the display 408
9 2 3 Engine for crane operation 409
Side panel 409
Console, rear 410
ECOS display 410
9 2 4 DEF system 411
Instrument panel 411
ECOS display 411
9 2 5 Engine for driving 413
Side panel 413
Main menu 413
Outriggers submenu 414
9 2 6 Seat contact switch and dead man’s switch 415
9 2 7 ECOS crane control 417
Control unit 417
9 2 8 Outrigger 420
Hand-held control 420
In the Outrigger submenu 421
In the Settings submenu 422
On the outrigger control units 423
9 2 9 Inclination indicators 425
9 2 10 Outrigger pressure displays 426
Outriggers submenu 426
Outrigger control units 426
9 2 11 Anemometer display 426
9 2 12 Counterweight submenu 427
Counterweight submenu 427
9 2 13 Main hoist 430
9 2 14 Auxiliary hoist 432
9 2 15 Slewing gear 433
Submenu 434
9 2 16 Derricking gear 437
9 2 17 Telescoping mechanism 438
Control panels 438
Submenu 439
In the Settings submenu 443
9 2 18 Hydraulic system 445
9 2 19 Houselock 446
9 2 20 Rated capacity limiter (RCL) 447
Input elements with displays 447
Display elements 450
RCL override 453
External displays 454
9 2 21 Electrical system 455
9 2 22 Lighting, windscreen wiper/washing system 455
Lighting 455
Windscreen wiper/washing system 457
9 2 23 Hand-held control 458
Sockets for hand- held control 458
Engine control panel 459
Horn 459
Outrigger control panel 460
9 2 24 Diagnostics 462
9 2 25 Windows, doors, keys 462
Windscreen 462
Rear window 463
Crane cab door 463
Keys 464
9 3 Short description of the operating elements – driving from the crane cab 465
9 3 1 Driving submenu 465
9 3 2 Engine for driving 466
9 3 3 Transmission 467
9 3 4 Final drive 468
9 3 5 Brakes 469
Side panel 469
ECOS display 469
9 3 6 Steering 470
Normal steering 471
Separate steering 471
10 Starting/turning off the engine – for crane operation 475
10 1 Starting the engine – from the crane cab 475
10 1 1 CHECKLIST: Starting the engine 475
10 1 2 CHECKLIST: At low temperatures 478
10 1 3 Refuel 479
Fuel tank 479
DEF tank 481
Tank – auxiliary heater 482
10 1 4 Checks before starting the engine 483
On hydraulic tank 483
Battery master switch 483
Checking the hand-held control 484
10 1 5 Switching on the ignition 484
10 1 6 Lamp test/switching state equalisation 485
Lamp test 485
Equalisation of the switching states 486
10 1 7 Adjusting display brightness 487
10 1 8 Starting the engine 488
Without flame start system 488
With flame start system 489
10 1 9 Checks after starting the engine 490
10 1 10 Monitoring submenu 491
10 1 11 Setting idling speed 492
10 2 Starting the engine – with the hand-held control 493
Prerequisites 493
Starting the engine 493
10 3 Turning off the engine 495
10 3 1 During normal operation, with the ignition lock/with the handheld control 495
After turning off 495
10 3 2 In emergencies, with the emergency stop switches 496
Resetting the emergency stop switch 496
10 4 Air intake inhibitor 497
Releasing the air intake inhibitor 497
11 Crane operation 501
11 1 Before operating the crane 501
11 1 1 CHECKLIST: Checks before operating the crane 501
11 1 2 Checking the condition of the truck crane 505
Visual inspection 505
Checking the position of the hoist ropes 505
Checking the electrical system 506
11 1 3 Adjusting the crane cab seat and front control panel 507
Crane cab seat 507
Front panel 508
11 1 4 Checking the safety equipment 509
Rated capacity limiter 509
Lifting limit switch 509
Emergency stop switch 510
Seat contact switch 511
11 1 5 Earthing the load 512
11 1 6 Preheating the hydraulic oil 513
11 1 7 Switching the Houselock on/off 514
Switching on the Houselock 514
Switching off the Houselock 516
11 2 Operation of the rated capacity limiter 517
11 2 1 Switching on the RCL 518
Switching on 518
Lamp test on the RCL 520
Brightness of the displays 520
11 2 2 Enter rigging mode 521
Entering the RCL code 522
Entering the reeving 525
Entering individual components 526
11 2 3 Checks before operating the crane 530
11 2 4 Displays during crane operation 532
Continuous displays 532
Optional displays 534
11 2 5 RCL early warning 536
11 2 6 RCL shutdown 536
Shutdown due to overload 536
11 2 7 Error message 538
11 2 8 RCL override – version A 539
11 2 9 RCL override – version B 540
Overview status display 540
When rigging 541
To raise the boom 542
In emergencies 543
11 2 10 Displaying and entering the time and date 544
Display 544
11 3 Crane operation with main boom 547
11 3 1 Checks during crane operation 547
Horizontal alignment 547
Safe distances 547
Checking the wind speed 548
11 3 2 Permissible slewing ranges and working positions 549
360 slewing range 549
0 to the rear working position 549
180 to the front rigging position 550
Free-on-wheels working position 550
11 3 3 Main hoist 551
Switching on the main hoist 552
Lifting and lowering 552
Switching off the main hoist 553
11 3 4 Auxiliary hoist 555
Switching on the auxiliary hoist 556
Lifting and lowering 556
Switching off the auxiliary hoist 557
11 3 5 Lifting limit switch, lowering limit switch, height contact switch 559
Lifting limit switch 559
Lowering limit switch 561
11 3 6 Derricking gear 561
Switching on the derricking gear 562
Raising and lowering 562
Re-enable raising function 563
Switching off the derricking gear 564
Lowering the main boom to a horizontal position 564
11 3 7 Telescoping mechanism 565
Overview 566
Telescoping process 566
Assignment for display 568
Fixed length, intermediate length, telescoping length 570
Telescoping 571
Telescoping sequence 571
Checks before starting work 572
Switching on the telescoping mechanism 572
Function of the control lever 573
Switching off the telescoping mechanism 575
Manual telescoping 575
Checking the initial position 576
Unlocking the telescoping cylinder 578
Extending/ retracting the telescoping cylinder 580
Lock telescoping cylinder 581
Unlocking the telescopic section 582
Telescoping the telescopic section 584
Locking the telescopic section 585
Locking the telescopic section for on-road driving 586
Telescoping with teleautomation 587
Telescoping the main boom when horizontal 591
11 3 8 High-speed mode 592
Switch on function 592
Derricking gear/ telescoping mechanism 592
Hoist 593
11 3 9 Slewing gear 594
Slewing gear brake 594
Switching on the slewing gear 595
Releasing the slewing gear brake 595
Engaging the slewing gear brake 595
Slew 596
Braking the slewing movement 598
Slewing gear freewheel 598
Switching off the slewing gear 599
11 3 10 Possible movement combinations 600
11 3 11 Hydraulic oil cooling 600
11 4 Settings and displays for crane operation 601
11 4 1 Inclining the crane cab 601
11 4 2 Setting idling speed 602
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 602
11 4 4 Limiting the power unit speeds 603
11 4 5 Setting the characteristic curves for the control levers 604
11 4 6 Critical load control 605
Function 605
Switching on and off 605
11 4 7 Using the slewable spotlights 606
11 4 8 Displaying the operating hours 607
11 4 9 Warning submenu 608
Meaning of the symbols 608
Exiting the submenu 611
11 4 10 Notes on torque reduction 612
11 4 11 Error submenu 613
11 5 Working range limiter 615
11 5 1 Opening the working range limiter submenu 616
11 5 2 Viewing current settings 617
11 5 3 Entering limit values 619
Overall height/ working radius 619
Slewing angle 620
Entering objects 622
11 5 4 Entering limit values/objects manually 625
Limit values 625
Objects 626
11 5 5 Switching monitoring functions on/off 627
11 5 6 Shutdown by working range limiter 628
11 6 Work break 629
11 6 1 In case of short work breaks 629
11 6 2 In case of work breaks of more than 8 hours 630
To secure the truck crane 630
11 7 Heating and air-conditioning system 631
11 7 1 Standard heating system 631
Switching on 631
Heating 631
Air distribution 632
Switching off 633
11 7 2 Air-conditioning system 635
Information 635
Switching on/off 636
Cooling 636
Drying the air 637
11 7 3 Auxiliary water heater 637
Preheating the engine 638
Preheating the crane cab 638
Switching on 639
Setting the day and time 640
Storing the heating start 641
Setting the heating period 642
Switching heating start on/off 643
Switching off 643
Setting the remaining time 644
11 7 4 Auxiliary air heater 645
Switching on 645
Temperature 646
Switching off 646
Other functions 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 657
12 2 Choosing a suitable site 661
12 2 1 Determining the required ground bearing area 661
12 2 2 Safe distance from slopes and pits 664
12 2 3 Earthing the truck crane 665
12 2 4 Safe distance from electrical cables 666
12 3 Rigging work after driving with a trailer 669
12 3 1 Switching off the boom floating position 669
12 3 2 Switching off the slewing gear freewheel 670
Before slewing 670
12 3 3 Switching off boom pre-tensioning 671
12 4 Connecting/disconnecting the hand-held control 673
12 5 Starting the engine for driving for rigging work 675
12 5 1 Starting/turning off the engine with the hand-held control 675
Prerequisites 675
Starting the engine 676
Turning off the engine 676
12 5 2 Starting/turning off the engine from the crane cab 677
Prerequisites 677
Starting the engine 677
After starting the engine 678
Turning off the engine 678
12 6 Outrigger 679
12 6 1 CHECKLIST: Extending the outriggers 679
12 6 2 CHECKLIST: Retracting the outriggers 681
12 6 3 Permissible outrigger spans 682
12 6 4 Preparing the truck crane 683
In the driver’s cab 683
Outrigger control units 683
12 6 5 Setting the outrigger spans 684
For on-road driving 685
12 6 6 Extending/retracting outrigger beams 686
From the control units 686
With the hand- held control 687
From the crane cab 689
12 6 7 Moving the outrigger pads into working/driving position 691
12 6 8 Enlarging the ground bearing area 692
12 6 9 Extending/retracting supporting cylinders 693
From the control units 694
With the hand- held control 695
From the crane cab 696
12 6 10 Level the truck crane on outriggers 698
Inclination indicators 698
Prerequisites 699
Manual alignment 700
Automatic alignment 701
12 6 11 Levelling the free-on-wheels truck crane 703
12 6 12 Outrigger pressure display 705
12 7 Rigging/unrigging the counterweight 707
12 7 1 Counterweight sections 707
Version A 707
Version B 708
Version C 708
12 7 2 Identification 709
12 7 3 Slinging points on the counterweight sections 710
12 7 4 CHECKLIST: Rigging the counterweight 711
12 7 5 CHECKLIST: Unrigging the counterweight 712
12 7 6 Assembling counterweight versions – on the turntable 714
12 7 7 Assembling counterweight versions – on the counterweight platform 715
Setting down the 2 2t base plate 715
Version 716
Notes on the different versions 717
With version A 720
With version B 722
With version C 724
12 7 8 Counterweight hoist unit 728
Counterweight submenu 728
Extending/ retracting the lifting cylinders 729
Automatic mode rigging 730
Automatic mode unrigging 731
Cancel automatic mode 733
12 7 9 Removing/installing the counterweight on the turntable 734
Installing 735
Removing 736
12 7 10 Setting down counterweight for driving the truck crane 737
12 7 11 Slewing with rigged counterweight 740
12 8 Rigging work on the main boom 743
12 8 1 Hook block on the bumper 743
Picking up the hook block 743
Attaching the hook block 744
12 8 2 Hook block on a separate vehicle 745
Picking up the hook block 746
Setting down the hook block 746
12 8 3 Reeving and unreeving the hoist rope 748
Pocket lock 748
Fork 749
Rope end clamp 750
Reeving the hoist rope 751
Unreeving the hoist rope 755
12 8 4 Possible reeving methods on the main boom 757
With 7 head sheaves 757
With 8 head sheaves 760
12 8 5 Installing/removing the lifting limit switch 763
Installing the lifting limit switch 763
Removing the lifting limit switch 766
12 8 6 Locking/unlocking the lifting limit switch 767
Locking 767
Releasing locking 768
12 8 7 Anemometer and air traffic control light 769
Installing 769
Removing 770
12 9 Other rigging work 771
12 9 1 Rigging in free on wheels working position 771
12 9 2 Railings on the turntable 775
12 9 3 Mirror for crane operation 776
12 9 4 Cameras for crane operation 777
Cameras on the hoists 777
Camera on main boom 777
Turning the monitor on/off and switching 780
13 Driving with rigged truck crane 783
13 1 Safety instructions 783
13 2 Driving distance 785
13 3 Before driving the rigged truck crane 785
13 3 1 Check the tyre pressure and the wind speed 785
13 4 Permissible rigging modes and axle loads 787
13 4 1 Axle loads 787
13 4 2 To drive without a load 787
13 4 3 To drive with a load 788
13 5 Driving from the driver’s cab 789
13 5 1 Preparing to drive 789
Transmission 789
Switching on separate steering 789
Connections 789
13 5 2 While driving 790
13 6 Driving from the crane cab 791
13 6 1 Preparing to drive 791
13 6 2 Opening/closing the Driving mode submenu 792
Automatic 792
Manual 794
Closing 794
13 6 3 Starting/turning off the engine for driving 795
Start the engine 795
Turning off the engine 796
13 6 4 Steering system 796
Switching on 796
Adjusting the steering direction 796
Displays when steering 797
Normal steering 797
Separate steering 798
13 6 5 Operating the transmission 799
Driving direction 800
Selecting the transmission mode 800
13 6 6 Camera system for driving from the crane cab 801
13 6 7 Starting 802
13 6 8 While driving 802
13 6 9 Warning messages 803
13 6 10 Possible connections 804
Longitudinal/ transverse differential locks 805
13 6 11 After driving 806
13 7 Driving in combined operation 807
13 7 1 Switching combined operation on/off 807
Prerequisites 807
Switching on 808
Switching off 808
13 7 2 Starting/turning off the engine 809
13 7 3 Preparing to drive 810
Transmission 810
Switching on separate steering 810
Connections 810
13 7 4 While driving 811
Without load 811
With load 812
14 Malfunctions during crane operation 815
14 1 Emergency stop switch 815
14 2 What to do when malfunctions occur during crane operation 817
Load can be lowered 817
Load cannot be lowered 817
14 3 Fuses on the superstructure 819
Notes on changing fuses 819
14 3 1 Fuses on the turntable 820
Fuse groups F1/F2 820
Fuses on the circuit board 821
14 3 2 Fuses in the crane cab 822
14 3 3 Fuses in the battery box 824
14 3 4 RCL fuses 825
14 4 Finding and eliminating malfunctions 827
14 4 1 Malfunctions on the engine for crane operation 827
14 4 2 Malfunctions on the DEF system 829
14 4 3 Malfunctions on the main hoist/auxiliary hoist 830
14 4 4 Malfunctions in the hoist cameras 831
14 4 5 Malfunctions in the main boom camera 831
14 4 6 Malfunctions on the derricking gear 832
14 4 7 Malfunctions in the telescoping mechanism 833
Telescoping mechanism error messages 835
14 4 8 Malfunctions on the slewing gear 836
14 4 9 Malfunctions on the counterweight hoist unit 837
14 4 10 Malfunctions in the hydraulic system/hydraulic oil cooler 838
14 4 11 Malfunctions when inclining the crane cab 838
14 4 12 Malfunctions when operating with the hand-held control 838
14 4 13 Malfunctions when driving from the crane cab 839
14 4 14 Malfunctions of the outriggers 840
14 4 15 Troubleshooting the RCL 841
General malfunctions 841
Error messages 842
Table of error codes 844
Switching off the sensor/tachogenerator 847
14 4 16 Malfunctions ECOS – superstructure 848
ECOS programme version 848
General malfunctions 848
Error messages 849
Exiting the submenu 850
14 4 17 Malfunctions on CraneSTAR system 851
14 5 Emergency operations and programmes 855
14 5 1 Mechanical emergency activation for retracting 856
Prior to the emergency activation, check 856
Procedure 856
Mechanical emergency activation 857
14 5 2 Telescoping emergency programme 859
Start the emergency program 859
Determining the error type 860
Error on length indicator 861
If there is an error at a proximity switch 864
Terminating the emergency program 866
Tables for approaching the locking points 867
14 5 3 Entering the current telescoping 869
14 5 4 Emergency operation with the hand-held control 871
Preparations 871
Operating a power unit 872
Stopping movements 874
Stopping movements in emergencies 874
Turning off the engine 874
14 5 5 Switching on emergency operation in coolant circuit 875
14 6 Hydraulic emergency operation 877
14 6 1 Operating principle 877
14 6 2 Connecting/disconnecting hoses 879
Establishing connections 879
Disconnecting 880
14 6 3 Switching emergency operation on/off 881
14 6 4 Establishing the hydraulic circuits required 882
Switching over valves 882
For lifting/ lowering 884
For slewing 885
14 6 5 Performing emergency operation 886
Slew 886
Derricking 887
Lifting/lowering 887
14 6 6 After emergency operation 888
Switching off emergency operation 888
Switching over to crane operation 888
Disconnecting the hoses 888
14 6 7 Emergency supply of another crane 889
For emergency supply 889
After emergency supply 889
14 7 Other emergency operations 891
14 7 1 External starting socket 891
Performing a jump start 892
14 7 2 Battery charger 892
15 Index 895
A 897
B 897
C 897
D 899
E 901
F 903
H 904
I 905
K 905
L 905
M 906
O 907
P 908
R 908
S 909
T 910
V 912
W 912
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