Grove Crane GMK 3060 Operating Instruction Manual 3302622 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 3060 Operating Instruction Manual 3302622 – PDF DOWNLOAD
Language : English
Pages : 900
Downloadable : Yes
File Type : PDF
Size: 25.1 MB
DESCRIPTION:
Grove Crane GMK 3060 Operating Instruction Manual 3302622 – PDF DOWNLOAD
Basic safety instructions:
Intended Use:
- Modification of the truck crane is only allowed with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK3060 truck crane may 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 rectified immediately.
- The GMK3060 truck crane may only be operated without the corresponding special equipment within the permitted temperature range (refer to Technical Data, p. 1-7).
- The GMK3060 truck crane is designed exclusively for lifting loads within the permitted GMK3060 lifting capacities. The load must be slung to a vertically positioned hook block as prescribed before lifting.
Intended use also includes:
- Observing the entire crane documentation, including the operating manual(s), lifting capacity table, outrigger pressure table, and safety manual.
- Adhering to the inspection and maintenance requirements specified in the maintenance manual.
- The GMK3060 may only be operated with approved equipment parts that are approved by Manitowoc Crane Group Germany GmbH and labeled with the serial number of the GMK3060.
- The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK3060 truck crane. The user assumes full responsibility for any such use.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 3060 Operating Instruction Manual 3302622 – PDF DOWNLOAD
Additional pages 3
Reduction of slewing speed – can be switched on and off 3
Important notes 3
Operation 4
Additional and modified operating elements 4
Switching reduction off and on 5
CCS display 7
Menu changes 7
Start menus 7
Displays for the counterweight 8
Outrigger spans 11
Telescoping emergency programme 13
Return run of the telescoping cylinder 13
1 Overview 47
1 1 Accidents 47
1 2 Branch offices 49
1 2 1 Manitowoc Crane Care 49
1 2 2 Dealer list 49
1 3 Warranty specifications 49
1 4 Terms used 50
1 5 Technical data 53
1 5 1 Maximum lifting capacity (DIN/ISO/EN) 53
1 5 2 Dimensions and weights of the truck crane, axle loads 54
Dimensions 55
Weight and axle loads 55
1 5 3 Dimensions and weights of removable parts 56
Spare wheel 56
Outriggers 56
Counterweight sections 56
Hook blocks and hook tackle 57
1 5 4 Carrier 59
Engine, 59
Transmission 59
Transfer case 59
Axle lines 59
Steering 60
Tyres 60
Electrical system 60
Tool 60
Towing coupling 60
Driving speeds 60
Climbing ability 61
Outriggers 61
Turning radii 62
1 5 5 Superstructure 62
Main hoist 62
Auxiliary hoist 63
Slewing gear 63
Derricking gear 63
Main boom 63
Lattice extension 63
Operating speeds 64
1 6 Documentation supplied 65
1 6 1 Questions on documentation 66
1 7 Notes on the operating manual 67
1 7 1 What do the symbols used mean? 67
1 7 2 How is the operating manual structured? 69
Division 69
Structure of thechapters 69
Structure of thepages 70
1 7 3 How do I find the information I need? 71
Cross-references example 72
1 7 4 What information is available for operations planning? 74
1 8 Conversion table for US measuring units 75
1 9 Training – Information 77
1 10 Identification 78
1 11 EC Declaration of Conformity 80
2 Basic safety instructions 81
2 1 Intended use 81
2 1 1 Improper use 82
2 2 Organisational measures 83
2 3 Personnel qualifications 85
2 4 Safety instructions for driving the truck crane 87
2 5 Safety instructions for crane operation 89
2 6 Instructions on transporting persons 93
Equipment for lifting persons 93
Personnel 94
Operation 94
Truck crane 95
3 Operating elements for driving 97
3 1 Overview of the operating elements 97
3 1 1 On the outside of the truck crane 98
3 1 2 Driver’s cab 100
Overview 100
Behind the cover 102
Page 103
Doors 104
Front 105
3 1 3 Instrument panel 106
Middle 106
Left/right 110
3 1 4 Transmission operating elements 111
3 1 5 Driving mode display 112
3 1 6 Steering column/steering wheel 113
3 1 7 Tachograph 114
3 1 8 Standard heating system 115
Auxiliary water heating system 116
Auxiliary air heater 117
3 1 9 CCS control unit 118
3 1 10 CCS – menu-dependent displays 120
3 1 11 CCS display – Start menu 121
3 1 12 CCS – Overview menu groups 122
3 1 13 Carrier menu group 123
Suspension/ level adjustment menu 124
Driving menu 125
Exhaust system menu 126
Air intake inhibitor menu 127
3 1 14 Settings menu group 128
Menu for setting the display brightness and date/time 129
3 1 15 Information menu group 130
Operating hours menu 131
Engine/ transmission error menu 132
Crane operation error menu 133
3 1 16 Various controls menu group 134
3 1 17 Outrigger control units 135
3 2 Brief description of the operating elements 137
3 2 1 Definition of direction information 137
Basic rule 137
Switches and buttons 138
3 2 2 General notes on the operating elements 138
3 2 3 General rules for buttons and symbols on the display 139
3 2 4 Engine, 140
Steering column 140
Multipurpose switch 140
Instrument panel 140
3 2 5 AdBlue (DEF) exhaust system 142
CCS display 142
Instrument panel 143
Driving mode display 144
3 2 6 Air intake inhibitor 145
CCS display 145
3 2 7 Crane control CCS 146
3 2 8 Electrical system 150
3 2 9 Transmission 151
Transmission control unit 151
Driving mode display 152
3 2 10 Reversing camera 154
3 2 11 BirdView system 270 155
3 2 12 Final drive 157
3 2 13 Brakes 159
Service brake 159
Additional brakes 160
Parking brake 161
3 2 14 Steering / separate steering 162
Instrument panel 162
Driver’s door 162
CCS display 163
3 2 15 Suspension 165
CCS display 165
3 2 16 Lighting/windscreen wipers/horn 166
Steering column 166
Instrument panel 166
Roof 169
3 2 17 Level adjustment system 170
3 2 18 Tachograph/speedometer 172
Tachograph 172
3 2 19 Diagnostics 173
3 2 20 Windows, doors, keys 174
Window winder 174
Doors 175
Keys 176
3 2 21 Front flap 176
4 Starting the engine for driving / switching it off 177
4 1 Starting the engine from the driver’s cab 177
4 1 1 CHECKLIST: Starting the engine 177
4 1 2 CHECKLIST: At low temperatures 180
4 1 3 Ladders 181
4 1 4 Refuelling 185
Fuel tank 185
Refill the AdBlue (DEF) tank 187
Auxiliary heatertank 188
4 1 5 Checks before starting the engine 189
At the hydraulictank 189
Battery master switch 190
4 1 6 Switch on the ignition 190
4 1 7 Lamp test/equalisation of the switching states 191
Lamp test 191
Equalisation of switching conditions 191
4 1 8 Display – setting the brightness 192
4 1 9 Torque reduction 193
AdBlue (DEF) tank 193
System malfunctions 194
4 1 10 Overriding the torque reduction 195
4 1 11 Cleaning the exhaust system 196
Automatic cleaning 196
Manual cleaning 197
Disabling cleaning 198
4 1 12 Start the engine 199
Without flame start system 200
With flame startsystem 201
4 1 13 Inspections after starting the engine 202
Checking in the main menu 202
Indicator lamps on the instrument panel 202
4 1 14 Monitoring elements 203
Instrument panel 203
4 1 15 Start menu 204
4 2 Switching off the engine 205
4 2 1 At the ignition lock and with the outrigger control units 205
After turning off 205
4 2 2 With emergency stop switches 206
Resetting the emergency stopswitch 206
4 3 Air intake inhibitor 207
Releasing the air intake inhibitor 207
5 Driving 209
5 1 Before driving 209
5 1 1 CHECKLIST: Checks before on-road driving 209
5 1 2 Check the condition of the truck crane 214
Electrical system 214
Adjust the mirrors 214
Warning plates for vehicle width 216
Displaying vehicle height 216
Supply pressure 217
Parking brake 218
5 1 3 Adjusting the seat and the steering column 219
Driver’s seat 219
Passenger’s seat 221
Adjusting the steering column 222
Storage compartment under the driver’s seat 222
5 1 4 Switching the suspension on/off 223
Open the menu 223
Switching the suspension on 224
Switching the suspension off 224
5 1 5 Setting the tachograph 225
Prerequisites 225
In the event of malfunctions 225
Setting the tachograph 226
5 1 6 Entering the time/date 230
5 1 7 Displaying and resetting operating hours 231
5 1 8 Settings/indications on the driving display 232
5 2 Operating the transmission 233
5 2 1 Switching on 233
5 2 2 Switching the transmission to the neutral position 234
5 2 3 Selecting the direction of travel and starting gear 235
Selecting the driving direction 235
Selecting the starting gear 236
5 2 4 Changing the operating mode 237
Changing to automatic mode 237
Change-over to manual mode 237
5 2 5 Starting 238
5 2 6 Driving and changing gears 240
In automatic operating mode 240
In manual operating mode 241
5 2 7 Changing the driving direction 242
5 2 8 Stopping 242
Stopping for a long period of time 242
5 2 9 DM and RM transmission mode 243
Switching on 243
Switching off 244
5 2 10 On the roller type dynamometer 245
5 2 11 Preheating transmission 245
5 3 Driving and turning off the truck crane 247
5 3 1 Checks while driving 247
Immediately after you start to move 247
While driving 249
5 3 2 Cruise control 250
Switching on 250
Switching off 251
5 3 3 Temposet 251
Switching on 251
Switching off 251
5 3 4 Driving downhill 252
Starting 252
Checks when driving downhill 253
Downshifting 253
Additional brakes 254
5 3 5 Driving uphill 255
Starting 255
Driving 255
5 3 6 Warning or malfunction messages on the instrument panel 256
Meaning of thelamps 256
5 3 7 Notes on torque reduction 258
5 3 8 Warning messages in the start menu 259
5 3 9 Switching the truck crane off 260
Secure it against rolling away 260
When stationary for more than 8hours 261
5 3 10 Fold-up berth 262
5 4 Off-road driving 263
Adjustments to the transmission 263
Connections 263
Changing the vehicle level 263
Rocking the vehicle free and towing 263
5 4 1 Longitudinal and transverse differential locks 264
5 4 2 Operating the level adjustment system 266
Open the menu 266
Setting the on-road level 267
Pre-selecting suspension struts 267
Changing the vehicle level 268
Viewing the current inclination 268
Exiting the menu 269
5 4 3 Freeing an immobilised truck crane 270
Rocking the truck crane free 270
Towing free forwards 271
Towing free totherear 271
5 5 Separate steering 273
5 5 1 Switching to separate steering 273
Manually 274
Automatically 275
5 6 Heating and air-conditioning system 277
5 6 1 Standard heating system, 277
Switching on 277
Temperature 277
Fan 277
Fresh air/ recirculated air 278
Air distribution 278
Switching off 279
5 6 2 Auxiliary water heater 280
Preheating theengine 280
Preheating the driver’s cab 281
Switching on 281
Setting the dateand time 283
Storing the heating start 284
5 6 3 Auxiliary air heater 286
Switching on 286
Setting the heating level 287
Setting the day and time 288
Setting the preselection time 288
Preselection times Delete 290
Switching off 290
5 6 4 Air-conditioning system 291
Switching on 291
Operation 291
Drying the air 292
Switching off 292
5 7 Towing a trailer 293
Effects on the axleloads 293
Coupling the trailer 294
Connecting the supply lines 295
Removing supplylines 296
Uncoupling thetrailer 296
Checking the braking force 298
6 Driving modes 299
6 1 Driving modes 299
Information about the axle loads 299
6 1 1 How to use the tables 300
6 1 2 Table for a maximum axle load of 12 t 301
Tyres 385/95 R25 301
Tyres 445/95 R25 302
Tyres 525/80 R25 303
6 2 Weighing the truck crane 304
Weighing error 304
Axle groups 305
Weighing procedure 306
Evaluation 307
7 Transport 309
7 1 Transport with transport vehicle 309
7 1 1 CHECKLIST: Checks before transport 310
7 1 2 Drive the truck crane on to the transport vehicle 312
Driving on 313
Lashing 313
7 2 Transport by ship 314
8 Malfunctions in driving mode 315
8 1 Emergency stop switches 315
8 2 What to do when a malfunction occurs in road traffic 317
8 3 Towing away the truck crane 319
8 3 1 Towing after engine/transmission damage 320
Compressed-air supply 320
Electric power supply 320
On the transmission 321
Axle drives 321
Parking brake 321
Towing the truck crane out of the danger area 322
Longer towing distances 322
8 3 2 Tow starting 322
8 4 Other emergency operations 323
8 4 1 Externally starting the truck crane 323
8 4 2 Battery charger 324
Prerequisites 324
8 5 Wheels and tyres 325
8 5 1 Wheel change 325
Removing a damaged wheel 326
On the spare wheel holder 326
Mounting a wheel 327
8 5 2 Inflating the tyres yourself 329
Connecting thefilling hose 329
Inflating the tyres 330
Remove the fillinghose 330
8 6 Tilting/lowering the driver’s cab 331
8 6 1 Prerequisites and information on tilting 331
8 6 2 Tilting/lowering the driver’s cab 332
Operating the hand pump 332
Tilting the driver’scab 333
Lowering the driver’s cab 334
8 7 Fuses on the carrier 335
Information on replacing fuses 335
8 7 1 Fuses in the driver’s cab 336
8 7 2 Fuses in the battery box 342
8 8 Troubleshooting 343
8 8 1 Malfunctions on the engine 343
When operating with the dual tank 345
8 8 2 Faults on the AdBlue (DEF) system 345
8 8 3 Malfunctions of the differential locks 346
8 8 4 Malfunctions in the transmission 347
8 8 5 Malfunctions of the steering 348
8 8 6 Malfunctions of the service brake 349
8 8 7 Malfunctions on the suspension 349
8 8 8 Malfunctions of the level adjustment system 350
8 8 9 Malfunctions in the hydraulic system/hydraulic oil cooler 350
8 9 Warnings in the start menu 351
Symbols in the display area 351
8 9 1 Engine/transmission error menu 356
Open the menu 356
Exiting the menu 356
8 10 Procedure in the event of malfunctions 357
8 10 1 Switching on emergency operation in coolant circuit 357
8 10 2 Procedure in the event of transmission malfunctions 358
Error messages 358
Displaying errorcodes 360
9 Operating elements for crane operation 361
9 1 Overview of the operating elements 361
9 1 1 Exterior of the truck crane 362
9 1 2 Crane cab 366
Side panel 368
Crane cab, rear 370
9 1 3 Control panels 372
Left 372
Right 373
9 1 4 Control lever configuration 374
Version 1 374
Version 2 375
9 1 5 Heating system 377
9 1 6 CCS control unit 378
9 1 7 Menu-independent displays 380
9 1 8 CCS – Start menu 381
9 1 9 CCS – Overview menu groups 382
9 1 10 Superstructure menu group 386
Superstructure lock sub-menu 387
Counterweight menu 388
9 1 11 Outrigger menu group 389
Outrigger cylinders menu 390
Outrigger menu 392
9 1 12 Teleautomation menu group 393
Telescoping full automation menu 394
Telescoping semi-automation menu 395
Main boom configuration menu 396
9 1 13 Working range limiter menu group 397
Overall height menu 398
Working radius menu 399
Slewing anglemenu 400
Hoist rope travel limitation menu 401
9 1 14 Information menu group 1 402
Hydraulic pressure and fuel consumption menu 403
9 1 15 Driving menu group 404
Driving mode menu 406
9 1 16 Telescoping emergency program menu group 408
Manual telescoping menu 409
Telescoping emergency program menu 410
Unknown telescoping menu 411
9 1 17 Settings menu group 412
Adjust wiper stroke interval menu 413
Set display brightness and date/time menu 414
Switch units menu 415
Set control lever characteristic curve menu 416
Power unit speedsmenu 417
9 1 18 Information menu group 2 419
Operating hours menu 420
Engine/ transmission error menu 421
Crane operation error menu 422
Program version menu 423
9 1 19 Various controls 424
9 1 20 RCL control unit 426
9 1 21 Menu-independent displays 428
9 1 22 RCL – menu groups 429
9 1 23 Crane operation menu group 430
Enter rigging mode menu 431
Monitoring menu 432
Lifting capacity table menu 434
9 1 24 Additional functions menu group 435
Datalogger menu 436
9 1 25 Hand-held control 437
9 1 26 Outrigger control units 438
Button 438
Outrigger button 439
Inclination and outrigger pressure display 440
9 1 27 For emergency hydraulic operation 441
9 2 Brief description of the operating elements 443
9 2 1 Definition of direction information 443
Basic rule 443
Switches 443
9 2 2 General rules for buttons and symbols on the display 444
9 2 3 Engine 445
Side panel 445
CCS display 445
9 2 4 AdBlue (DEF) system 446
CCS display 446
9 2 5 Seat contact switch and dead man’s switch 447
9 2 6 Crane control CCS 448
9 2 7 Outrigger – crane cab 455
Control panels 455
CCS display 455
9 2 8 Outrigger – control units 457
General information 457
Outrigger menu 458
9 2 9 Inclination indicators 460
9 2 10 Outrigger pressure displays 461
Outrigger submenu 461
Outrigger control units 461
9 2 11 Anemometer displays 461
9 2 12 Counterweight menu 462
9 2 13 Superstructure lock/house lock menu 464
Superstructure lock 464
House lock 465
9 2 14 Main hoist 467
Control panels 467
CCS display 467
9 2 15 Auxiliary hoist 469
Control panels 469
CCS display 470
9 2 16 Slewing gear 471
Control panels 471
CCS display 472
9 2 17 Derricking gear 473
Control panels 473
CCS display 474
9 2 18 Telescoping mechanism 475
Control panels 475
CCS display 475
Telescoping full automation menu 476
Telescoping semi- automation menu 477
Manual telescoping menu 479
Main boom configuration menu 482
9 2 19 Hydraulic system 483
9 2 20 Rated capacity limiter (RCL) 484
Control unit control console RCL 484
Display RCL 485
Enter rigging mode menu 487
Monitoring menu 490
Lifting capacity tables menu 493
Datalogger menu 494
RCL override – version A 495
RCL override – version B 496
9 2 21 Electrical system 497
9 2 22 Lighting, windscreen wiper/washing system 498
Lighting 498
Windscreen wiper/washing system 500
9 2 23 Hand-held control 501
Sockets on truckcrane 501
Engine control panel 502
Horn 502
9 2 24 Diagnostics 505
9 2 25 Windows, doors, keys 506
Windscreen 506
Rear window 506
Crane cab door 507
Keys 508
9 3 Short description of the operating elements – driving from the crane cab 509
9 3 1 Driving mode menu 509
9 3 2 Transmission 510
9 3 3 Final drive 511
9 3 4 Brakes 512
CCS display 512
Side panel from above 513
9 3 5 Steering 514
CCS display 514
Steering modes 515
Separate steering 515
Control panels 516
10 Starting/switching off the engine – for crane operation 517
10 1 When starting the engine for the first time in the day 517
10 2 Starting the engine – from the crane cab 519
10 2 1 Checking the fuel level and AdBlue (DEF) level 519
Fuel 519
AdBlue (DEF) 519
10 2 2 Checks before starting the engine 520
Checks on the carrier 520
Checking the hand-held control 520
10 2 3 Switch on the ignition 520
10 2 4 Equalisation of the switching states 521
10 2 5 Display – setting the brightness 521
10 2 6 Start the engine 522
10 2 7 Inspections after starting the engine 523
10 2 8 Set idling speed 524
10 3 Starting the engine – with the hand-held control 525
10 4 Switching off the engine 527
10 4 1 On the ignition lock / with hand-held control 527
After starting from the crane cab 527
After starting up with the hand- held control 527
After turning off 527
10 4 2 Using the emergency stop switches 528
Resetting the emergency stopswitch 528
11 Crane operation 529
11 1 Before operating the crane 529
11 1 1 CHECKLIST: Checks before operating the crane 529
11 1 2 Checking the condition of the truck crane 533
Auxiliary heater – tank 533
Visual inspection 534
Checking the position of the hoist ropes 534
Checking the electrical system 535
11 1 3 Adjusting the crane cab seat and front control panel 536
Crane cab seat 536
Front panel 537
11 1 4 Checking the safety equipment 538
Rated capacity limiter 538
Lifting limit switch 538
Emergency stop switches 539
Seat contact switch 540
11 1 5 Earthing the load 541
11 1 6 Preheating the hydraulic oil 542
11 1 7 Locking/unlocking the superstructure 544
Locking points 544
Lock the superstructure 545
Unlocking the superstructure 545
11 1 8 Switching the houselock on/off 546
Switching on the houselock 546
Switching off the houselock 548
11 2 Operation of the rated capacity limiter 549
11 2 1 Switch on the RCL 550
Switching on 550
Brightness of thedisplays 552
Temperature onthe display 552
11 2 2 Enter rigging mode 553
Entering individual components 554
Entering the RCLcode 558
Entering the reeving 559
Accepting the rigging mode 559
11 2 3 Checks before operating the crane 561
Open the menu 561
Checks 561
11 2 4 Displays during crane operation 564
11 2 5 RCL early warning 567
11 2 6 RCL shutdown 567
Shutdown due to overload 567
11 2 7 Display in the event of errors 569
11 2 8 RCL override – version A 570
Overview status display 570
When rigging 571
To raise the boom 572
In emergencies 573
11 2 9 RCL override – version B 574
11 2 10 Displaying the lifting capacity tables 575
11 2 11 Datalogger 577
Export data 577
Display the data 578
11 3 Crane operation with main boom 581
11 3 1 Checks during crane operation 581
Horizontal alignment 581
Safe distances 581
Checking the windspeed 582
11 3 2 Permissible slewing ranges and working positions 583
360 slewing range 583
Working position 0to the rear 583
180 to the front rigging position 584
Free on wheels working position 584
11 3 3 Main hoist 585
Switching on themain hoist 586
Lifting and lowering 586
Switching off the main hoist 587
11 3 4 Auxiliary hoist 588
Switching on the auxiliary hoist 588
Lifting and lowering 589
Switching off the auxiliary hoist 590
11 3 5 Lifting limit switch and lowering limit switch 591
Lifting limit switch 591
Lowering limit switch 593
11 3 6 Derricking gear 594
Switching on the derricking gear 594
Raising and lowering 595
Re-enable raising function 596
Switching off the derricking gear 596
Lowering the main boom to ahorizontal position 597
11 3 7 Telescoping mechanism 598
Overview 599
Telescoping process 599
Assignment for display 602
Fixed length, intermediate length, telescoping length 603
Telescoping 604
Telescoping sequence 604
Checks prior tostarting operations 605
Switching on thetelescoping mechanism 606
Function of the control lever 606
Switching off thetelescoping mechanism 608
Manual telescoping 609
Checking the initial position 609
Unlocking the telescoping cylinder 611
Extending/ retracting the telescoping cylinder 613
Lock telescoping cylinder 614
Unlocking the telescopic section 615
Telescoping the telescopic section 616
Locking the telescopic section 617
Locking the telescopic section for on-road driving 618
Telescoping with semi-automaton 618
Telescoping with full automation 621
Telescoping the main boom when horizontal 622
Telescoping with main boom configuration 622
11 3 8 High-speed mode 623
Derricking gear telescoping mechanism 623
Hoists 624
11 3 9 Slewing gear 625
Switching on the slewing gear 625
Slewing 626
Braking the slewing movement 627
Applying the slewing gear brake 628
Releasing the slewing gear brake 628
Slewing gear freewheel 628
Switching off the slewing gear 629
11 3 10 Switching the reduction of slewing speed on and off 630
Switching reduction off 630
11 3 11 Possible movement combinations 631
11 4 Settings and displays for crane operation 633
11 4 1 Inclining the crane cab 633
11 4 2 Set idling speed 634
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 634
11 4 4 Limiting the power unit speeds 635
11 4 5 Switching units of measure 636
11 4 6 Setting the characteristic curves for the control levers 637
11 4 7 Using the slewable spotlights 638
Manually swinging 638
Automatic load tracking 639
11 4 8 Overriding the torque reduction 640
11 4 9 Displaying the operating hours 641
11 5 Working range limiter 643
11 5 1 Viewing current settings 644
On the RCL display 644
11 5 2 Opening the working range limiter menu 645
11 5 3 Entering limit values 648
Overall height 648
Working radius 649
Slewing angle 649
Hoist rope travel limitation 650
11 5 4 Entering limit values manually 652
Limit values 652
11 5 5 Switching monitoring functions on/off 654
11 5 6 Shutdown by working range limiter 655
11 6 Work break 657
11 6 1 In case of short work breaks 657
11 6 2 In case of work breaks of more than 8 hours 658
To secure the truck crane 658
11 7 Heating and ventilating the crane cab 659
11 7 1 Heating system 659
Switching on 660
Temperature 660
Fan 661
Fresh air/ recirculated air 661
Air distribution 661
Setting the day and time 663
Storing the heating start 664
Setting the heating period 665
Switching the heating start onand off 665
Switching off 666
Setting the remaining runtime 666
11 7 2 Air-conditioning system 667
Switching on 667
Operation 667
Drying the air 668
Switching off 668
11 8 CraneSTAR system 669
11 8 1 Overview 669
11 8 2 Position of the components 669
12 Rigging work 671
12 1 Rigging work checklists for crane operation with themain boom 671
12 1 1 CHECKLIST: Rigging 671
12 1 2 CHECKLIST: Unrigging 676
12 2 Selecting the suitable site 679
12 2 1 Determining the required load-bearing area 679
12 2 2 Safe distance from slopes and pits 682
12 2 3 Earthing the truck crane 683
12 2 4 Safe distance from overhead power lines 684
12 3 Connecting/disconnecting the hand-held control 687
12 4 Starting the engine for rigging 689
12 4 1 Starting/turning off the engine with the hand-held control 689
Prerequisites 689
Start the engine 690
Switching off theengine 690
12 4 2 Starting/switching off the engine from the outrigger control units 691
Prerequisites 691
Start the engine 691
Switching off the engine 691
12 5 Outrigger 693
12 5 1 CHECKLIST: Extending the outriggers 693
12 5 2 CHECKLIST: Retracting the outriggers 695
12 5 3 Permissible outrigger spans 696
12 5 4 Preparing the truck crane 697
In the driver’s cab 697
Outrigger control units 697
12 5 5 Setting the spans 699
12 5 6 Extending/retracting outrigger beams 701
From the control units 702
From the cranecab 703
12 5 7 Moving the outrigger pads into working/driving position 705
12 5 8 Enlarging the load-bearing area 706
12 5 9 Extending/retracting supporting cylinders 707
From the control units 708
From the cranecab 709
12 5 10 Levelling the truck crane on outriggers 711
Inclination indicators 711
Prerequisites 712
Manual alignment 713
Automatic alignment 714
12 5 11 Levelling the free-on-wheels truck crane 715
12 5 12 Outrigger pressure display 717
12 6 Rigging/unrigging the counterweight 719
12 6 1 Instructions on rigging 719
When rigging 719
When unrigging 720
12 6 2 Counterweight sections and identification 721
Counterweight sections 721
Identification 722
12 6 3 Slinging points on the counterweight sections 723
12 6 4 CHECKLIST: Rigging the counterweight 724
12 6 5 CHECKLIST: Unrigging the counterweight 727
12 6 6 Assembling counterweight versions 729
Version A 730
Version B 732
Version A and B 734
Further combinations, version A 736
Further combinations, version B 738
12 6 7 Counterweight hoist unit 742
Counterweight menu 742
Extending/ retracting the lifting cylinders 743
Locking/ Unlocking counterweight 745
12 6 8 Setting down counterweight for driving the truck crane 746
12 6 9 Slewing with the rigged counterweight 747
12 7 Rigging work on the main boom 749
12 7 1 Hook block on the bumper 749
Picking up the hook block 749
Attaching the hook block 750
12 7 2 Hook block on a separate vehicle 751
Picking up the hook block 752
Setting down the hook block 752
12 7 3 Hook blocks with ballast plates 754
Removing 754
Installing 755
Information on crane operation 755
Reeving the hoistrope 758
Unreeving hoistrope 761
12 7 5 Rigging aid for the hoist rope 762
Establishing/ disconnecting connections 762
Rigging the hoistrope 763
12 7 6 Possible reevings on the main boom 764
With 5 head sheaves 765
With 6 head sheaves 767
12 7 7 Installing/removing the lifting limit switch 770
Installing lifting limit switch 770
Removing the lifting limit switch 773
12 7 8 Locking/unlocking the lifting limit switch 775
Locking 775
Removing the lock 775
12 7 9 Anemometer and air traffic control light 776
Installing 776
Switching the air traffic control light on and off 777
Removing 778
12 8 Other rigging work 779
12 8 1 Folding mirrors in/out and adjusting 779
Camera on main boom 780
Camera on thehoists 783
Camera on the driver’s cab 783
Operating thecamera 784
12 8 3 Step at the crane cab 785
13 Driving with a rigged truck crane 787
13 1 Route 787
13 2 Permissible rigging modes and axle loads 788
13 2 1 To drive without a load 788
13 2 2 To drive with a load 788
13 2 3 Axle loads 789
13 3 Before driving the rigged truck crane 791
13 3 1 Check the tyre pressures and wind speed 791
13 3 2 Secure the superstructure against slewing 791
13 3 3 Putting the truck crane on the wheels 792
13 4 Driving from the driver’s cab 795
13 4 1 Preparing to drive 795
Transmission 795
Switching on separate steering 795
Connections 795
13 4 2 Whilst driving 796
13 5 Driving from the crane cab 797
13 5 1 Preparing to drive 798
13 5 2 Opening/closing the Driving menu 799
Opening 799
Closing 800
13 5 3 Steering system 801
Switching on 801
Adjusting the steering direction 801
Displays when steering 802
Normal steering mode 802
Separate steering 803
13 5 4 Operating the transmission 805
Driving direction 805
Crane’s hydraulic system on/off 805
Selecting the transmission mode 806
13 5 5 While driving 807
DMand RM transmission mode 807
Transmission mode D 807
Warning messages 807
13 5 6 Possible connections 808
Longitudinal/ transverse differential locks 808
13 5 7 After driving 810
14 Malfunctions during crane operation 811
14 1 Emergency stop switches 811
14 2 What to do when malfunctions occur during crane operation 813
The load can be set down 813
Load cannot be setdown 813
14 3 Fuses in the crane cab 815
Information on replacing fuses 815
14 4 Finding and eliminating malfunctions 820
14 4 1 Malfunctions on the engine 820
14 4 2 Malfunctions when operating with the hand-held control 820
14 4 3 Malfunctions on the turntable lock 821
14 4 4 Malfunctions when inclining the crane cab 821
14 4 5 Malfunctions on the main hoist 822
14 4 6 Malfunctions in the telescoping mechanism 823
14 4 7 Malfunctions in the hoist cameras 824
14 4 8 Malfunctions in the main boom camera 825
14 4 9 Malfunctions on the derricking gear 826
14 4 10 Malfunctions on the slewing gear 827
14 4 11 Malfunctions on the counterweight hoist unit 828
14 4 12 Malfunctions in the hydraulic system/hydraulic oil cooler 829
14 4 13 Malfunctions when driving from the crane cab 829
14 4 14 Malfunctions of the outriggers 830
14 5 Warning and error messages 831
Program version 831
14 5 1 Warning messages on the CCS display 831
Meaning of the symbols 832
14 5 2 Warning messages on the RCL display 835
14 5 3 Error messages on the CCS display 839
14 5 4 Malfunctions in the CraneStar system 841
14 6 Emergency operations and programs 843
14 6 1 Mechanical emergency activation for retracting 844
Prior to the emergency activation, check 844
Procedure 844
Mechanical emergency activation 845
14 6 2 Telescoping emergency program 847
Open the Emergency program submenu 847
Determining the type of error 848
If there is an erroron the length indicator 849
Tables for approaching the locking points 853
14 6 3 Entering the current telescoping 855
14 6 4 Emergency operation with the hand-held control 857
Preparations 857
Pre-selecting a power unit 858
Operating a powerunit 858
Stopping movements 859
Stopping movements in emergencies 860
Switching off theengine 860
14 7 Hydraulic emergency operation 861
14 7 1 Connect/Disconnect hoses 861
14 7 2 Establishing the hydraulic circuits required 862
Switching overvalves 862
For lifting/ lowering 864
14 7 3 Performing emergency activation 865
14 7 4 After the emergency activation 865
14 8 Hydraulic emergency operation BGR 159 867
14 8 1 Operating principle 867
14 8 2 Connecting/disconnecting hoses 868
For transformers 868
For the hand pump 869
14 8 3 Establishing the hydraulic circuits required 870
Switching positions of the valves 870
Switching over valves 870
For lifting/ lowering 872
For slewing 873
14 8 4 Performing emergency operation 873
Derricking 874
Lifting/lowering 875
Slewing 875
14 8 5 After emergency operation 876
Switching off emergency operation 876
Switching over to crane operation 876
Disconnecting thehoses 876
14 8 6 Emergency supply of another crane 877
After emergency supply 878
15 Index 879
A 881
B 881
C 881
D 884
E 886
F 888
H 888
I 888
K 889
L 889
M 890
O 890
P 891
R 892
S 893
T 894
V 896
W 896
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