Grove Crane Manitowoc GMK 3060 Operating Instruction Manual 3302623 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane Manitowoc GMK 3060 Operating Instruction Manual 3302623 – PDF DOWNLOAD
Language : English
Pages : 902
Downloadable : Yes
File Type : PDF
Size: 25.1 MB
DESCRIPTION:
Grove Crane Manitowoc GMK 3060 Operating Instruction Manual 3302623 – PDF DOWNLOAD
Documentation supplied:
The precise number of documents supplied depends on the rigging mode
of the truck crane. The following documents are included in the delivery:
– Operating Instructions
Contains information on driving and crane operation.
– Lattice extension operating manual
Is supplied only when the truck crane is equipped with a lattice extension
or other parts for extending the main boom (e.g. auxiliary single-sheave
boom top and heavy load lattice extension).
– Operating manual for additional equipment
This is supplied only when the truck crane is supplied with additional
equipment which is not described in the operating manual for driving and
crane operation.
– Documents from other manufacturers
Original documentation for parts not manufactured by Manitowoc Crane
Group Germany GmbH, such as the engine and central lubrication system,
as well as the tachograph, auxiliary heaters, radio and, where
appropriate, other additional equipment.
– Maintenance manual
Contains solely information on maintenance work and contains no
instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical systems, hydraulic systems and
pneumatic systems are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different
rigging modes
Basic safety instructions:
2.1 Intended use:
The GMK3060 truck crane is constructed in accordance with the latest
technology and the recognised safety regulations. Nevertheless, the
operator or third parties can still be endangered and the crane or other
property put at risk while using it.
The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH.
The GMK3060 truck crane may be used only when it is in perfect technical
condition and for its intended purpose and with due attention paid to safe
operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately.
The GMK3060 truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
data, p. 1 – 7.
The GMK3060 truck crane is designed solely for lifting loads which are
within the permitted GMK3060 lifting capacities. The load must be slung as
prescribed to a hook block which is positioned vertically over the load prior
to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating
manual(s), the lifting capacity table, the outrigger pressure table and the
safety manual
– adhering to the inspection and maintenance requirements specified in the
maintenance manual.
The GMK3060 may only be operated with parts of equipment which
approved by Manitowoc Crane Group Germany GmbH and which are labelled
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 shall take on full
responsibility for any such use.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane Manitowoc GMK 3060 Operating Instruction Manual 3302623 – PDF DOWNLOAD
Additional page 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
Overview metres (feet) / per cent 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 Maximum lifting capacity (ASME B 30 5) 53
1 5 3 Dimensions and weights of the truck crane, axle loads 54
Dimensions 55
Weight and axle loads 55
1 5 4 Dimensions and weights of removable parts 56
Spare wheel 56
Outriggers 56
Counterweight sections 56
Hook blocks and hook tackle 57
1 5 5 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 6 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 (26,500 lbs) 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 346
8 8 2 Faults on the AdBlue (DEF) system 346
8 8 3 Malfunctions of the differential locks 347
8 8 4 Malfunctions in the transmission 348
8 8 5 Malfunctions of the steering 349
8 8 6 Malfunctions of the service brake 350
8 8 7 Malfunctions on the suspension 350
8 8 8 Malfunctions of the level adjustment system 351
8 8 9 Malfunctions in the hydraulic system/hydraulic oil cooler 351
8 9 Warnings in the start menu 353
Symbols in the display area 353
8 9 1 Engine/transmission error menu 358
Open the menu 358
Exiting the menu 358
8 10 Procedure in the event of malfunctions 359
8 10 1 Switching on emergency operation in coolant circuit 359
8 10 2 Procedure in the event of transmission malfunctions 360
Error messages 360
Displaying errorcodes 362
9 Operating elements for crane operation 363
9 1 Overview of the operating elements 363
9 1 1 Exterior of the truck crane 364
9 1 2 Crane cab 368
Side panel 370
Crane cab, rear 372
9 1 3 Control panels 374
Left 374
Right 375
9 1 4 Control lever configuration 376
Version 1 376
Version 2 377
9 1 5 Heating system 379
9 1 6 CCS control unit 380
9 1 7 Menu-independent displays 382
9 1 8 CCS – Start menu 383
9 1 9 CCS – Overview menu groups 384
9 1 10 Superstructure menu group 388
Superstructure lock sub-menu 389
Counterweight menu 390
9 1 11 Outrigger menu group 391
Outrigger cylinders menu 392
Outrigger menu 394
9 1 12 Teleautomation menu group 395
Telescoping full automation menu 396
Telescoping semi-automation menu 397
Main boom configuration menu 398
9 1 13 Working range limiter menu group 399
Overall height menu 400
Working radius menu 401
Slewing anglemenu 402
Hoist rope travel limitation menu 403
9 1 14 Information menu group 1 404
Hydraulic pressure and fuel consumption menu 405
9 1 15 Driving menu group 406
Driving mode menu 408
9 1 16 Telescoping emergency program menu group 410
Manual telescoping menu 411
Telescoping emergency program menu 412
Unknown telescoping menu 413
9 1 17 Settings menu group 414
Adjust wiper stroke interval menu 415
Set display brightness and date/time menu 416
Switch units menu 417
Set control lever characteristic curve menu 418
Power unit speedsmenu 419
9 1 18 Information menu group 2 421
Operating hours menu 422
Engine/ transmission error menu 423
Crane operation error menu 424
Program version menu 425
9 1 19 Various controls 426
9 1 20 RCL control unit 428
9 1 21 Menu-independent displays 430
9 1 22 RCL – menu groups 431
9 1 23 Crane operation menu group 432
Enter rigging mode menu 433
Monitoring menu 434
Lifting capacity table menu 436
9 1 24 Additional functions menu group 437
Datalogger menu 438
9 1 25 Hand-held control 439
9 1 26 Outrigger control units 440
Button 440
Outrigger button 441
Inclination and outrigger pressure display 442
9 1 27 For emergency hydraulic operation 443
9 2 Brief description of the operating elements 445
9 2 1 Definition of direction information 445
Basic rule 445
Switches 445
9 2 2 General rules for buttons and symbols on the display 446
9 2 3 Engine 447
Side panel 447
CCS display 447
9 2 4 AdBlue (DEF) system 448
CCS display 448
9 2 5 Seat contact switch and dead man’s switch 449
9 2 6 Crane control CCS 450
9 2 7 Outrigger – crane cab 457
Control panels 457
CCS display 457
9 2 8 Outrigger – control units 459
General information 459
Outrigger menu 460
9 2 9 Inclination indicators 462
9 2 10 Outrigger pressure displays 463
Outrigger submenu 463
Outrigger control units 463
9 2 11 Anemometer displays 463
9 2 12 Counterweight menu 464
9 2 13 Superstructure lock/house lock menu 466
Superstructure lock 466
House lock 467
9 2 14 Main hoist 469
Control panels 469
CCS display 469
9 2 15 Auxiliary hoist 471
Control panels 471
CCS display 472
9 2 16 Slewing gear 473
Control panels 473
CCS display 474
9 2 17 Derricking gear 475
Control panels 475
CCS display 476
9 2 18 Telescoping mechanism 477
Control panels 477
CCS display 477
Telescoping full automation menu 478
Telescoping semi- automation menu 479
Manual telescoping menu 481
Main boom configuration menu 484
9 2 19 Hydraulic system 485
9 2 20 Rated capacity limiter (RCL) 486
Control unit control console RCL 486
Display RCL 487
Enter rigging mode menu 489
Monitoring menu 492
Lifting capacity tables menu 495
Datalogger menu 496
RCL override – version A 497
RCL override – version B 498
9 2 21 Electrical system 499
9 2 22 Lighting, windscreen wiper/washing system 500
Lighting 500
Windscreen wiper/washing system 502
9 2 23 Hand-held control 503
Sockets on truckcrane 503
Engine control panel 504
Horn 504
9 2 24 Diagnostics 507
9 2 25 Windows, doors, keys 508
Windscreen 508
Rear window 508
Crane cab door 509
Keys 510
9 3 Short description of the operating elements – driving from the crane cab 511
9 3 1 Driving mode menu 511
9 3 2 Transmission 512
9 3 3 Final drive 513
9 3 4 Brakes 514
CCS display 514
Side panel from above 515
9 3 5 Steering 516
CCS display 516
Steering modes 517
Separate steering 517
Control panels 518
10 Starting/switching off the engine – for crane operation 519
10 1 When starting the engine for the first time in the day 519
10 2 Starting the engine – from the crane cab 521
10 2 1 Checking the fuel level and AdBlue (DEF) level 521
Fuel 521
AdBlue (DEF) 521
10 2 2 Checks before starting the engine 522
Checks on the carrier 522
Checking the hand-held control 522
10 2 3 Switch on the ignition 522
10 2 4 Equalisation of the switching states 523
10 2 5 Display – setting the brightness 523
10 2 6 Start the engine 524
10 2 7 Inspections after starting the engine 525
10 2 8 Set idling speed 526
10 3 Starting the engine – with the hand-held control 527
10 4 Switching off the engine 528
10 4 1 On the ignition lock / with hand-held control 528
After starting from the crane cab 528
After starting up with the hand- held control 528
After turning off 528
10 4 2 Using the emergency stop switches 529
Resetting the emergency stopswitch 529
11 Crane operation 531
11 1 Before operating the crane 531
11 1 1 CHECKLIST: Checks before operating the crane 531
11 1 2 Checking the condition of the truck crane 535
Auxiliary heater – tank 535
Visual inspection 536
Checking the position of the hoist ropes 536
Checking the electrical system 537
11 1 3 Adjusting the crane cab seat and front control panel 538
Crane cab seat 538
Front panel 539
11 1 4 Checking the safety equipment 540
Rated capacity limiter 540
Lifting limit switch 540
Emergency stop switches 541
Seat contact switch 542
11 1 5 Earthing the load 543
11 1 6 Preheating the hydraulic oil 544
11 1 7 Locking/unlocking the superstructure 546
Locking points 546
Lock the superstructure 547
Unlocking the superstructure 547
11 1 8 Switching the houselock on/off 548
Switching on the houselock 548
Switching off the houselock 550
11 2 Operation of the rated capacity limiter 551
11 2 1 Switch on the RCL 552
Switching on 552
Brightness of thedisplays 554
Temperature onthe display 554
11 2 2 Enter rigging mode 555
Entering individual components 556
Entering the RCLcode 560
Entering the reeving 561
Accepting the rigging mode 561
11 2 3 Checks before operating the crane 563
Open the menu 563
Checks 563
11 2 4 Displays during crane operation 566
11 2 5 RCL early warning 569
11 2 6 RCL shutdown 569
Shutdown due to overload 569
11 2 7 Display in the event of errors 571
11 2 8 RCL override – version A 572
Overview status display 572
When rigging 573
To raise the boom 574
In emergencies 575
11 2 9 RCL override – version B 576
11 2 10 Displaying the lifting capacity tables 577
11 2 11 Datalogger 579
Export data 579
Display the data 580
11 3 Crane operation with main boom 583
11 3 1 Checks during crane operation 583
Horizontal alignment 583
Safe distances 583
Checking the windspeed 584
11 3 2 Permissible slewing ranges and working positions 585
360 slewing range 585
Working position 0to the rear 585
180 to the front rigging position 586
Free on wheels working position 586
11 3 3 Main hoist 587
Switching on themain hoist 588
Lifting and lowering 588
Switching off the main hoist 589
11 3 4 Auxiliary hoist 590
Switching on the auxiliary hoist 590
Lifting and lowering 591
Switching off the auxiliary hoist 592
11 3 5 Lifting limit switch and lowering limit switch 593
Lifting limit switch 593
Lowering limit switch 595
11 3 6 Derricking gear 596
Switching on the derricking gear 596
Raising and lowering 597
Re-enable raising function 598
Switching off the derricking gear 598
Lowering the main boom to ahorizontal position 599
11 3 7 Telescoping mechanism 600
Overview 601
Telescoping process 601
Assignment for display 604
Fixed length, intermediate length, telescoping length 605
Telescoping 606
Telescoping sequence 606
Checks prior tostarting operations 607
Switching on thetelescoping mechanism 608
Function of the control lever 608
Switching off thetelescoping mechanism 610
Manual telescoping 611
Checking the initial position 611
Unlocking the telescoping cylinder 613
Extending/ retracting the telescoping cylinder 615
Lock telescoping cylinder 616
Unlocking the telescopic section 617
Telescoping the telescopic section 618
Locking the telescopic section 619
Locking the telescopic section for on-road driving 620
Telescoping with semi-automaton 620
Telescoping with full automation 623
Telescoping the main boom when horizontal 624
Telescoping with main boom configuration 624
11 3 8 High-speed mode 625
Derricking gear telescoping mechanism 625
Hoists 626
11 3 9 Slewing gear 627
Switching on the slewing gear 627
Slewing 628
Braking the slewing movement 629
Applying the slewing gear brake 630
Releasing the slewing gear brake 630
Slewing gear freewheel 630
Switching off the slewing gear 631
11 3 10 Switching the reduction of slewing speed on and off 632
Switching reduction off 632
11 3 11 Possible movement combinations 633
11 4 Settings and displays for crane operation 635
11 4 1 Inclining the crane cab 635
11 4 2 Set idling speed 636
11 4 3 Adjusting the wiper stroke interval of the windscreen wiper 636
11 4 4 Limiting the power unit speeds 637
11 4 5 Switching units of measure 638
11 4 6 Setting the characteristic curves for the control levers 639
11 4 7 Using the slewable spotlights 640
Manually swinging 640
Automatic load tracking 641
11 4 8 Overriding the torque reduction 642
11 4 9 Displaying the operating hours 643
11 5 Working range limiter 645
11 5 1 Viewing current settings 646
On the RCL display 646
11 5 2 Opening the working range limiter menu 647
11 5 3 Entering limit values 650
Overall height 650
Working radius 651
Slewing angle 651
Hoist rope travel limitation 652
11 5 4 Entering limit values manually 654
Limit values 654
11 5 5 Switching monitoring functions on/off 656
11 5 6 Shutdown by working range limiter 657
11 6 Work break 659
11 6 1 In case of short work breaks 659
11 6 2 In case of work breaks of more than 8 hours 660
To secure the truck crane 660
11 7 Heating and ventilating the crane cab 661
11 7 1 Heating system 661
Switching on 662
Temperature 662
Fan 663
Fresh air/ recirculated air 663
Air distribution 663
Setting the day and time 665
Storing the heating start 666
Setting the heating period 667
Switching the heating start onand off 667
Switching off 668
Setting the remaining runtime 668
11 7 2 Air-conditioning system 669
Switching on 669
Operation 669
Drying the air 670
Switching off 670
11 8 CraneSTAR system 671
11 8 1 Overview 671
11 8 2 Position of the components 671
12 Rigging work 673
12 1 Rigging work checklists for crane operation with themain boom 673
12 1 1 CHECKLIST: Rigging 673
12 1 2 CHECKLIST: Unrigging 678
12 2 Selecting the suitable site 681
12 2 1 Determining the required load-bearing area 681
12 2 2 Safe distance from slopes and pits 684
12 2 3 Earthing the truck crane 685
12 2 4 Safe distance from overhead power lines 686
12 3 Connecting/disconnecting the hand-held control 689
12 4 Starting the engine for rigging 691
12 4 1 Starting/turning off the engine with the hand-held control 691
Prerequisites 691
Start the engine 692
Switching off theengine 692
12 4 2 Starting/switching off the engine from the outrigger control units 693
Prerequisites 693
Start the engine 693
Switching off the engine 693
12 5 Outrigger 695
12 5 1 CHECKLIST: Extending the outriggers 695
12 5 2 CHECKLIST: Retracting the outriggers 697
12 5 3 Permissible outrigger spans 698
12 5 4 Preparing the truck crane 699
In the driver’s cab 699
Outrigger control units 699
12 5 5 Setting the spans 701
12 5 6 Extending/retracting outrigger beams 703
From the control units 704
From the cranecab 705
12 5 7 Moving the outrigger pads into working/driving position 707
12 5 8 Enlarging the load-bearing area 708
12 5 9 Extending/retracting supporting cylinders 709
From the control units 710
From the cranecab 711
12 5 10 Levelling the truck crane on outriggers 713
Inclination indicators 713
Prerequisites 714
Manual alignment 715
Automatic alignment 716
12 5 11 Levelling the free-on-wheels truck crane 717
12 5 12 Outrigger pressure display 719
12 6 Rigging/unrigging the counterweight 721
12 6 1 Instructions on rigging 721
When rigging 721
When unrigging 722
12 6 2 Counterweight sections and identification 723
Counterweight sections 723
Identification 724
12 6 3 Slinging points on the counterweight sections 725
12 6 4 CHECKLIST: Rigging the counterweight 726
12 6 5 CHECKLIST: Unrigging the counterweight 729
12 6 6 Assembling counterweight versions 731
Version A 732
Version B 734
Version A and B 736
Further combinations, version A 738
Further combinations, version B 740
12 6 7 Counterweight hoist unit 744
Counterweight menu 744
Extending/ retracting the lifting cylinders 745
Locking/ Unlocking counterweight 747
12 6 8 Setting down counterweight for driving the truck crane 748
12 6 9 Slewing with the rigged counterweight 749
12 7 Rigging work on the main boom 751
12 7 1 Hook block on the bumper 751
Picking up the hook block 751
Attaching the hook block 752
12 7 2 Hook block on a separate vehicle 753
Picking up the hook block 754
Setting down the hook block 754
12 7 3 Hook blocks with ballast plates 756
Removing 756
Installing 757
Information on crane operation 757
Reeving the hoistrope 760
Unreeving hoistrope 763
12 7 5 Rigging aid for the hoist rope 764
Establishing/ disconnecting connections 764
Rigging the hoistrope 765
12 7 6 Possible reevings on the main boom 766
With 5 head sheaves 767
With 6 head sheaves 769
12 7 7 Installing/removing the lifting limit switch 772
Installing lifting limit switch 772
Removing the lifting limit switch 775
12 7 8 Locking/unlocking the lifting limit switch 777
Locking 777
Removing the lock 777
12 7 9 Anemometer and air traffic control light 778
Installing 778
Switching the air traffic control light on and off 779
Removing 780
12 8 Other rigging work 781
12 8 1 Folding mirrors in/out and adjusting 781
Camera on main boom 782
Camera on thehoists 785
Camera on the driver’s cab 785
Operating thecamera 786
12 8 3 Step at the crane cab 787
13 Driving with a rigged truck crane 789
13 1 Route 789
13 2 Permissible rigging modes and axle loads 790
13 2 1 To drive without a load 790
13 2 2 To drive with a load 790
13 2 3 Axle loads 791
13 3 Before driving the rigged truck crane 793
13 3 1 Check the tyre pressures and wind speed 793
13 3 2 Secure the superstructure against slewing 793
13 3 3 Putting the truck crane on the wheels 794
13 4 Driving from the driver’s cab 797
13 4 1 Preparing to drive 797
Transmission 797
Switching on separate steering 797
Connections 797
13 4 2 Whilst driving 798
13 5 Driving from the crane cab 799
13 5 1 Preparing to drive 800
13 5 2 Opening/closing the Driving menu 801
Opening 801
Closing 802
13 5 3 Steering system 803
Switching on 803
Adjusting the steering direction 803
Displays when steering 804
Normal steering mode 804
Separate steering 805
13 5 4 Operating the transmission 807
Driving direction 807
Crane’s hydraulic system on/off 807
Selecting the transmission mode 808
13 5 5 While driving 809
DMand RM transmission mode 809
Transmission mode D 809
Warning messages 809
13 5 6 Possible connections 810
Longitudinal/ transverse differential locks 810
13 5 7 After driving 812
14 Malfunctions during crane operation 813
14 1 Emergency stop switches 813
14 2 What to do when malfunctions occur during crane operation 815
The load can be set down 815
Load cannot be setdown 815
14 3 Fuses in the crane cab 817
Information on replacing fuses 817
14 4 Finding and eliminating malfunctions 822
14 4 1 Malfunctions on the engine 822
14 4 2 Malfunctions when operating with the hand-held control 822
14 4 3 Malfunctions on the turntable lock 823
14 4 4 Malfunctions when inclining the crane cab 823
14 4 5 Malfunctions on the main hoist 824
14 4 6 Malfunctions in the telescoping mechanism 825
14 4 7 Malfunctions in the hoist cameras 826
14 4 8 Malfunctions in the main boom camera 827
14 4 9 Malfunctions on the derricking gear 828
14 4 10 Malfunctions on the slewing gear 829
14 4 11 Malfunctions on the counterweight hoist unit 830
14 4 12 Malfunctions in the hydraulic system/hydraulic oil cooler 831
14 4 13 Malfunctions when driving from the crane cab 831
14 4 14 Malfunctions of the outriggers 832
14 5 Warning and error messages 833
Program version 833
14 5 1 Warning messages on the CCS display 833
Meaning of the symbols 834
14 5 2 Warning messages on the RCL display 837
14 5 3 Error messages on the CCS display 841
14 5 4 Malfunctions in the CraneStar system 843
14 6 Emergency operations and programs 845
14 6 1 Mechanical emergency activation for retracting 846
Prior to the emergency activation, check 846
Procedure 846
Mechanical emergency activation 847
14 6 2 Telescoping emergency program 849
Open the Emergency program submenu 849
Determining the type of error 850
If there is an erroron the length indicator 851
Tables for approaching the locking points 855
14 6 3 Entering the current telescoping 857
14 6 4 Emergency operation with the hand-held control 859
Preparations 859
Pre-selecting a power unit 860
Operating a powerunit 860
Stopping movements 861
Stopping movements in emergencies 862
Switching off theengine 862
14 7 Hydraulic emergency operation 863
14 7 1 Connect/Disconnect hoses 863
14 7 2 Establishing the hydraulic circuits required 864
Switching overvalves 864
For lifting/ lowering 866
14 7 3 Performing emergency activation 867
14 7 4 After the emergency activation 867
14 8 Hydraulic emergency operation BGR 159 869
14 8 1 Operating principle 869
14 8 2 Connecting/disconnecting hoses 870
For transformers 870
For the hand pump 871
14 8 3 Establishing the hydraulic circuits required 872
Switching positions of the valves 872
Switching over valves 872
For lifting/ lowering 874
For slewing 875
14 8 4 Performing emergency operation 875
Derricking 876
Lifting/lowering 877
Slewing 877
14 8 5 After emergency operation 878
Switching off emergency operation 878
Switching over to crane operation 878
Disconnecting thehoses 878
14 8 6 Emergency supply of another crane 879
After emergency supply 880
15 Index 881
A 883
B 883
C 883
D 886
E 888
F 890
H 890
I 890
K 891
L 891
M 892
O 892
P 893
R 894
S 895
T 896
V 898
W 898
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