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Grove GMK4100L-1
Manitowoc Grove GMK4100L-1 User Manual
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Rigging work
12.11 Other riggin
g work
12 - 138
3 302 690 en
Operating manual
GMK4100L-1
23.11.2017
Blank page
883
885
Table of Contents
Default Chapter
37
Table of Contents
37
Overview
67
Accidents
67
Branch Offices
69
Manitowoc Crane Care
69
Dealer List
69
Warranty Specifications
69
Terms Used
70
Technical Data
73
Maximum Lifting Capacity (DIN/ISO/EN)
73
Maximum Lifting Capacity (ASME B 30.5)
73
Dimensions and Weights of the Truck Crane, Axle Loads
74
Dimensions and Weights of Removable Parts
76
Carrier
81
Superstructure
85
Documentation Supplied
87
Questions on Documentation
88
Notes on the Operating Manual
89
What Do the Symbols Used Mean
89
How Is the Operating Manual Structured
91
How Do I Find the Information I Need
93
What Information Is Available for Operations Planning
96
Conversion Table for US Measuring Units
97
Training - Information
99
Identification
100
EC Declaration of Conformity
102
Basic Safety Instructions
103
Intended Use
103
Improper Use
104
Organisational Measures
105
Personnel Qualifications
107
Safety Instructions for Driving the Truck Crane
108
Safety Instructions for Crane Operation
109
Instructions on Transporting Persons
112
Operating Elements for Driving
115
Overview of the Operating Elements
115
On the Outside of the Truck Crane
116
Driver's Cab
120
15 Steering Column/Steering Wheel
121
Instrument Panel
121
Transmission Operating Elements
124
On-Board Computer
127
Tachograph
130
Heating and Air-Conditioning System
131
CCS Control Unit
135
CCS - Menu-Dependent Displays
136
CCS - Start Menu
137
CCS - Overview Menu Groups
138
Carrier Menu Group
140
Settings Menu Group
143
Menu Group Information
146
Various Controls Menu Group
150
Emergency Operations Menu Group
151
Outrigger Control Units
152
Short Description of the Operating Elements
153
Definition of Information Relating to Directions of Movement
154
General Rules for Buttons and Symbols on the Display
155
Motor
156
Adblue System
158
Battery Master Switch
159
Electrical System
160
Crane Control CCS
161
Transmission
163
Reverse Camera
166
Birdview System 270
167
Transfer Case
169
Final Drive
170
Brakes
172
Steering/Separate Steering
174
Suspension
178
Lighting/Windscreen Wipers/Horn
179
Level Adjustment System
182
Tachograph/Speedometer
184
Diagnostics
185
Push-Up Roof
185
On-Board Computer
186
Starting the Engine for Driving / Switching It off
195
Starting the Engine from the Driver's Cab
195
CHECKLIST: Starting the Engine
195
CHECKLIST: at Low Temperatures
198
Filling up
199
Checks before Starting the Engine
202
Switch the Ignition on
203
Lamp Test/Equalisation of the Switching States
204
Display - Setting the Brightness
205
Starting the Engine
207
Checks after Starting the Engine
209
Setting the Idling Speed
211
Switch off the Engine
212
At the Ignition Lock and with the Outrigger Control Units
212
Using the Emergency Stop Switches
213
Air Intake Inhibitor
214
Driving
215
Before Driving
215
CHECKLIST: Checks before On-Road Driving
215
Check the Condition of the Truck Crane
221
Adjusting the Seat and the Steering Column
227
Switching the Suspension On/Off
230
Setting the Tachograph
232
Setting the Time
237
Displaying and Resetting Operating Hours
238
Operating the Transmission
239
Switching on
239
Switching the Transmission to the Neutral Position
240
Selecting the Direction of Travel and Starting Gear
241
Changing the Operating Mode
243
Starting
244
Driving and Changing Gears
245
Changing the Driving Direction
247
Stopping
247
On the Roller Type Dynamometer
248
Preheating Transmission
248
Driving the Truck Crane and Switching It off
249
Checks Whilst Driving
249
Cruise Control
252
Temposet
254
Driving Downhill
255
Driving Uphill
258
Overriding Torque Reduction
259
Switching the Truck Crane off
260
Fold-Up Berth
262
Off-Road Driving
263
Transfer Case - Switching the Off-Road Gear On/Off
264
Longitudinal and Transverse Differential Locks
265
Operating the Level Adjustment System
267
Freeing Truck Crane Stuck in Terrain
271
Separate Steering
273
Switching to Separate Steering
274
Switching to Normal Steering Mode
277
Switching Units of Measure
278
Heating and Air-Conditioning System
279
Standard Heating System
279
Air-Conditioning System
282
Auxiliary Water Heating System
284
Auxiliary Air Heater
290
Radio
294
Towing a Trailer
295
Driving Modes
301
6.1 Driving Modes
302
How to Use the Tables
302
Maximum Permitted Speeds with an Axle Load of over 12 T (26,500 Lbs)
307
Weighing the Truck Crane
309
Rigging Work for Driving with a Dolly
313
Switching on the Slewing Gear Freewheel
314
Switching on the Boom Floating Position
315
Switching on Boom Pre-Tensioning
316
Rigging the Auxiliary Hoist
317
Slinging the Auxiliary Hoist
317
CHECKLIST: Installing the Auxiliary Hoist
318
CHECKLIST: Removing the Auxiliary Hoist
319
Making/Breaking the Connection between the Auxiliary Hoist and the Turntable
320
Establishing/Disconnecting the Hydraulic Connections
321
Disconnecting/Establishing the Electrical Connection
322
Making/Breaking the Connection to the Central Lubrication
323
Transporting the Auxiliary Hoist
324
Check that the Auxiliary Hoist Is Functioning Properly
325
Rigging Aid for the Hoist Rope
326
Installing/Removing the Outrigger Beams
329
CHECKLIST: Removing the Outrigger Beams
330
CHECKLIST: Installing the Outrigger Beams
332
Centre of Gravity Data
334
Preparations - for Removal
334
Preparations - on the Truck Crane
335
Removing/Attaching Outrigger Pads
336
Disconnecting/Establishing Hydraulic Connection
338
Disconnecting/Establishing the Electrical Connection
339
Unscrewing/Screwing in the Spacers
340
Disconnecting/Establishing the Connections to the Supporting Box
342
Pulling Out/Inserting the Outrigger Beam
342
Transporting the Outrigger Beams
346
Note on Error Messages with Removed Outrigger Beams
347
Transport
349
Transport with Transport Vehicle
349
CHECKLIST: Checks before Transport
350
Drive the Truck Crane on to the Transport Vehicle
352
Transport by Ship
354
Malfunctions in Driving Mode
355
Emergency Stop Switch
355
Procedure During Malfunctions
356
What to Do When a Malfunction Occurs in Road Traffic
356
Procedure During Engine Malfunctions
357
Procedure During Transmission Malfunctions
358
Warning and Error Messages
359
Warning or Malfunction Messages on the Instrument Panel
359
Warning and Malfunction Messages on the On-Board Computer Display
363
Warning Messages on the CCS Display
367
Engine/Transmission Error Messages
371
Troubleshooting
373
Malfunctions on the Engine
373
Faults on the Adblue System
375
Differential Lock Malfunctions
376
Transfer Case Malfunctions
376
Malfunctions in the Transmission
377
Malfunctions of the Steering
378
Malfunctions of the Service Brake
379
Malfunctions of the Level Adjustment System
380
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
380
Emergency Operation and Breakdown Assistance
381
Starting the Truck Crane Externally
381
Battery Charger
382
Towing the Truck Crane
383
Wheel Change
387
Inflating the Tyres Yourself
391
Emergency Operation, Steering 3Rd Axle Line
393
Tilting/Lowering the Driver's Cab
397
Prerequisites and Information on Tilting
397
Tilting and Lowering the Driver's Cab
398
Fuses on the Carrier
403
Fuses in the Driver's Cab
404
Fuses in the Battery Box
410
Operating Elements for Crane Operation
411
Overview of the Operating Elements
411
Exterior of the Truck Crane
412
Crane Cab
416
Control Panels
422
Control Lever Assignment
424
CCS Control Unit
426
Menu-Independent Displays
428
CCS - Start Menu
429
CCS - Overview Menu Groups
432
Superstructure Menu Group
436
Menu Group Outrigger/Driving
439
Rcl/Telescoping Menu Group
447
Active Working Range Limiter Menu Group
457
Information Menu Group 1
462
Heating/Engine/Additional Equipment Menu Group
464
Telescoping Emergency Program Menu Group
469
Settings Menu Group
474
Information Menu Group 2
480
Various Controls
485
RCL Control Unit
486
Menu-Independent Displays
487
RCL - Menus
488
Hand-Held Control
493
Outriggers Control Units
495
Short Description of the Operating Elements
499
Definition of Information Relating to Directions of Movement
499
General Rules for Buttons and Symbols on the Display
500
Engine
501
Adblue System
502
Seat Contact Switch and Dead Man's Switch
504
Crane Control CCS
505
Outrigger - Crane Cab
510
Outrigger Control Units
513
Raise Axle
516
Inclination Indicators
518
Outrigger Pressure Displays
519
Anemometer Displays
519
Counterweight Menu
520
Main Hoist
524
Auxiliary Hoist
526
Slewing Gear
528
Derricking Gear
530
Telescoping Mechanism
532
Hydraulic System
538
Superstructure Lock/House Lock Menu
539
Remote Control
542
Rated Capacity Limiter (RCL)
543
Electrical System
555
Lighting, Windscreen Wiper/Washing System
556
Hand-Held Control
560
Windows and Doors
564
Diagnostics
566
Other
566
Short Description of the Operating Elements - Driving from the Crane Cab
567
Driving Mode Menu
567
Transmission
568
Final Drive
569
Brakes
571
Steering
573
Starting/Switching off the Engine - for Crane Operation
577
When Starting the Engine for the First Time in the Day
577
Starting the Engine - from the Crane Cab
579
Check the Fuel Level and Adblue Level
579
Checks before Starting the Engine
580
Switch the Ignition on
581
Comparison of Switching States
582
Display - Setting the Brightness
582
Starting the Engine
583
Checks after Starting the Engine
584
Setting the Idling Speed
585
Starting the Engine - with the Hand-Held Control
586
Switch off the Engine
587
At the Ignition Lock and with Hand-Held Control
587
With the Idling Button
587
Using the Emergency Stop Switches
588
Crane Operation
589
Before Operating the Crane
589
CHECKLIST: Checks before Operating the Crane
589
Check the Condition of the Truck Crane
593
Adjusting the Crane Cab Seat and Front Control Panel
596
Checking the Safety Equipment
598
Earthing the Load
601
Preheating Hydraulic Oil
602
Locking/Unlocking the Superstructure
603
Switching the Houselock On/Off
605
Standard Slewing Range Type
609
Permissible Slewing Ranges and Working Positions
609
Maxbase Slewing Range Type
611
Specifications in the Lifting Capacity Tables
612
Lifting Capacities and Slewing Ranges for Outrigger Spans Without Separate Lifting Capacity Tables
616
Operation of the Rated Capacity Limiter
617
Switch on the RCL
618
Enter Rigging Mode
620
Pre-Selecting Telescoping
628
Confirm the Rigging Mode and Lifting Capacity Table
629
Checks before Operating the Crane
633
Display During the Crane Operation
637
RCL Early Warning
645
RCL Shutdown
645
Displaying the Lifting Capacity Tables
647
RCL Override - Version B
655
Datalogger
656
Crane Operation with Main Boom
661
Checks During Crane Operation
661
Main Hoist
663
Auxiliary Hoist
667
Lifting Limit Switch and Lowering Limit Switch
670
Derricking Gear
673
Telescoping Mechanism
677
High-Speed Mode
701
Slewing Gear
703
Switching the Reduction of Slewing Speed on and off
709
Possible Movement Combinations
710
Settings and Displays for Crane Operation
711
Inclining the Crane Cab
711
Setting the Idling Speed
712
Adjusting the Wiper Stroke Interval of the Windscreen Wiper
712
Limiting the Power Unit Speeds
713
Economy Mode
714
Switching Units of Measure
716
Setting the Characteristic Curves for the Control Levers
717
Using the Slewable Spotlights
718
Overriding Torque Reduction
720
Displaying the Operating Hours
721
Working Range Limiter
723
Viewing Current Settings
724
Opening the Working Range Limiter Menu
725
Entering Limit Values
728
Entering Limit Values Manually
732
Switching Monitoring Functions On/Off
734
Shutdown by Working Range Limiter
735
Work Break
737
In Case of Short Work Breaks
737
In Case of Work Breaks of more than 8 Hours
738
Heating and Air-Conditioning System
739
Standard Heating System
739
Air-Conditioning System
741
Auxiliary Heater
743
Cranestar System
746
Overview
746
Position of the Components
746
Rigging Work
747
Rigging Work Checklists for Crane Operation with the Main Boom
747
CHECKLIST: Rigging
747
CHECKLIST: Unrigging
753
Choice of a Suitable Positioning Site
757
Determining the Required Load-Bearing Area
757
Safe Distance from Slopes and Pits
760
Earthing the Truck Crane
761
Safe Distance from Overhead Power Lines
762
Rigging Work after Driving with a Dolly
765
Switching off the Boom Floating Position
765
Switching off the Slewing Gear Freewheel
766
Switching off Boom Pre-Tensioning
767
Connecting/Disconnecting the Hand-Held Control
769
Starting the Engine for Rigging
773
Slewing Range - Only with the Standard Slewing Range Type
775
Representation in the Lifting Capacity Tables
775
Enabled Outrigger Spans
776
Outriggers - Overview - Maxbase Slewing Range Type
777
Definitions
777
Representation in the Lifting Capacity Tables
779
Enabled Outrigger Spans
780
Outrigger Operation
785
CHECKLIST: Extending the Outriggers
785
CHECKLIST: Retracting the Outriggers
787
Preparing the Truck Crane
788
Setting the Outrigger Spans
790
Extending/Retracting Outrigger Beams
793
Moving the Outrigger Pads into Operating/Driving Position
797
Enlarging the Load-Bearing Area
799
Extending/Retracting Supporting Cylinders
800
Levelling the Truck Crane on Outriggers Horizontally
804
Levelling the Free-Standing Truck Crane
808
Operating the Axle Raising System
810
Outrigger Pressure Display
812
Rigging/Unrigging the Counterweight
815
Information on Rigging
815
Counterweight Sections
817
Identification
819
Slinging Points on the Counterweight Sections
820
CHECKLIST: Rigging the Counterweight
822
CHECKLIST: Unrigging the Counterweight
824
Assembling Counterweight Combination
826
Counterweight Hoist Unit
831
Setting down Counterweight for Driving
838
Unlocking/Locking the Rear Counterweight Platform
841
Slewing with Rigged Counterweight
843
Rigging Work on the Main Boom
845
Hook Block on the Bumper
845
Hook Block on a Separate Vehicle
847
Hook Block, Separable
850
Hook Block with Ballast Plates
852
Reeving and Unreeving the Hoist Rope
854
Possible Reevings on the Main Boom
860
Installing/Removing the Lifting Limit Switch
866
Locking/Unlocking the Lifting Limit Switch
871
Anemometer and Air Traffic Control Light
872
Other Rigging Work
875
Railings on the Turntable
875
Folding the Mirrors in and Out, and Adjusting Them
876
Slinging Points for Personal Protective Equipment
877
Cameras for Crane Operation
878
Step at the Crane Cab
883
Driving with a Rigged Truck Crane
885
Route
885
Permissible Rigging Modes and Axle Loads
886
To Drive Without a Load
889
To Drive with a Load
889
Axle Loads
890
Before Driving the Rigged Truck Crane
891
Check the Tyre Pressures and Wind Speed
891
Secure the Superstructure against Slewing
891
Putting the Truck Crane on the Wheels - with Raise Axle Function
892
Putting the Truck Crane on the Wheels - with the Outriggers
894
Driving from the Driver's Cab
897
Preparing to Drive
897
Whilst Driving
898
After Driving
899
Driving from the Crane Cab
901
Preparing to Drive
902
Opening/Closing the Driving Menu
902
Steering
905
Operating the Transmission
911
Whilst Driving
912
Possible Connections
913
After Driving
915
Malfunctions During Crane Operation
917
Emergency Stop Switch
917
What to Do When Malfunctions Occur During Crane Operation
918
Warning and Error Messages
919
Warning Messages on the CCS Display
919
Error Messages on the CCS Display
923
Warning Messages on the RCL Display
925
Troubleshooting
929
Malfunctions on the Engine
929
Malfunctions on the Main Hoist/Auxiliary Hoist
929
Malfunctions in the Hoist Cameras
931
Malfunctions in the Main Boom Camera
931
Malfunctions on the Derricking Gear
932
Malfunctions in the Telescoping Mechanism
933
Malfunctions on the Slewing Gear
934
Malfunctions on the Counterweight Hoist Unit
936
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
936
Malfunctions When Inclining the Crane Cab
936
Malfunctions When Operating with the Hand-Held Control
937
Malfunctions When Inclining the Crane Cab
937
Malfunctions When Raising the Axles
937
Malfunctions of the Outriggers
938
Malfunctions on the Turntable Lock
938
Malfunctions on the CCS/RCL Control Units
939
Malfunctions When Driving from the Crane Cab
939
Malfunctions on the Cranestar System
940
Emergency Operations and Programs
943
Mechanical Emergency Activation for Retracting
944
Telescoping Emergency Program
947
Entering the Current Telescoping
959
Emergency Operation with the Hand-Held Control
961
Notes on Slewing in Emergency Operation
964
Hydraulic Emergency Operation with the Hand Pump
967
Switching over the Crane's Hydraulic System
967
Establishing the Hydraulic Circuits Required
968
Performing Emergency Activation
971
After Emergency Activation
971
14.7 Hydraulic Emergency Operation as Per BGR 159
973
Applications and Function
973
CHECKLIST: Emergency Operation
975
CHECKLIST: after Emergency Operation
976
Connecting/Removing Transformer - for Self-Sufficiency
977
Switching Emergency Operation On/Off
979
Connecting/Removing Transformer - for External Energy Source
980
Establishing the Required Hydraulic Circuits
981
Performing Emergency Operation
985
Emergency Supply of Another Crane
987
Fuses in the Crane Cab
989
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Manitowoc Grove GMK4100L-1 Specifications
General
Brand
Manitowoc
Model
Grove GMK4100L-1
Category
Construction Equipment
Language
English
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