Manitowoc Grove GMK 4100L-1 Operating Manual Download Page 373

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Malfunctions in driving mode

8.4 Troubleshooting

Operating manual

3 302 690 en

8 - 19

GMK4100L-1

201

8.4

Troubleshooting

8.4.1

Malfunctions on the engine

In addition to this information;

Separate engine operating instructions,

provided by the manufacturer

Malfunction

Cause

Solution

Engine does not start –
Starter does not turn

Battery master switch is
switched off

Switch on the battery
master switch;

p. 4 - 9

Switch the ignition off

Switch the ignition on

p. 4 - 9

Transmission not in neutral
position

Switching the

transmission to the neutral
position

, p. 5 - 26

Parking brake released

Lock the parking brake;

p. 5 - 46

Fuse F1/1, F1/2 blown

Replace blown fuses;

p. 8 - 49

Emergency stop switch
pressed

Release the emergency stop
switch;

p. 4 - 19

Engine does not start –
Starter turns

Batteries insufficiently
charged

Charge the batteries;

Maintenance manual

The symbol is displayed

Fuel tank empty

1. Refuel;

p. 4 - 5

2. Bleed the fuel system;

Maintenance manual

Separate engine operating

instructions, provided by the
manufacturer

The symbol is displayed

Air intake inhibitor closed

Releasing the air intake

inhibitor

, p. 4 - 20

The lamp does not light
after the ignition is
switched on when the
engine is cold

Fuse F6/8 blown

Replace blown fuses;

p. 8 - 49

The symbol is displayed

Air filter clogged

Replace the dry air filter;

Maintenance manual

The symbol is displayed

Coolant level too low

Top up coolant;

Maintenance manual

Summary of Contents for Grove GMK 4100L-1

Page 1: ...Operating manual 3 302 690 en 23 11 2017 ...

Page 2: ...woc Crane Group Germany GmbH Industriegelände West D 26389 Wilhelmshaven Germany Phone 49 0 44 21 294 0 Fax 49 0 44 21 294 301 The passing on or reproduction of this document as well as the utilisation and disclosure of its contents is prohibited unless expressly permitted Infringement will incur liability for compensation All rights pertaining to registration of patent or utility model are reserv...

Page 3: ...nt crane types of what per cent you have to move the outrigger beams on the control units in order to obtain the desired outrigger span H Depending on the operating instructions supplied the outrigger spans are given as the overall width or additionally as an individual width s GMK5250L GMK5200 1 GMK5180 1 Length specifications Percentages Overall widths Individual widths Control unit Lifting capa...

Page 4: ... 2 ft 1 250 m 4 1 ft 0 0 GMK4100L 1 Length specifications Percentages Overall widths Individual widths Control unit Lifting capacity table 7 200 m 23 6 ft 3 600 m 11 8 ft 100 100 6 250 m 20 6 ft 3 125 m 10 3 ft 81 80 5 300 m 17 4 ft 2 650 m 8 7 ft 61 60 3 800 m 12 4 ft 1 900 m 6 2 ft 31 40 2 340 m 7 6 ft 1 170 m 3 8 ft 0 0 GMK3060 Length specifications Percentages Overall widths Individual widths ...

Page 5: ...f the operating elements Driving from the crane cab These sections replace the information in the operating manual about the Driving menu Note These additional pages describe the option of carrying out crane move ments whilst driving In the case of the GMK4100L 1 the crane movements are disabled whilst driving the symbol 1 remains grey when in driving mode and the crane s hydraulic system Driving ...

Page 6: ...16 01 2018 2 3 302 710 en Additional pages GMK4100L 1 Overview of Driving menu I ...

Page 7: ...ential locks on off à p 9 à p 9 11 Longitudinal differential lock display Longitudinal differential lock on off à p 9 à p 9 12 Supply pressure brake circuits 1 and 2 display à p 10 13 Parking brake indicator lamp à p 10 14 Display of crane s hydraulic system driving mode on off à p 6 15 Steering mode switched on indicator 16 Normal steering mode on road driving on à p 13 17 Separate steering manua...

Page 8: ...16 01 2018 4 3 302 710 en Additional pages GMK4100L 1 Blank page ...

Page 9: ... Select symbol 1 and confirm menu is opened The menu is also opened the first time the parking brake is released à p 11 Applying The parking brake must be engaged Crane operation mode must be switched on Press button 2 or 3 once menu is closed à p 17 1 Display in the front semi circle A 2 Display in the rear semi circle B display of symbol 3 à p 20 ...

Page 10: ...ched on Select and confirm symbol 2 Symbol 2 white Symbol 1 green Buttons 3 have High speed mode function Transmission in gear 15 Crane s hydraulic system Driving mode off à Selecting the operating mode p 17 Display of crane s hydraulic system driving mode on off White Driver s cab Ignition key in position 1 Crane cab Operating elements for driving active Red Driver s cab Ignition key not in posit...

Page 11: ...ransmission mode R s To switch on Select and confirm symbol letter is white no gear is engaged To switch off Shift to a different gear letter is blue To switch on Select and confirm symbol letter is white Select forwards starting gear Crane s hydraulic system Driving mode off Crane movements disabled To switch off Shift to a different gear letter is blue To switch on Select and confirm symbol lett...

Page 12: ... transmission will not shift Crane s hydraulic system Driving mode on Crane movements released To switch off Shift to a different gear letter is blue To switch on Select and confirm symbol letter is white Gear 1 reverse on transmission will not shift Crane s hydraulic system Driving mode on Crane movements released To switch off Shift to a different gear letter is blue ...

Page 13: ... lock display B transverse differential lock display The current status is shown using different symbols Opening Select symbol 1 and confirm menu is opened To switch on Select symbol 1 and confirm symbol is red To switch off Select symbol 1 and confirm symbol is green To switch on Select symbol 1 and confirm symbol is red To switch off Select symbol 1 and confirm symbol is green 1 Green locks off ...

Page 14: ...of the braking force CCS display Supply pressure brake circuits 1 and 2 display Parking brake indicator lamp Side panel from above Parking brake indicator lamp Red Supply pressure less than approx 5 bar Green Supply pressure greater than 5 5 bar Red Parking brake applied Grey Parking brake released On Parking brake applied Out Parking brake released ...

Page 15: ...for the first time after ignition on Press up once Driving menu opens Apply the service brake Wait for about 5 seconds Press up once lamp 1 goes out Parking brake released After the first release Apply the service brake Press up once lamp 1 goes out Parking brake released à After driving p 30 Opening Select symbol 1 and confirm menu is opened 1 Straight ahead 2 Driving around corners 3 Crab travel...

Page 16: ...ompared to steering wheel To switch over Select the desired symbol and confirm the setting will be saved Function Press button 1 to the right the wheels turn to the right steering wheel turns to the right Press button 1 to the left the wheels turn to the left steering wheel turns to the left Function Press button 1 to the right the wheels turn to the left steering wheel turns to the left Press but...

Page 17: ...mal steering mode on road driving on off s To switch on Select symbol 1 and confirm symbol 2 is displayed To switch off Select a different steering mode symbol 3 à p 22 To switch on Select symbol 1 and confirm symbol 2 is displayed To switch off Select a different steering mode symbol 3 à p 22 To switch on Select symbol 1 and confirm symbol 2 is displayed To switch off Select a different steering ...

Page 18: ...mbol 2 is displayed Steer 1st and 2nd axle lines with the button 1 to the left 3rd and 4th axle lines turn to the left to the right 3rd and 4th axle lines turn to the right à p 24 to the left 1st and 2nd axle lines turn to the left 3rd and 4th axle lines the matching steering angle for steering mode to the right 1st and 2nd axle lines turn to the right 3rd and 4th axle lines the matching steering ...

Page 19: ... load does not swing G Risk of accidents due to partially obstructed view of the truck crane While driving always stay in visual or radio contact with a banksman who can observe the parts which you cannot see such as the erected main boom G Risk of overturning by slewing the superstructure When driving with the truck crane rigged the slewing gear must be switched off slewing gear brake must be eng...

Page 20: ...on key must be in position 1 so that the steering cannot block The driver s cab must be locked with the second ignition key in order to secure it against unauthorised use e g braking The parking brake must be applied In the crane cab The ignition must be switched on The hand held control must be disconnected and bridging plugs plugged into all the sockets The superstructure must be locked The park...

Page 21: ...vailable operating modes are crane operation and driving Crane operation Symbol 1 green symbol 2 white In this operating mode you can perform crane operation in exactly the same way as when the Driving menu is closed This operating mode is selected when the menu is opened Driving Symbol 1 white symbol 2 green In this operating mode the operating elements for driving are activated and you can choos...

Page 22: ... speed function The crane s hydraulic system Driving mode is switched off symbol 6 grey The engine speed for crane operation is regulated using the pedal 5 In driving operation The symbol 2 is green The transmission is in neutral position display 1 The operating elements 3 are released The buttons 4 are assigned the Steering function The crane s hydraulic system Driving mode is switched on symbol ...

Page 23: ...he Driving menu If you want to stop driving à After driving p 30 Apply the parking brake Press button 3 down once lamp 2 lights up Switch to crane operation mode Select symbol 1 and confirm symbol is white Close the Driving menu Press button 4 or 5 once 1 Arrow orange crane s hydraulic system Driving mode on The transmission mode RM DM or neutral position N is selected you can carry out crane move...

Page 24: ...g wheel Turn to the right Press button 1 to the right steering wheel turns to the right with right control lever Turn to the left Press button 1 to the left steering wheel turns to the left with right control lever In the rear semi circle The steering direction can be switched between Steering wheel and Reversed The current steering direction is displayed With steering direction Reversed symbol 2 ...

Page 25: ...ions and descriptions in the following sections refer to the steer ing direction Steering wheel When you switch to the Reversed steering direc tion remember that the wheels will turn in the opposite direction Displays when steering The current steering angle of the wheels is displayed The symbols show the current steering angle s 1 Steering direction Steering wheel 2 Steering direction Reversed co...

Page 26: ...arate steering is switched on you can turn the wheels of the front and rear axle lines in the same direction the truck crane drives sideways Switching to separate steering Select and confirm the symbol for the desired steering mode The symbol 4 indicates the selected steering mode e g driving around corners If the error symbol is displayed contact Manitowoc Crane Care 1 Manual 3rd and 4th axle lin...

Page 27: ...ion is reached The electronics will register the steering angle on the 1st and 2nd axle lines and steer the wheels of the 3rd and 4th axle lines correspondingly A When driving around corners The 3rd and 4th axle lines are steered in the opposite direction to the 1st and 2nd axle lines B For crab travel mode The 3rd and 4th axle lines are steered in the same direction as the 1st and 2nd axle lines ...

Page 28: ...ton 2 The axle lines are steered as long as you keep the button pressed or until an end position is reached A For driving around corners Steer the 3rd and 4th axle lines opposite to the 1st and 2nd axle lines B For crab travel mode Steer the 3rd and 4th axle lines in the same direction as the 1st and 2nd axle lines To turn to the left Press buttons 1 2 to the left To turn to the right Press button...

Page 29: ...the current wheel position is displayed Select and confirm the symbol 3 symbol 4 is displayed If the error symbol is displayed contact Manitowoc Crane Care Steering in normal steering mode The symbol 2 is displayed Steer the 1st and 2nd axle lines with the button 1 The wheels of the 4th axle line are turned correspondingly for driving around the corner To turn to the left Press button 1 to the lef...

Page 30: ...ions Switch to transmission mode DM or RM The crane s hydraulic system Driving mode is switched on symbol 1 orange The transmission shifts only into the 1st gear reverse or forwards The speed is limited to approx 5 km h 3 mph In these transmission modes you can start moving more slowly than in the transmission modes D or R These transmission modes are intended for manoeuvring mode and for driving ...

Page 31: ...h gear Use this transmission mode only when The main boom is completely retracted The main boom is resting in the boom rest The outrigger beams cylinders are fully retracted Warning messages If a symbol is displayed in the area 1 refer to the sections for warning messages on the CCS display and error messages on the CCS display à Supplied operating manual G Risk of accidents when driving with a li...

Page 32: ...ferential locks With a 10 x 8 x 10 drive the drive of the 2nd axle line is switched on and off together with the longitudinal differential locks Straighten the steering Stop the truck crane For switching on and off the current speed needs to be under about 5 km h 3 mph S Risk of damage to the differential locks Leave the transverse differential locks switched on only for as long as necessary Alway...

Page 33: ... slowly display first symbol 2 yellow then symbol 3 red differential locks on Switch off Select and confirm the symbol 1 for the Longitudinal differential locks A or Transverse differential locks B Display first symbol 2 yellow then symbol 3 green differential locks off If symbol 3 is not green then drive back and forth slowly If the error symbol is displayed contact Manitowoc Crane Care ...

Page 34: ... off transverse differential locks 2 Switch on normal steering mode 4 Press button 7 down once The lamp 6 lights up symbol 5 is red the parking brake is applied If necessary switch the engine off à Supplied operating manual Remove the ignition key from the ignition lock in the driver s cab and lock the driver s cab to prevent unauthorised access Support the truck crane on outriggers if you do not ...

Page 35: ...ing elements for driving 4 Starting the engine for driving switching it off 5 Driving 6 Driving modes 7 Transport 8 Malfunctions in driving mode 9 Operating elements for crane operation 10 Starting switching off the engine for crane operation 11 Crane operation 12 Rigging work 13 Driving with a rigged truck crane 14 Malfunctions during crane operation 15 Index ...

Page 36: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 ...

Page 37: ...ane axle loads 3 8 1 5 4 Dimensions and weights of removable parts 3 10 1 5 5 Carrier 3 15 1 5 6 Superstructure 3 19 1 6 Documentation supplied 3 21 1 6 1 Questions on documentation 3 22 1 7 Notes on the operating manual 3 23 1 7 1 What do the symbols used mean 3 23 1 7 2 How is the operating manual structured 3 25 1 7 3 How do I find the information I need 3 27 1 7 4 What information is available...

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Page 39: ...instructions 2 1 Intended use 4 1 2 1 1 Improper use 4 2 2 2 Organisational measures 4 3 2 3 Personnel qualifications 4 5 2 4 Safety instructions for driving the truck crane 4 6 2 5 Safety instructions for crane operation 4 7 2 6 Instructions on transporting persons 4 10 ...

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Page 41: ...16 Various controls menu group 5 36 3 1 17 Emergency operations menu group 5 37 3 1 18 Outrigger control units 5 38 3 2 Short description of the operating elements 5 39 3 2 1 Definition of information relating to directions of movement 5 40 3 2 2 General rules for buttons and symbols on the display 5 41 3 2 3 Motor 5 42 3 2 4 AdBlue system 5 44 3 2 5 Battery master switch 5 45 3 2 6 Electrical sys...

Page 42: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 2 22 Front flap 5 73 3 2 23 Windows and doors 5 74 3 2 24 Access ladders and ladders 5 77 ...

Page 43: ... 4 Checks before starting the engine 6 8 4 1 5 Switch the ignition on 6 9 4 1 6 Lamp test equalisation of the switching states 6 10 4 1 7 Display setting the brightness 6 11 4 1 8 Starting the engine 6 13 4 1 9 Checks after starting the engine 6 15 4 1 10 Setting the idling speed 6 17 4 2 Switch off the engine 6 18 4 2 1 At the ignition lock and with the outrigger control units 6 18 4 2 2 Using th...

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Page 45: ...ng the driving direction 7 33 5 2 8 Stopping 7 33 5 2 9 On the roller type dynamometer 7 34 5 2 10 Preheating transmission 7 34 5 3 Driving the truck crane and switching it off 7 35 5 3 1 Checks whilst driving 7 35 5 3 2 Cruise control 7 38 5 3 3 Temposet 7 40 5 3 4 Driving downhill 7 41 5 3 5 Driving uphill 7 44 5 3 6 Overriding torque reduction 7 45 5 3 7 Switching the truck crane off 7 46 5 3 8...

Page 46: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 5 6 2 Air conditioning system 7 68 5 6 3 Auxiliary water heating system 7 70 5 6 4 Auxiliary air heater 7 76 5 7 Radio 7 80 5 8 Towing a trailer 7 81 ...

Page 47: ...ns 8 21 6 4 6 Disconnecting establishing the electrical connection 8 22 6 4 7 Making breaking the connection to the central lubrication 8 23 6 4 8 Transporting the auxiliary hoist 8 24 6 4 9 Check that the auxiliary hoist is functioning properly 8 25 6 4 10 Rigging aid for the hoist rope 8 26 6 5 Installing removing the outrigger beams 8 29 6 5 1 CHECKLIST Removing the outrigger beams 8 30 6 5 2 C...

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Page 49: ...3 302 690 en GMK4100L 1 23 11 2017 7 7 Transport 7 1 Transport with transport vehicle 9 1 7 1 1 CHECKLIST Checks before transport 9 2 7 1 2 Drive the truck crane on to the transport vehicle 9 4 7 2 Transport by ship 9 6 ...

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Page 51: ...stem 10 21 8 4 3 Differential lock malfunctions 10 22 8 4 4 Transfer case malfunctions 10 22 8 4 5 Malfunctions in the transmission 10 23 8 4 6 Malfunctions of the steering 10 24 8 4 7 Malfunctions of the service brake 10 25 8 4 9 Malfunctions of the level adjustment system 10 26 8 4 10 Malfunctions in the hydraulic system hydraulic oil cooler 10 26 8 5 Emergency operation and breakdown assistance...

Page 52: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 ...

Page 53: ...p 11 59 9 1 16 Settings menu group 11 64 9 1 17 Information menu group 2 11 70 9 1 18 Various controls 11 75 9 1 19 RCL control unit 11 76 9 1 20 Menu independent displays 11 77 9 1 21 RCL menus 11 78 9 1 22 Hand held control 11 83 9 1 23 Outriggers control units 11 85 9 2 Short description of the operating elements 11 89 9 2 1 Definition of information relating to directions of movement 11 89 9 2...

Page 54: ...Rated capacity limiter RCL 11 133 9 2 23 Electrical system 11 145 9 2 24 Lighting windscreen wiper washing system 11 146 9 2 25 Hand held control 11 150 9 2 26 Windows and doors 11 154 9 2 27 Diagnostics 11 156 9 2 28 Other 11 156 9 3 Short description of the operating elements driving from the crane cab 11 157 9 3 1 Driving mode menu 11 157 9 3 2 Transmission 11 158 9 3 3 Final drive 11 159 9 3 4...

Page 55: ...e starting the engine 12 4 10 2 3 Switch the ignition on 12 5 10 2 4 Comparison of switching states 12 6 10 2 5 Display setting the brightness 12 6 10 2 6 Starting the engine 12 7 10 2 7 Checks after starting the engine 12 8 10 2 8 Setting the idling speed 12 9 10 3 Starting the engine with the hand held control 12 10 10 4 Switch off the engine 12 11 10 4 1 At the ignition lock and with hand held ...

Page 56: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 ...

Page 57: ...out separate lifting capacity tables 13 28 11 4 Operation of the rated capacity limiter 13 29 11 4 1 Switch on the RCL 13 30 11 4 2 Enter rigging mode 13 32 11 4 3 Pre selecting telescoping 13 40 11 4 4 Confirm the rigging mode and lifting capacity table 13 41 11 4 5 Checks before operating the crane 13 45 11 4 6 Display during the crane operation 13 49 11 4 7 RCL early warning 13 57 11 4 8 RCL sh...

Page 58: ... 11 6 10 Displaying the operating hours 13 133 11 7 Working range limiter 13 135 11 7 1 Viewing current settings 13 136 11 7 2 Opening the working range limiter menu 13 137 11 7 3 Entering limit values 13 140 11 7 4 Entering limit values manually 13 144 11 7 5 Switching monitoring functions on off 13 146 11 7 6 Shutdown by working range limiter 13 147 11 8 Work break 13 149 11 8 1 In case of short...

Page 59: ...tion in the lifting capacity tables 14 29 12 6 2 Enabled outrigger spans 14 30 12 7 Outriggers Overview MAXbase slewing range type 14 31 12 7 1 Definitions 14 31 12 7 2 Representation in the lifting capacity tables 14 33 12 7 3 Enabled outrigger spans 14 34 12 8 Outrigger operation 14 39 12 8 1 CHECKLIST Extending the outriggers 14 39 12 8 2 CHECKLIST Retracting the outriggers 14 41 12 8 3 Prepari...

Page 60: ...ok block on the bumper 14 99 12 10 2 Hook block on a separate vehicle 14 101 12 10 3 Hook block separable 14 104 12 10 4 Hook block with ballast plates 14 106 12 10 5 Reeving and unreeving the hoist rope 14 108 12 10 6 Possible reevings on the main boom 14 114 12 10 7 Installing removing the lifting limit switch 14 120 12 10 8 Locking unlocking the lifting limit switch 14 125 12 10 9 Anemometer an...

Page 61: ...erstructure against slewing 15 7 13 3 3 Putting the truck crane on the wheels with Raise axle function 15 8 13 3 4 Putting the truck crane on the wheels with the outriggers 15 10 13 4 Driving from the driver s cab 15 13 13 4 1 Preparing to drive 15 13 13 4 2 Whilst driving 15 14 13 4 3 After driving 15 15 13 5 Driving from the crane cab 15 17 13 5 1 Preparing to drive 15 18 13 5 2 Opening closing ...

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Page 63: ...4 11 Malfunctions when operating with the hand held control 16 21 14 4 12 Malfunctions when inclining the crane cab 16 21 14 4 13 Malfunctions when raising the axles 16 21 14 4 14 Malfunctions of the outriggers 16 22 14 4 15 Malfunctions on the turntable lock 16 22 14 4 16 Malfunctions on the CCS RCL control units 16 23 14 4 17 Malfunctions when driving from the crane cab 16 23 14 4 18 Malfunction...

Page 64: ...rmer for self sufficiency 16 61 14 7 5 Switching emergency operation on off 16 63 14 7 6 Connecting removing transformer for external energy source 16 64 14 7 7 Establishing the required hydraulic circuits 16 65 14 7 8 Performing emergency operation 16 69 14 7 9 Emergency supply of another crane 16 71 14 8 Fuses in the crane cab 16 73 ...

Page 65: ...Operating manual 3 302 690 en GMK4100L 1 23 11 2017 15 15 Index ...

Page 66: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 ...

Page 67: ...ice of Manitowoc Crane Care in the country in which you are working and specify your crane type and serial number Adhere to the requirements regarding the obligation to report accidents prevalent in the country in which you are working and inform the supervi sory authorities responsible for that particular type of accident e g material damage injuries to persons ...

Page 68: ...Overview 1 1 Accidents 1 2 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 69: ...pport with the operation on your truck crane you can contact our branches at the following addresses Manitowoc Crane Care http www manitowoccranes com 1 2 2 Dealer list Visit the following address for a global list of dealers http www manitowoccranes com 1 3 Warranty specifications Please see the separately enclosed warranty certificate for information ...

Page 70: ...Overview 1 4 Terms used 1 4 3 302 690 en Operating manual GMK4100L 1 23 11 2017 1 4 Terms used ...

Page 71: ...m 4 Axle lines 5 Outrigger beams 6 Outrigger cylinders 7 Outrigger pads B Superstructure 8 Slewing gear 9 Crane cab 10 Main boom with telescoping mechanism 11 Telescopic sections 12 Hook block 13 Derricking cylinder derricking gear 14 Telescoping cylinder 15 Turntable 16 Counterweight 17 Main hoist 18 Auxiliary hoist1 1 Additional equipment ...

Page 72: ...Overview 1 4 Terms used 1 6 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 73: ...1 Part 1 Crane application Service crane as per DIN 15 001 Part 2 Crane classification Hoist class H1 to DIN 15 018 Part 1 Crane class A1 to ISO 4301 Part 2 Max load bearing capacity Within the 360 slewing range 1 84 t 185 000 lbs 0 to the rear 1 90 t 198 000 lbs 0 to the rear 2 100 t 220 000 lbs Max load moment Within the 360 slewing range 306 tm 34 0 t x 9 m 1 With additional equipment 2 With sp...

Page 74: ...Overview 1 5 Technical data 1 8 3 302 690 en Operating manual GMK4100L 1 23 11 2017 1 5 3 Dimensions and weights of the truck crane axle loads All dimensions in the illustration are in mm ...

Page 75: ...5 Max level change At on road level 3 94 m 12 9 ft 3 99 m 13 1 ft 130 170 mm 5 1 6 7 in B Width 385 95 R25 445 95 R25 525 80 R25 2 55 m 8 4 ft 2 75 m 9 0 ft 2 75 m 9 0 ft 2 88 m 9 4 ft C Angle of negotiable banks Front Rear At on road level 385 95 R25 approx 14 approx 8 1 For the version with swing away lattice 1 7 7 7 m 5 6 25 3 ft or 1 7 14 3 m 5 6 46 9 ft Total weight depending on driving mode ...

Page 76: ...R 25 1 36 x 1 36 x 0 40 4 45 x 4 45 x 1 30 245 540 Spare wheel 445 95 R 25 1 50 x 1 50 x 0 45 4 95 x 4 95 x 1 50 332 732 Spare wheel 525 80 R 25 1 50 x 1 50 x 0 53 4 92 x 4 92 x 1 74 362 798 Description Diameter x Height in m ft Weight in kg lbs Plastic outrigger pad diameter 0 50 x 0 16 1 64 x 0 52 22 48 5 Steel outrigger pad diameter 0 50 x 0 16 1 64 x 0 52 30 66 1 Front outrigger1 complete per ...

Page 77: ...parable hook block s Dimensions m ft and weights kg lbs 1 2 3 4 5 6 Length 1 98 6 50 0 90 2 95 1 20 3 94 1 98 6 50 0 90 2 95 1 30 4 27 Width 0 70 2 30 0 70 2 30 0 70 2 30 0 70 2 30 0 70 2 30 0 70 2 30 Height 0 76 2 49 0 32 1 05 0 76 2 49 0 76 2 49 0 45 1 48 0 76 2 49 Weight in kg 960 2 116 275 606 685 1 510 1 600 3 527 465 1 025 1 135 2 502 ...

Page 78: ...lbs Single or double hook 7 sheaves 1 50 x 0 56 x 0 76 4 90 x 1 80 x 1 30 1 300 2 866 Single or double hook 5 sheaves 1 50 x 0 55 x 0 40 4 90 x 1 80 x 1 30 1 200 2 646 Single or double hook 3 sheaves 1 40 x 0 55 x 0 30 4 60 x 1 80 x 1 00 900 1 984 Single hook 1 sheave 1 35 x 0 55 x 0 25 4 45 x 1 80 x 0 82 450 992 Hook tackle 0 90 x 0 35 x 0 35 2 95 x 1 15 x 1 15 200 440 ...

Page 79: ...k block 3 sheave with ballast plates 0 82 x 0 50 x 0 59 2 70 x 1 64 x 1 94 450 Hook block 3 sheave without ballast plates 1 36 x 0 53 x 0 19 4 46 x 1 74 x 0 62 275 1 ballast plate 23 Description No 03296564 1 x 2 x 3 in m Weight In kg Hook block 1 sheave with ballast plates 1 41 x 0 56 x 0 44 4 63 x 1 84 x 1 44 450 Hook block 1 sheave without ballast plates 1 41 x 0 56 x 0 35 4 63 x 1 84 x 1 15 32...

Page 80: ...34 x 2 53 x 0 16 3 15 x 8 40 x 0 5 1 000 2 205 7 1 t counterweight section 1 34 x 2 53 x 0 54 3 15 x 8 40 x 0 82 7 100 15 653 1 5 t counterweight section 1 14 x 0 86 x 0 34 3 15 x 8 40 x 0 82 1 500 3 307 2 2 t counterweight section 1 34 x 2 53 x 0 18 3 15 x 8 40 x 0 82 2 200 4 850 4 0 t counterweight section 1 34 x 2 53 x 0 28 3 15 x 8 40 x 0 82 4 000 8 820 2 4 t counterweight pieces each 0 97 x 0...

Page 81: ...ifications AdblueTank2 approx 40 l 10 6 gal Fuel tank3 2 x 200 l 2 x 52 8 gal 1 See also engine data card 2 Additional equipment 3 For additional equipment 2 x 325 l 85 9 gal Drive 8 x 6 x 8 1 axle line Steered and driven axle line 2 axle line Steered axle line 3 axle line Steered and driven axle line steering can be switched on 4 axle line Steered and driven axle line Drive 8 x 8 x 81 1 axle line...

Page 82: ...7 8 x 445 95 R 251 on disc wheels 11 00 25 1 7 8 x 525 80 R 251 on disc wheels 17 00 25 1 7 Torque for wheel nuts 650 Nm 480 lbf ft Tyre pressure with cold tyres for axle loads up to max 12 t Turning turning radii All dimensions in the illustration are in mm 1 Additional equipment 385 95 R25 10 bar 145 psi 445 95 R25 9 bar 131 psi 525 80 R25 7 bar 102 psi R values for normal steering mode Ra value...

Page 83: ... x 17 4 ft 8 660 x 3 800 m 28 4 x 12 4 ft 8 660 x 2 340 m 28 4 x 7 6 ft 100 80 60 40 0 Outrigger span MAXbase à Enabled outrigger spans p 12 34 Outrigger pads Diameter 500 mm 19 7 in Surface 1 962 cm2 304 1 in2 Stroke of supporting cylinders 600 mm 23 6 in Maximum outrigger pressure Front 40 0 t 88 185 lbs Rear 58 0 t 127 868 lbs Inclination indicator In the crane cab at the outrigger control unit...

Page 84: ...ility Transport weight 48 t 105 822 lbs Alternator 28 V 100 A Batteries 2 each of 12 V 180 Ah Voltage 24 V Front towing coupling 100 kN 22 480 lbf permissible tension1 Rear tow lug 75 kN 16 860 lbf permissible tension1 1 Only permissible at certain tension angles à p 5 58 Forwards max 80 0 km h 49 7 mph Reverse approx 6 km h 3 7 mph depending on the tyres Drive Climbing ability with tyres 385 95 R...

Page 85: ...4301 2 Load spectrum L 1 Load spectrum factor Km 0 125 Theoretical service life D 3 200 h Drum diameter 371 mm 14 61 in Rope diameter 19 mm 0 75 in Rope length 255 m 836 ft Rope pull 70 6 kN line 15 872 lbf Power unit group M 3 to ISO 4301 2 Load spectrum L 1 Load spectrum factor Km 0 125 Theoretical service life D 3 200 h Make Siebenhaar Type 01 DD Power unit group M2 to ISO 4301 2 Cylinder Diffe...

Page 86: ...nit group Telescoping mechanism M 1 to ISO 4301 2 1 Additional equipment Main hoist Rope speed when lifting and lowering Normal speed maximum 65 m min 213 ft min High speed mode maximum 120 m min 394 ft min Auxiliary hoist Rope speed when lifting and lowering Normal speed maximum 65 m min 213 ft min High speed mode maximum 120 m min 394 ft min Slewing gear 0 to 1 7 revolutions per minute without l...

Page 87: ...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 appropri ate other additional equi...

Page 88: ...ent of spare parts Information about the position and quantity of plating 1 6 1 Questions on documentation Consult your dealer if you have questions on the documentation supplied for your truck crane You can find your responsible dealer here à Dealer list p 1 3 You can also send questions in either German or English directly to Email whv techpublications manitowoc com For repeat orders for documen...

Page 89: ...ation to the crane driver based on his prior knowledge of the individual operating steps and procedures 1 7 1 What do the symbols used mean The following designations and symbols are used in the operating manual and in the maintenance manual to highlight particularly important information The vertical line to the left of the hazards and warnings indicates that This text regardless of its length re...

Page 90: ...an example The text used for examples is in a different font S This symbol indicates dangers which represent a hazard to objects e g damage to the truck crane or other parts which are located within the work ing range B This symbol warns you about situations where there is a danger of electric shock O This symbol is to remind you that you are working with substances which pose a risk to the enviro...

Page 91: ...perations For more extensive processes the description is given with checklist and operating instructions The checklists show the procedure in the required sequence e g for rig ging work From there cross references take you to the corresponding operation descriptions The operation descriptions describe the work in detail including the required warnings and safety instructions You are obliged to re...

Page 92: ...operating elements with parts of the truck crane or with pictograms Different methods of emphasis are used in the text column When a section is preceded by a hyphen as in this section for example you will find a list When a section is preceded by a bullet you will be required to take con crete action e g Shift the transmission to neutral The following text passages are highlighted in italics Desig...

Page 93: ...abetic list of keywords and search terms with a reference to the relevant page in the operating manual Cross references are labelled with an arrow à and refer to other pages in the operating instructions These pages contain more detailed informa tion or information that relates to the topic in question Furthermore you can use the cross references to systematically familiar ize yourself with genera...

Page 94: ...rating manual 1 28 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Cross references example The illustrations texts and cross references in this section are only an example and may differ from the conditions on your truck crane ...

Page 95: ...ntains a cross reference in the form 2 Parking brake à p 3 52 C Page 3 52 gives a brief description of all the functions of the parking brake If further information is available the brief description contains a cross reference e g 4 Test posi tion for tow ing a trailer Pull the lever down until it locks into place Press in the lever and pull it further downwards The parking brake for the trailer i...

Page 96: ...efficient operation of the truck crane The operating manual contains Dimensions and weights of the truck crane à p 1 8 driving modes permitted on public roads à p 6 1 dimensions and weights of parts of equipment that can be removed à p 1 10 turning radii à p 1 16 The permissible outrigger spans for the Standard slewing range type à p 12 30 The permissible outrigger spans for the MAXbase slewing ra...

Page 97: ...t use US units of measurement Converting from into Multiply by mm into 0 03937 into mm 25 4 m ft 3 28084 ft m 0 30479 m2 ft2 10 76391 cm2 in2 0 155 cm3 in3 0 061 ltr gal US 0 264178 kg lbs 2 204622 lbs kg 0 45359 t lbs 2 204 622 lbs t 0 0004536 kN lbf 224 809 daN cm2 lbf in2 14 50378 lbf in2 daN cm2 0 06895 bar psi 14 50378 psi bar 0 06895 m s ft s 3 28084 km h or km mph or mi 0 62137 mph or mi km...

Page 98: ...Overview 1 8 Conversion table for US measuring units 1 32 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 99: ...our crane or else consolidates your specialist know how of sales marketing and service Our range of training programmes includes more than 20 different courses Take advantage of our services Training for prevention of accidents and crane operation Crane technology training Training tailored to your needs and level of experience for different levels of difficulty from beginner to specialist Theoret...

Page 100: ...Overview 1 10 Identification 1 34 3 302 690 en Operating manual GMK4100L 1 23 11 2017 1 10 Identification ...

Page 101: ...n is described in the corresponding chap ters or in the relevant operating manual provided 1 Serial number and crane type 2 the CE mark which is only applicable for truck cranes whose equip ment and configuration complies with the guidelines and standards specified in the supplied EC Declaration of Conformity 3 Driver s cab serial number at the strut of the door access 4 Chassis number and crane t...

Page 102: ...is valid only if the truck crane complies with all of the guidelines and standards specified in the EC Declaration of Conformity This applies in particular to the programming and function of the overload protection Only then does the truck crane receive a CE mark upon delivery The Declaration of Conformity shall become invalid and the CE mark must be removed if any modifications that do not comply...

Page 103: ...ely The GMK4100L 1 truck crane may only be operated without the correspond ing special equipment within the permitted temperature range à Technical data p 1 7 The GMK4100L 1 truck crane is designed solely for lifting loads which are within the permitted GMK4100L 1 lifting capacities The load must be slung as prescribed to a hook block which is positioned vertically over the load prior to lifting I...

Page 104: ...eration on the main boom head without additional equipment Setting RCL codes that do not correspond to the actual rigging mode Working with an overridden RCL or overridden lifting limit switch After RCL shutdown increasing the working radius by pulling the raised load at an angle e g with a chain hoist Misuse of the outrigger pressure display as a safety function to prevent the crane from overturn...

Page 105: ...e regulations concerning the operation of a crane Make sure that persons who will work on the truck crane are provided with the required information prior to starting operations Instruct your person nel e g banksmen slingers rigging personnel accordingly Make sure the maintenance personnel have the necessary expertise for safe crane operation Make sure the maintenance personnel have access to the ...

Page 106: ...afety This also applies to the installation of safety devices the adjustment of safety devices and valves All welding work especially on load carrying members may only be per formed by qualified professional personnel with the prior written permis sion of Manitowoc Crane Group Germany GmbH To avoid damage especially to electronic parts there are certain measures you must take before doing any weld...

Page 107: ...itly for crane operators who have been trained to operate truck cranes Personnel in training may only operate the truck crane under supervision Only reliable personnel may operate or carry out work on the truck crane As a crane operator you must fulfil a number of requirements You must possess a driving licence for this type of vehicle that is valid in the country in which you are working You must...

Page 108: ...e you start the vehicle Check the condition of the truck crane carefully using the checklists in the operat ing manual Do not assume everything is in working order simply because it was in working order at the end of the last shift Check that all covers and safety devices are fitted properly and that they are in good condition before starting the vehicle Use the appropriate access aids when checki...

Page 109: ...sume everything is in working order simply because it was in working order at the end of the last shift Check daily that all covers and safety devices are fitted properly and are in good condition before crane operation Check the safety devices RCL lifting limit switch dead man s switch emergency stop switches every day before you start work Use the appropriate access aids when carrying out overhe...

Page 110: ...rea clearly and mark the area as such When lifting a load balance out the increase in working radius caused by flexure of the boom by raising the boom so that the load is lifted vertically and does not drag injure helpers or topple into the hoist rope e g from a vehicle or scaffolding Inform any banksmen and helpers about this issue as well Support the truck crane with the outrigger span required ...

Page 111: ...or other pipelines is dangerous and requires special precautionary measures Please observe the instructions in the section titled Crane operation under special operating conditions in the Safety manual and the respective national regulations Testing the truck crane by lifting an excessively heavy load overload test ing is prohibited This presents the danger of hidden damage that can lead to severe...

Page 112: ...addition to the provisions of in this section always also observe the legal requirements and guidelines for transporting persons applicable in the country in which you are working Further information on transporting persons can be found under the address http fem eur com Equipment for lift ing persons When lifting persons only use equipment for lifting persons that comply with the requirements spe...

Page 113: ...working order Before transporting persons the crane operator must make sure that the lifting limit switch is not overridden The operating manual and the lifting capacity table must be in the crane cab and in easy reach of the crane operator All crane movements must be performed slowly and with extreme care The crane operator is not allowed to leave the crane cab until the equipment for lifting per...

Page 114: ...ent for lifting persons is being used and is in a stationary position then the slewing gear hoist derricking gear and telescoping mechanism must be secured against accidental use by being switched off Truck crane The truck crane must be equipped e g with hydraulic emergency opera tion so that the equipment for lifting persons can be set down and the per sons being transported can safely leave it e...

Page 115: ...n are described in Chapter 9 3 1 Overview of the operating elements This section shows the position and designation of the operating elements for driving This also includes display elements such as lights or displays H Operating elements available only with additional equipment are desig nated accordingly These designations are made in this section only and are not repeated in the following sectio...

Page 116: ...Operating elements for driving 3 1 Overview of the operating elements 3 2 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 1 On the outside of the truck crane 30 31 ...

Page 117: ...oler second cooler1 8 Auxiliary hoist Operation1 Rigging the auxiliary hoist1 à p 9 116 à p 6 17 9 APS connection interface Auxiliary Power Supply 1 3 10 Spare wheel1 Towbar coupling1 à p 8 33 à p 5 81 11 BirdView system 270 Camera1 à p 3 53 12 Chocks1 à p 5 46 13 Storage space for the folding ladder à p 3 77 14 Outrigger Operation Lighting Installing removing the outrigger beams à p 12 39 à p 12 ...

Page 118: ...Operating elements for driving 3 1 Overview of the operating elements 3 4 3 302 690 en Operating manual GMK4100L 1 23 11 2017 30 31 ...

Page 119: ... Switching off the boom floating position1 à p 6 15 à p 12 19 25 Switching on boom pre tensioning1 Switching off boom pre tensioning1 à p 6 16 à p 12 21 26 Air intake inhibitor1 à p 4 20 27 Driver s cab tilt mechanism à p 8 44 28 Compressed air supply Inflating the tyres yourself à p 8 29 à p 8 37 29 Starting the truck crane externally1 Battery charger1 à p 8 27 à p 8 28 30 Switching on the slewin...

Page 120: ...Operating elements for driving 3 1 Overview of the operating elements 3 6 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 2 Driver s cab Front overview ...

Page 121: ...5 7 à p 5 8 12 Adjusting the air vents à p 5 66 13 Cab lighting à p 3 67 14 Instrument panel Left right à p 3 11 15 Steering column steering wheel à p 3 10 16 Tachograph or cover à p 3 16 17 Battery heating1 2 18 Instrument panel Middle à p 3 12 19 Auxiliary water heating system1 à p 3 18 20 Radio USB1 2 à p 5 80 21 Auxiliary water heating system1 à p 3 18 22 Heating and air conditioning system à ...

Page 122: ...rview of the operating elements 3 8 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Rear overview 1 Fold up berth1 à p 5 48 2 Rest 3 Storage spare key etc on delivery 4 Storage compartment e g for battery charger 1 Additional equipment ...

Page 123: ...Operating elements for driving 3 1 Overview of the operating elements Operating manual 3 302 690 en 3 9 GMK4100L 1 23 11 2017 Behind the cover 1 Fuses in the driver s cab à p 8 50 ...

Page 124: ... idling speed Setting cruise control Setting the Temposet Engine retarder transmission retarder1 Hands free unit2 à p 3 42 à p 3 43 à p 3 43 à p 3 59 3 Horn à p 3 65 4 Headlight flasher headlight full beam Turn signal indicator wiper washing system à p 3 65 à p 3 65 5 Transmission operating elements à p 3 14 6 Ignition lock à p 3 42 7 Adjusting the steering column à p 5 15 1 Additional equipment 2...

Page 125: ...right s 1 Lighting on off à p 3 66 2 Separate manual steering à p 3 61 3 Battery master switch à p 3 45 4 Heating system à p 3 17 5 Hazard warning system on off à p 3 66 6 Dual tank à p 4 6 7 Override torque reduction à p 3 44 8 Rotating beacon on off à p 3 67 9 Air conditioning system1 à p 3 17 10 12 V power socket on off à p 3 46 1 Additional equipment ...

Page 126: ...Operating elements for driving 3 1 Overview of the operating elements 3 12 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Middle ...

Page 127: ... high warning à p 3 43 9 Brake malfunction à p 3 58 10 ABS warning à p 5 35 11 Display Time Outdoor air temperature à p 3 73 à p 3 73 12 Checking headlight full beam à p 3 65 13 Check the retarder 14 Clutch indicator à p 3 51 15 Parking brake indicator lamp à p 3 60 16 Parking light indicator à p 3 66 17 Kilometre counter à p 3 70 18 Fuel level display à p 4 5 19 Steering system warning à p 3 61 2...

Page 128: ...ements 3 14 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 5 Transmission operating elements 1 Selecting the driving direction à p 3 49 2 Changing the operating mode à p 3 49 3 Shift down manual à p 3 49 4 Shift up manual à p 3 49 5 Gear indicator à p 3 49 ...

Page 129: ...of the operating elements Operating manual 3 302 690 en 3 15 GMK4100L 1 23 11 2017 3 1 6 On board computer 1 Main menu display à p 3 72 2 Display menu Name à p 3 72 3 Submenu display à p 3 72 4 Display area à p 3 72 5 Display information à p 3 72 ...

Page 130: ...aph1 à p 5 18 1 Display à p 5 21 2 Time correction à p 3 70 3 Time correction à p 3 70 4 Opening the drawer à p 5 19 5 Setting the time group driver 1 à p 5 20 6 Setting the time group driver 2 à p 5 20 7 Correction of time à p 3 70 8 Drawer à p 5 19 B Cover1 9 Time correction à p 3 70 10 Time correction à p 3 70 1 A or B present depending on the version ...

Page 131: ...ents Operating manual 3 302 690 en 3 17 GMK4100L 1 23 11 2017 3 1 8 Heating and air conditioning system Standard s 1 Setting the fan à p 5 65 2 Air distribution à p 5 66 3 Setting the temperature à p 5 65 4 Air conditioning system à p 5 68 5 Setting the fan à p 5 65 ...

Page 132: ...1 Overview of the operating elements 3 18 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Auxiliary water heating system 1 Auxiliary water heating system Preheating the engine Preheating the driver s cab à p 5 70 à p 5 70 à p 5 71 ...

Page 133: ...e operating elements Operating manual 3 302 690 en 3 19 GMK4100L 1 23 11 2017 Auxiliary air heater 1 Selecting a function à p 5 76 2 Menu line 3 Program column 4 Display line 5 Switching on Switching off à p 5 76 à p 5 80 6 Confirm the entry à p 5 76 ...

Page 134: ...Operating elements for driving 3 1 Overview of the operating elements 3 20 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 135: ...23 2 Service diagnostics connection1 à p 3 71 3 Exiting the menu input mode à p 3 47 4 Selector buttons à p 3 47 5 Selecting deselecting favourites à p 3 49 6 Sensor for brightness à p 3 48 7 Main menu overview à p 3 47 8 Input confirmation à p 3 47 9 no function 10 Display temperature warning display à p 3 48 1 For Service personnel only not suitable for external devices e g mobile phone ...

Page 136: ...MK4100L 1 23 11 2017 3 1 10 CCS menu dependent displays 1 Transverse differential locks display Longitudinal differential lock display à p 3 56 à p 3 57 2 Display of retarder function on off à p 5 43 3 Suspension display à p 3 64 4 Display area for error and warning messages à p 8 13 5 Display time à p 3 30 ...

Page 137: ...play of crane type 2 Serial number display 3 Display of transverse and longitudinal differential locks on off à p 3 28 4 Voltage monitoring display à p 4 15 5 Hydraulic oil temperature display à p 4 15 6 AdBlue level display à p 4 15 7 Display of current inclination à p 3 69 8 Steering mode display à p 3 62 9 Steering system malfunction warning à p 3 61 ...

Page 138: ...Operating elements for driving 3 1 Overview of the operating elements 3 24 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 12 CCS Overview menu groups ...

Page 139: ...u group à p 3 29 Set display brightness and date time menu Switch units menu Lamp test 3 Information menu group à p 3 31 Operating hours menu Engine transmission error menu Crane operation error menu 4 Various controls menu group à p 3 36 Outrigger lighting on off Reverse camera on off1 5 Emergency operations menu group à p 3 37 Switching emergency operation on off Switching towing mode on off 1 A...

Page 140: ... elements for driving 3 1 Overview of the operating elements 3 26 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 13 Carrier menu group 1 Suspension level adjustment menu à p 3 27 2 Driving menu à p 3 28 ...

Page 141: ... 3 68 2 Level adjustment system enabled display à p 3 68 3 Suspension operation pressure gauge à p 3 64 4 Left level pre selection à p 3 68 5 Overall level pre selection à p 3 68 6 Right level pre selection à p 3 68 7 Display of current inclination à p 3 69 8 Rear level pre selection à p 3 68 9 Setting the on road level à p 3 69 10 Vehicle level display à p 3 69 11 Suspension on off à p 3 64 ...

Page 142: ...n off à p 3 56 à p 3 56 4 Longitudinal differential lock display Longitudinal differential lock on off à p 3 57 à p 3 57 5 Steering mode display à p 3 62 6 Steering system malfunction warning à p 3 61 7 Normal steering mode on road driving on off à p 3 62 8 Manual separate steering on off à p 3 62 9 Separate steering for driving around corners on off à p 3 62 10 Separate steering crab travel mode ...

Page 143: ...ng 3 1 Overview of the operating elements Operating manual 3 302 690 en 3 29 GMK4100L 1 23 11 2017 3 1 14 Settings menu group s 1 Set display brightness and date time menu à p 3 30 2 Switch units menu à p 3 31 3 Lamp test à p 4 10 ...

Page 144: ...display brightness and date time menu 1 Selection setting the display brightness à p 4 11 2 Increasing reducing the value à p 4 11 3 Display in percentage à p 4 11 4 Display brightness à p 4 11 5 Adjust time selection à p 5 23 6 Setting the time à p 5 23 7 Increasing reducing the value à p 5 23 8 Switching the display type à p 5 23 ...

Page 145: ... Overview of the operating elements Operating manual 3 302 690 en 3 31 GMK4100L 1 23 11 2017 Switch units menu 1 Display units in Metres Degrees Celsius Kilograms Bar à p 5 64 2 Display units in Feet Degrees Fahrenheit lbs Psi à p 5 64 ...

Page 146: ...ing 3 1 Overview of the operating elements 3 32 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 15 Menu group Information 1 Operating hours menu à p 3 33 2 Engine error menu à p 3 34 3 Crane operation error menu à p 3 35 ...

Page 147: ...g 3 1 Overview of the operating elements Operating manual 3 302 690 en 3 33 GMK4100L 1 23 11 2017 Operating hours menu s 1 Keycode input à p 5 24 2 Carrier à p 5 24 3 Motor à p 5 24 4 Transmission à p 5 24 5 Selection all à p 5 24 ...

Page 148: ... 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Engine transmis sion error menu 1 Display of error total errors à p 8 17 2 Engine symbol display à p 8 17 3 Transmission symbol display à p 8 17 4 Error code display à p 8 17 5 Previous error à p 8 17 6 Next error à p 8 17 ...

Page 149: ...en 3 35 GMK4100L 1 23 11 2017 Crane operation error menu Since this menu is required for crane operation it is in the chapter Operating elements for crane operation à Crane operation error menu p 9 73 1 Current errors total errors display 2 Error code 3 Deleting errors 4 Next error 5 Previous error ...

Page 150: ...nts for driving 3 1 Overview of the operating elements 3 36 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 16 Various controls menu group 1 Outrigger lighting on off à p 3 67 2 Reverse camera on off à p 3 52 ...

Page 151: ...ving 3 1 Overview of the operating elements Operating manual 3 302 690 en 3 37 GMK4100L 1 23 11 2017 3 1 17 Emergency operations menu group 1 Switching emergency operation on off à p 14 63 2 Switching towing mode on off à p 8 30 ...

Page 152: ... for driving 3 1 Overview of the operating elements 3 38 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 1 18 Outrigger control units Contain operating elements for crane operation à Outriggers control units p 9 85 ...

Page 153: ... elements to be active If some operating elements do not work first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care G Risk of accident by operator error This section is not a complete operating manual It only provides a general overview of the functionality of the operating elements Before using the operating elements for the first ...

Page 154: ...rections always depend on whether the carrier or the superstructure is being operated On the carrier The driver s cab is always at the front which means that Forwards always means with driver s cab leading Backwards always means the rear lights on the carrier are to the front On the superstructure The main boom head is always at the front which means that 1 front 2 right 3 rear 4 left 1 front 2 ri...

Page 155: ...ponding symbol has been selected with the direction buttons 1 A selected menu is marked in colour and can be opened In these operating instructions we always refer to colours in terms of The symbol is red for instance Regardless of whether the background 1 of a symbol is red or only parts 2 of a symbol are red This applies to all symbols and all colours If the instruction given in this section is ...

Page 156: ...dling speed The truck crane must be stationary 0 Ignition off engine off key can be removed 1 Power supply on for Heating system engine transmission diagnostics radio telephone enabling of steering lock 2 Ignition on driving position 3 Starting position à p 4 9 Lock unlock steering column à p 5 15 1 Select the Engine speed menu 2 Reduces the idling speed 3 Increase idling speed 4 Idling speed sett...

Page 157: ...ruck crane must be driving at a speed at least 15 km h 9 mph Instrument panel Tachometer 2 Select the Cruise control menu symbol 1 is grey 3 Switches on or increases the speed symbol 1 is white 4 Switches on or reduces the speed 5 Switch off à p 5 38 1 Select Temposet symbol 2 is grey 3 Switches on or increases the speed limit symbol 2 is white 4 Switch off or reduce the speed limit 5 Switch Tempo...

Page 158: ...t Lit AdBlue system malfunction Flashing Adblue tank empty or fault à p 5 45 Off Torque reduction off Lit Torque reduction on Flashing Reduction in torque on the next time the engine is started à p 5 45 Press upwards once Torque reduction overridden for 30 minutes after 30 minutes Press up again Torque reduction overridden for 30 minutes after 30 minutes Press up again Torque reduction overridden ...

Page 159: ... 690 en 3 45 GMK4100L 1 23 11 2017 CCS display Adblue filling level indicator 3 2 5 Battery master switch Display Green Over 10 over 4 l 0 9 gal Yellow 5 to 10 2 to 4 l 0 4 to 0 9 gal Red Below 5 less than 2 l 0 4 gal à p 4 7 To switch on Push up To switch off unlock and then press in downwards à p 4 9 ...

Page 160: ...24 V Only connect electrical devices with the matching specification to the sockets Reading lamp 12 V As additional equipment the truck crane is equipped with a reading lamp If necessary plug the 12 V reading lamp into the 12 V socket Press the button 1 lamp on off To switch on Press in switch 1 at the top To switch off Press in switch 1 at the bottom 1 Socket 24 V max 15 A 2 Socket 12 V max 15 A ...

Page 161: ... on the CCS control panel the overview of the menu groups 2 appears A symbol is selected with the arrow buttons in order to call up a menu The selected symbol is shown in red The OK button on the control panel is pressed in order to open a menu Menu control Buttons for selecting activating and confirming areas on the CCS display Select Activate confirm The function of the buttons is different depe...

Page 162: ...ness p 4 11 Display temperature warning display The temperature of the control unit is measured by an internal sensor 1 Press The opened menu closes the menu from the next higher level is opened Input mode is deactivated 1 Press After the first press Menu groups overview display After a subsequent press Next previous group overview Blue flashing Temperature too low display will not be switched on ...

Page 163: ...t A symbol is selected such as symbol 2 Deselect A favourites symbol is selected 3 2 8 Transmission à Operating the transmission p 5 25 Transmission control unit Selecting the transmission mode The engine must be running s 1 Press The symbol is marked as a favourite 1 Press The favourites selection is cancelled Position N Select neutral No gear engaged Position D When at a standstill Select forwar...

Page 164: ...ards Select neutral The truck crane may be stationary or driving Press in once Change over between automatic and manual operating mode without change of gear à p 5 29 The truck crane must be stationary Push forwards once Shift up starting gear 1 gear Push to the rear once Shift down starting gear 1 gear If the truck crane is in motion Push forwards once Shift up 1 gear Manual operating mode on Pus...

Page 165: ...ay driving mode Transmission display Error messages display 1 Currently engaged gear forwards 1 to 16 e g 6 2 Neutral position switched on 3 Gear currently engaged 1st reverse gear 4 Gear currently engaged 2nd reverse gear 5 Automatic operating mode 6 Manual operating mode 1 Clutch heavily loaded 2 Clutch malfunction 3 Gear shift malfunction ...

Page 166: ...he reverse camera 1 displays the area behind the truck crane on the CCS display in the driver s cab Switching on Automatically when reversing 1 Manual select symbol 3 and confirm The display 5 shows the area behind the truck crane Switching off Automatically when driving forwards or in neutral position 4 Manual press button 6 The display 2 shows the CCS menu ...

Page 167: ...ity lies with the crane operator Manitowoc Crane Group Germany GmbH explicitly states that no liability is accepted for damage resulting from a failure to observe these instructions The BirdView system 270 shows rear and side views next to the carrier in the driver s cab All cameras 2 simultaneous show images on the monitor 1 The monitor 1 shows the area 3 to the rear and side of the carrier s S R...

Page 168: ...he cameras must not be removed or misadjusted If a camera is mounted on the storage box then the storage box must not be removed H There may be no spare wheel installed on the rear of carrier Switching on Switch on the ignition the monitor shows the area around the truck crane Switching off Switch off the ignition the monitor switches off ...

Page 169: ...case for off road gear on off à p 5 50 Transfer case display The current status is shown using different symbols To open Select symbol 1 and confirm menu is opened To switch on Select symbol 2 and confirm off road gear engaged To switch off Select symbol 1 and confirm off road gear disengaged 1 Off road gear on 2 Off road gear off on road driving 3 Select neutral 4 Error violet ...

Page 170: ...tial locks on off When a symbol 1 is selected both transverse differential locks are switched on or off Transverse differential locks display The current status is shown using different symbols To open Select symbol 1 and confirm menu is opened To switch on Select symbol 1 and confirm symbol is red To switch off Select symbol 1 and confirm symbol is green 1 Green locks off 2 Red locks on 3 Yellow ...

Page 171: ...k on off For drive 8 x 8 x 8 simultaneously drive of second axle line on out Longitudinal differential lock display The current status is shown using different symbols To switch on Select symbol 1 and confirm symbol is red To switch off Select symbol 1 and confirm symbol is green 1 Green lock off 2 Red lock on 3 Yellow intermediate position 4 Violet error à p 5 51 ...

Page 172: ...ply pressure sufficient à p 5 60 1 To engage the parking brake Pull the lever down until it locks into place 2 To release the parking brake Lift the lever and push it up until it latches into place 3 Operating as auxiliary brake Shift the lever to intermediate position The braking force is increased continuously by moving the lever from top to bottom 4 Test position for towing a trailer Push the l...

Page 173: ...ional brakes p 5 43 Multipurpose switch The braking effect is the least in position 1 and the greatest in position 5 Instrument panel Additional brake indicator lamp Lit Parking brake applied Out Parking brake released 0 Forward 0 1 Back 20 2 Back 40 3 Back 60 4 Back 80 5 Back 100 Lit Additional brake on Out Additional brake off Flashing Ignition on Multipurpose switch not in position 0 Engine is ...

Page 174: ...Engine off ignition on or Engine on fault stop check oil loss Out Engine on no fault à p 8 6 Lit approx 10 km h 6 mph not reached or Steering malfunction stop and check for oil loss Out Emergency steering pump ready to function à p 8 6 1 After switching on the ignition Lit goes out after about three seconds if there is no error Whilst driving Lit 1 x warning buzzer and goes out again Continued dri...

Page 175: ... warning The display 1 is shown in the Driving menu and in the Start menu s 1 After switching on the ignition Lit goes out after about three seconds if there is no error Whilst driving Lit symbol 2 red Steering system faulty 3 axle cannot be steered Stopping while taking the traffic situation into account Repair required à p 8 7 To the left 3 and 4th axle lines turn to the left To the right 3 and ...

Page 176: ...ff Manual separate steering on off When separate steering is switched on the speed is limited 2 Orange Steering mode switched on indicator Blue Automatic alignment of the steering angle is active To switch on Select symbol 1 and confirm Symbol 2 is displayed To switch off Select a different steering mode symbol 3 à p 5 60 To switch on Select symbol 1 and confirm Symbol 2 is displayed To switch off...

Page 177: ...MK4100L 1 23 11 2017 Steering locking status display The current status is shown using different symbols Current wheel position display The current status is shown using different symbols 1 Green locked 2 Red unlocked 3 Yellow intermediate position 4 Error 1 Straight ahead 2 Driving around corners 3 Crab travel mode ...

Page 178: ... on Select symbol 1 and confirm Symbol 2 green on road driving Suspension on enabled for on road driving Switch off Select symbol 1 and confirm Symbol 2 red Suspension off blocked for crane operation à p 5 16 1 Suspension pressure 1st and 2nd axle lines left hand side 2 Suspension pressure 1st and 2nd axle lines right hand side 3 Suspension pressure 3rd and 4th axle lines left hand side 4 Suspensi...

Page 179: ...nstrument panel Checking headlight full beam s 1 Parking light headlight Middle position 2 Flash the headlights Upwards The parking light headlight must be switched on 3 Headlight full beam Down latches into place 4 Right turn signal indicator Forwards 5 Left turn signal indicator Backwards 6 Windscreen wiper washing system Press 7 Windscreen wiper Rotate Off Interval slow Interval fast Continuous...

Page 180: ...ut Turn signal indicator off or turn signal indicator on and filament lamp faulty 1 Flashing Turn signal indicator on and trailer electrically connected Flashes once Turn signal indicator on and trailer not electrically connected Out Turn signal indicator off To switch on Press downwards light in the switch flashes To switch off Press in above gone out 1 Light off 2 Parking light on Instrument lig...

Page 181: ...Rotating beacon on off CCS display Outrigger lighting on off Roof The lamps on the driver s and passenger s side are identical Cab lighting Lit Headlight on Out Headlight off To switch on Push up To switch off Push down To switch on Select and confirm symbol 2 To switch off Select and confirm symbol 1 1 On 2 On off via door contact 3 Off 4 Reading lamp on ...

Page 182: ...elect and confirm the corresponding symbol Level adjustment system enabled display Level change Movement stops after the button is released and when an end position is reached To open Select symbol 1 and confirm menu is opened 2 Left level pre selection 1 Front level pre selection 4 Right level pre selection 5 Rear level pre selection 3 Overall level pre selection 1 Displayed Level pre selection o...

Page 183: ... is switched on Display of current inclination Switching between measuring ranges 1 On road level 2 Off road level 3 Error 4 Operation pressure in the suspension struts à p 5 53 1 Select and confirm level is changed until the on road level is reached 2 On road driving level reached à p 5 54 1 Directional indicator 2 Inclination indicator 3 Measuring range display à p 5 56 The current measuring ran...

Page 184: ...ilometre counter The ignition must be switched on 1 Open the time menu Press the button the time correction menu opens 2 Time correction Press the button the time is increased 3 Time correction Press the button the time is decreased 1 Time correction Press the button the time is increased 2 Time correction Press the button the time is decreased 1 Indicates the speed in km h 2 Indicates the speed i...

Page 185: ... staff from the engine manufacturer transmission manufacturer or by Manitowoc Crane Care The following connections are below the cover 4 3 2 20 Push up roof Opening Hold the push up roof 1 by the handles 2 and push up into the required position Closing Hold the push up roof by the handles 2 and pull down until it latches into place 1 Carrier electronics diagnostics 2 Transmission diagnostics 3 Eng...

Page 186: ...computer On the steering wheel Main menu display 1 Previous menu window menu entry upwards 2 Next main menu select next entry increase or reset value 3 Next menu window one menu entry downwards 4 Previous main menu select previous entry reduce value 5 Open and close data entry window acknowledge messages 6 Save display menu window 1 Tour data 2 Driving 3 Audio and communication 4 Operation and mai...

Page 187: ...ta menu 3 2 22 Front flap Opening Fold up the front flap 1 Fasten the support 2 in the clamp 3 Closing Lift the front flap 1 Fasten the support 2 in the clamp 4 Fold down the front flap Press the front flap against the driver s cab on both sides until you can hear it latch into place 1 Total mileage 2 Daily mileage 3 Time 4 Outside temperature ...

Page 188: ... and when an end position is reached Jog function Press button 1 briefly the window opens all the way to the end position Press button 2 briefly the window closes all the way to the end position G Risk of crushing when closing the windows If the window winders encounter resistance they do not stop but keep on moving at reduced power A Window winder driver s door B Window winder passenger door 1 To...

Page 189: ...iver s and passenger s door H Always take the ignition key with you before closing the door from outside with the handle pressed in 2 Once closed in this manner the door can only be opened again using the ignition key Locking Turn the key towards B or Press in the handle 2 Unlocking Turn the key towards A or Pull the handle 2 Opening Pull the handle 1 or Pull the handle 2 ...

Page 190: ...Operating elements for driving 3 2 Short description of the operating elements 3 76 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 191: ...pen the handles 3 can be reached The handle 4 is located on the outside of the crane cab For the version with the large receptacle the access ladders 5 are replaced by swing out ladders Swing out ladders Folding out Release the spring latch 1 Swing the ladder 2 outwards and fold downwards locking bar 3 engages If need be engage the spring latch 5 and pull out another access ladder 4 s G Hazard due...

Page 192: ...ing the ladder 2 on the carrier Secure the ladder 2 with the spring latch 1 Folding ladder shelf on the rear of carrier For the shelf under the driver s cab à p 3 79 For the use Ladder 4 to erect and fold out Taking off the clamp 2 and taking out the ladder Position the clamp 2 and secure the retaining pin or lock For driving crane operation Fold together the ladder 4 and push under the clamp 1 Fi...

Page 193: ...e Ladder 1 to erect and fold out Hold the clamp 2 and open the lock 3 Fold down the clamp 2 Take out he ladder Fold the clamp 2 upwards until it engages For driving crane operation Fold together the ladder 1 Place the ladder in the centre of the clamp 2 Push the ladder back so that the holder 5 engages on a rung 4 Fold the clamp 2 upwards until it engages Always secure the holder 2 before driving ...

Page 194: ...Operating elements for driving 3 2 Short description of the operating elements 3 80 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 195: ...driver s cab You can also start the engine from the outrigger control units à p 12 27 4 1 1 CHECKLIST Starting the engine H This checklist is not a complete operating manual There are accompanying operating instructions which are indicated by cross references Observe the warnings and safety instructions specified here 1 Check that the valves on the hydraulic tank are open à p 4 8 2 Check the coola...

Page 196: ...witch on the battery master switch à p 4 9 5 Check that all emergency stop switches have been reset à p 4 19 6 Check the oil level in the engine and gearbox à Maintenance manual 7 Check that the parking brake is engaged 8 Switch on the ignition and check the instruments and displays à p 4 9 9 Adjust the brightness of the CCS display if necessary à p 4 11 ...

Page 197: ...L 1 23 11 2017 10 Check the fluid supply à Fuel tank p 4 5 à AdBlue tank p 4 7 à Fuel tank auxiliary heater p 11 5 11 Shift the transmission to neutral à p 5 26 12 Start the engine à p 4 13 13 Conduct the necessary checks after starting the engine à p 4 15 14 In the event of low outside temperatures à CHECKLIST At low temperatures p 4 4 ...

Page 198: ...when operating the truck crane in low outside temperatures 1 The fuel and engine oil must be suitable for use at the respective outside temperature à Separate engine operating instructions provided by the manufacturer 2 The engine coolant must contain sufficient antifreeze à Separate engine operating instructions provided by the manufacturer 3 The windscreen washing system must contain sufficient ...

Page 199: ...ient space for the fuel to expand Close both tanks with the caps after refuelling Also fill the tank for the crane operator s cab heating system à Fuel tank auxiliary heater p 11 5 s G Danger of fire due to flammable gases Switch off the engine the heater and all additional heaters before refuelling G Risk of accidents if the tank is not closed Close the tank each time you have refilled it In this...

Page 200: ...uel for driving operation display 2 The fuel tank 4 is filled with the fuel for crane operation display 3 When refuelling open filler necks 1 or 4 Fill with the correct fuel in good time and close the tank correctly Leave sufficient space for the fuel to expand Close both tanks with the caps Switching over the fuel supply When fitted with dual tanks the fuel supply is automatically switched over d...

Page 201: ...he tank each time you have refilled it In this way you can prevent other vehicles from being endangered by the cap falling off or consumables escaping S Risk of damage to the engine and catalytic converter Unauthorised consumables can damage the engine and catalytic converter and void the warranty Only use consumables approved by the engine manufacturer G Risk of injury from ammonia vapours Ammoni...

Page 202: ...s the truck crane may only be driven with AdBlue Driving without AdBlue will invalidate the truck crane s licence for use on public roads and you are no longer permitted to drive on public roads 4 1 4 Checks before starting the engine At the hydraulic tank Before you start the engine all valves on the hydraulic tank must be open Check that the valves are open lever 1 parallel to the line Open all ...

Page 203: ... battery master switch will be switched on Checking the hand held control Check that the hand held control has been removed and that the bridging plugs for the hand held control are inserted into all sockets à p 9 83 4 1 5 Switch the ignition on Insert the ignition key into the ignition lock and turn the key to position 2 After switching on the ignition a lamp test is performed and switching state...

Page 204: ...witching states of the differential locks and the steering are compared Differential locks The state last saved is retrieved In the Driving menu the corresponding symbols 1 are shown and the electronics system triggers the switching operations Steering When you switch the ignition on the steering is always set to On road driving 2 irrespective of what setting was last saved S Risk of accident from...

Page 205: ... and keep them clean to avoid contamination that can affect the brightness adjustment Setting the minimum brightness H The brightness of the headlight is reduced to 40 regardless of the mini mum brightness setting but can be increased again manually at any time Open the Set display brightness and date time menu 1 Select and confirm the symbol 1 Set the desired brightness on the display 2 Confirm t...

Page 206: ...for driving switching it off 4 1 Starting the engine from the driver s cab 4 12 3 302 690 en Operating manual GMK4100L 1 23 11 2017 You can cancel the entry at any time using the 1 or 2 buttons The settings are then reset ...

Page 207: ...an also start the engine from the outrigger control units à p 12 27 Refer to the separate operating manual provided by the engine manufactur er for operating the engine The engine can only be started if The bridging plugs have been inserted in all sockets of the carrier and superstructure for the hand held control à p 9 83 The lamp 1 has gone out superstructure ignition off The parking brake must ...

Page 208: ...ing again If the engine does not start after several attempts à Malfunctions on the engine p 8 19 S Danger of explosion when using starter fuel The engine may never be started with the aid of starter fuel The starter fuel sprayed into the intake manifold can ignite S Risk of malfunctions in the carrier electronics Always wait until the start menu is displayed before starting the engine This preven...

Page 209: ...ning and malfunction messages on the on board computer display p 8 9 If a red symbol lights up or if a message demands it switch the engine off immediately Also check the following displays The colour of the bar under the value indicates the range within which the value lies s S Risk of damage to the engine Observe the symbols and messages in the display area of the main menu and in the on board c...

Page 210: ... must go out The lamp 3 only goes out when the vehicle starts moving Check that the lamps 1 and 2 go out If one or more lamps light up à Warning or malfunction messages on the instrument panel p 8 5 If the Steering system warning 1 red lamp does not go off then you must perform the required checks before you start off à p 8 5 G Risk of accidents from unexpected movement If the Steering system warn...

Page 211: ...d when the truck crane is stationary Increasing reducing the idling speed Press the button 1 repeatedly until Engine speed is shown in the on board computer display Increase or decrease the speed stepwise using the buttons 2 or 3 The engine speed is increased reduced by 20 rpm After about 3 seconds the setting is automatically saved Switching off the idling speed change Press the button 1 repeated...

Page 212: ...nother one or two minutes at increased idling speed Ignition lock Turn the ignition key to position 0 the engine will stop Outrigger control units Press the button 1 the engine will switch off After switching off If you want to park the truck crane à p 5 46 G Risk of accidents because the truck crane cannot be steered Switch the engine off only once the truck crane has come to a standstill If you ...

Page 213: ...or is present this is then triggered H Do not operate the emergency stop switch to switch the engine off in normal operation Only operate the emergency stop switch in an emergency situation Resetting the emergency stop switch You can restart the engine only after you have reset the emergency stop switch Switch off the ignition Turn the actuated emergency stop switch until it disengages again If ai...

Page 214: ...d is exceeded In this case the symbol 1 will turn red in the start menu display area à p 8 13 The symbol stays red until the ignition has been switched off The engine can be restarted only after the air intake inhibitor has been released Releasing the air intake inhibitor The following requirements must be met in order to release the air intake inhibitor The ignition must be switched off The emerg...

Page 215: ...rve the warnings and safety instructions specified here 1 For on road driving without a dolly Depending on the driving mode the counterweight must be unrigged à p 6 1 à p 12 69 The main boom must be telescoped for driving operation à p 11 110 All telescopic sections must be locked together The slewing gear is switched off à p 11 120 The boom must be resting in the boom rest à p 5 9 If the base pla...

Page 216: ...ght may be mounted on the rear counterweight platform 3 On the outrigger All outrigger beams must be fully retracted and secured to prevent extension à p 12 44 The outrigger pads are in the driving position à p 12 51 4 All mirrors for crane operation are folded in removed à p 12 130 All spotlights are switched off and swivelled if possible in such a way that no other drivers will be blinded by ref...

Page 217: ...t be folded in à p 12 129 9 Check the tyres Tyre pressure when tyres are cold in on road mode à p 1 16 Other checks à Maintenance manual 10 Check the level and function of the windscreen washing system à Maintenance manual 11 Carry out an inspection of the truck crane looking out in particular for any leaks of fluids oil fuel or water s ...

Page 218: ...fulfil the regulations of the country in which you are working as regards permissible weights and axle loads lengths widths height etc For a driving mode with a maximum axle load of 12 t 26 500 lbs à Driving modes p 6 1 14 The fold up berth must be folded up and secured à p 5 48 15 All additional parts which may be transported must be secured against falling down 16 Carry out all activities and in...

Page 219: ...00L 1 23 11 2017 18 Adjust the driver s seat à p 5 13 19 Adjust the steering column à p 5 15 20 Adjust the mirrors à p 5 7 21 Set the tachograph insert the diagram sheet à p 5 18 22 Start the engine and carry out all checks à Checks after starting the engine p 4 15 s ...

Page 220: ...ystem and the brakes à p 5 10 26 Check that all switching states for on road driving are set and that the corresponding symbols are shown Suspension switched on à p 5 17 Longitudinal and transverse differential locks switched off à p 5 51 Separate steering switched off the symbol for on road driving is dis played à p 5 63 On road level is set à p 5 54 Establish the switching states for on road dri...

Page 221: ...aired Parking light headlight rotating beacons fog tail light side marker lights Hazard warning system Brake lights Reversing lamp buzzer Headlight full beam Turn signal indicator Windscreen wipers Windscreen washing system Horn Adjusting the mirrors Adjust all the mirrors to suit your sitting position Manual adjustment Manually adjust the mirrors 1 3 and 4 The mirrors 2 are adjusted electrically ...

Page 222: ...ion fold up warning plates are fitted below the driver s cab The warning plates 1 must be folded down to indicate the vehicle width during on road driving For off road driving the warning plates can be folded up and fastened with the locking bar 2 A Neutral position B Mirror on the driver s side or C Mirror on the passenger side 1 Up 2 Right 3 Down 4 Left 1 To switch on Press button once lamp 3 tu...

Page 223: ...he Vehicle height check function is present the position of the main boom in the boom rest is monitored In this case a corresponding warning is shown on the CCS display if the main boom has not been correctly put down à Main boom not set down p 8 16 s S Risk of accidents by exceeding total permissible height Check whether the main boom is resting on the boom rest Otherwise the indicated total heig...

Page 224: ...ng brake is applied Allow the engine to run The supply pressure builds up and you can speed up this process by pressing the accelerator The light 1 turns off once the supply pressure reaches about 5 5 bar 80 psi Refill the supply pressure until about 8 bar 116 psi is reached and a valve audibly discharges pressure There is now sufficient supply pressure G Risk of accidents by truck crane moving un...

Page 225: ...ervice brake Release the parking brake When the supply pressure is sufficient the parking brake is released and the lamp 1 goes out G Risk of accidents by truck crane moving unintentionally Always apply the service brake before releasing the parking brake This prevents the truck crane rolling in an uncontrolled manner when the parking brake is released ...

Page 226: ...Driving 5 1 Before driving 5 12 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 227: ...ed in sufficient air pressure is available in the secondary consumer circuit You may have to build up the supply pressure à p 5 10 Sit on the driver s seat the seat will rise to the last position set You can make adjustments to suit your body size and shape Settings for body size s 1 Back rest angle 2 Seat heating on off1 3 Lower it to the lowest position 4 Seat height 5 Seat inclination 6 Spring ...

Page 228: ...e settings are made pneumatically The following applies to all buttons Adjusting the passenger seat The passenger s seat is adjusted mechanically 1 Lower lumbar area support 2 Upper lumbar area support 3 Lateral support Empty the air cushion Press Fill the air cushion Press 1 Seat inclination 2 Back rest angle ...

Page 229: ... consumer circuit à Building up supply pressure p 5 10 Push the 1 button down once The steering column is unlocked for about 6 seconds Move the steering column into the desired position Push the button 1 up once Or wait until the steering column locks auto matically after approx 6 seconds G Risk of accidents by unlocked steering column Always stop the truck crane before you unlock the steering col...

Page 230: ...current switching state of the suspension is shown on the display 1 in all the menus To switch the suspension on and off you must open the Suspension level adjustment menu Open menu You can open the menu only when the truck crane is stationary or when the current speed is below approx 5 km h 3 mph Open the Suspension level adjustment 1 menu Symbol green Suspension is switched on Symbol red Suspens...

Page 231: ...hed off the suspension cylinders are locked This state is intended only for crane operation Select and confirm the symbol 1 When the suspension is switched off the symbol 2 is red G Danger of overturning when switching on the suspension Do not switch the suspension on unless the truck crane has been rigged for on road driving and the main boom has been set down If the rigged truck crane was standi...

Page 232: ...perating manual There you will find detailed information marking the diagram sheets malfunctions etc Prerequisites To set the tachograph the following requirements must be met The ignition is switched on the truck crane is stationary No error message is displayed In the event of malfunctions Check that a malfunction has occurred If a malfunction has occurred the tachograph display 1 will show an e...

Page 233: ...far as it will go The diagram sheet mounting 2 and an isolat ing plate 1 are in the drawer Checking the time setting First check the time setting for the diagram sheet mounting 2 fold the isolating plate 1 upwards to do this Insert a diagram sheet Make sure that the diagram sheet is under the spring 4 Check whether the diagram sheet s time scale on the marking 3 is showing the current time Correct...

Page 234: ...e insert the diagram sheet 2 Fold the isolating plate downwards Put the diagram sheet 1 for driver 1 on the isolating plate Take care that the diagram sheet is under the holder 3 Push the drawer 2 back in until it engages For single driver operation the diagram sheet mounting under the isolating plate is empty and only the diagram sheet 1 for driver 1 is inserted S Risk of malfunctions in the elec...

Page 235: ...ime 5 Driver 1 time group 1 1 Driver 1 diagram sheet inserted 1 2 Total kilometres of the truck crane 3 Driver 2 time group 2 1 Driver 2 diagram sheet inserted 2 2 Setting the time groups Set the time group for driver 1 using the button 1 The set time group is shown with the symbol 1 1 Set the time group for driver 2 using the button 2 The set time group is shown with the symbol 2 1 s ...

Page 236: ...tand by time When setting the working hours and stand by time observe the applicable local regulations for the country in which you are working Stand by time Periods of presence at the truck crane e g crane operation maintenance work passenger time etc Breaks and periods of rest These times are prescribed by law and must be observed H If the drivers swap during two driver operation the diagram she...

Page 237: ...confirm the symbol 2 Select the current time expressed as a deviation from UTC time Confirm the selection The newly set time is shown on the display 6 Switching the display type Select and confirm the display 3 Select the symbol for the desired display type Confirm the selection the selected display type becomes orange You can cancel the input at any time Press button 1 no values are changed 4 24 ...

Page 238: ... cannot be deleted Open the Operating hours 1 menu Displays The operating hours are recorded as follows The value 1 indicates the total operating hours for example 1 680 hours The value 2 shows the operating hours which can be reset Reset The displayed operating hours 3 can be reset Select and confirm the symbols 1 one after the other Confirm the entry with the symbol 2 You can individually select...

Page 239: ...anges However gears can be changed manually at any time 5 2 1 Switching on When the ignition is switched off the transmission must always be in the neutral position N Shift to position N If you switch on the ignition in positions D or R malfunctions may occur Switch on the ignition The electronic transmission system is switched on and a warning buzzer sounds for several seconds ...

Page 240: ...itch the transmission to neutral position while driving the drive line will be interrupted As a result you will no longer be able to accelerate the truck crane for instance when trying to avoid an obstacle and the engine retarder will have no effect G Risk of accidents due to the truck crane rolling away Always apply the parking brake or the service brake before you switch to the neutral position ...

Page 241: ...rresponding message is also displayed If necessary wait until the supply pressure has built up and the message disappears à Building up supply pressure p 5 10 Release the accelerator In order to drive forwards shift to position D drive backwards shift to position R An acoustic signal is given with additional equipment The operating mode Automatic is now selected An appropriate starting gear is sel...

Page 242: ... gear that is automatically selected on starting H Only change the gear selected on starting if it is absolutely necessary to do so Starting is a gear that is too high causes premature clutch wear Pull the gearshift lever upwards once The starting gear is shifted up by one gear Press the gearshift lever downwards once The starting gear is shifted down by one gear The altered starting gear is shown...

Page 243: ... switches to the Automatic operating mode When at a standstill a suitable starting gear is engaged While driving the gears are changed automatically depending on the load Change to manual mode The Manual operating mode is intended for off road driving with load conditions changing at short notice You can change over either with a gear change or without a gear change Changing over without gear chan...

Page 244: ...ot off the accelerator and apply the service brake Switch to the neutral position N and leave the engine running until the clutch has cooled down and the symbol 1 is no longer shown on the display Select a lower starting gear Start to move again G Risk posed by unexpected rolling Also apply the parking brake before starting on sloping ground The gear will be engaged only once you depress the accel...

Page 245: ...down the transmission first shifts to a lower gear After that it will shift to a higher gear only once a higher engine speed has been reached so as to achieve maximum accel eration If you execute a manual gear change using the gearshift lever you simulta neously switch to Manual operating mode The transmission will only perform an automatic shift after you have switched to Automatic operating mode...

Page 246: ...hift lever downwards briefly The newly engaged gear will be shown in the display H If you initiate a gear change which would cause the maximum permitted engine speed to be exceeded the transmission does not shift In that case slow the truck crane down until a permissible engine speed is reached and downshift again Upshifting one gear Push up once Upshifting two gears Briefly push upwards twice Ups...

Page 247: ...0 km h you can pre select a reverse gear or for ward gear when driving The gear is switched when the truck crane comes to a stop The shifting operation is complete when the display shows the selected gear 5 2 8 Stopping In order to stop remove your foot from the accelerator and actuate the brake pedal The transmission declutches shortly before the vehicle comes to a halt The current gear remains e...

Page 248: ...ature is between 20 C and 25 C 4 F and 13 F the gear oil must be preheated before you start driving the truck crane Let the engine run at idling speed for at least 10 minutes before you start driving G Danger of unexpected moving off rollers Always shift to the neutral position on the roller type dynamometer In position D or R a suitable gear is engaged for the speed The engine braking power is ap...

Page 249: ...corresponding ABS system is faulty and the wheels will no longer be prevented from blocking The full braking force remains intact à Malfunctions of the service brake p 8 25 If the lamp 1 lights up then the braking process is supported by the ABS system s G Risk of accidents because the truck crane cannot be steered Never switch off the ignition or remove the ignition key while the truck crane is m...

Page 250: ...mp 2 is lit symbol 1 red Steering system warning Stop as quickly as possible and perform the required checks à p 8 7 Warning messages Observe all error and warning messages Note the warning messages at the CCS display 1 à p 8 13 Note the warning messages at the on board computer display 2 à p 8 13 S Risk of accident due to mobile crane that cannot be steered and leaking oil If a warning message oc...

Page 251: ...ir can be sucked in and the fuel system must then be bled à Maintenance manual Adblue supply display If possible never run the Adblue tank completely dry refuel in due time à p 4 7 If the Adblue tank is empty the lamp 1 lights and the slewing moment is reduced à p 5 45 Coolant temperature display 1 Green Economic consumption 2 Yellow Engine brake active 3 Red Engine speed too high danger à Checks ...

Page 252: ...the accelerator After the accelerator is released cruise control reverts to the set speed H On downhill slopes the speed set may be exceeded since cruise control does not brake the truck crane Switch the cruise control off on downhill slopes Increasing reducing the speed Increase with 1 Reduce with 2 Press the corresponding button until the desired speed is reached or Press the corresponding butto...

Page 253: ...ching off Press the button 1 once The cruise control is now switched off The symbol 2 goes out in the Driving display Cruise control is also switched off when the service brake or additional brake is applied when speed falls below 10 km h 6 mph when the Temposet function is switched on when the ignition is switched off ...

Page 254: ...e Driving display The current speed is taken as the maximum speed You can exceed the speed by pressing the accelerator as far down as it will go kick down The Temposet limits the speed again only once you release the accelerator and press it again Increasing reducing the maximum speed Increase with 1 Reduce with 2 Press the corresponding button until the desired speed is reached or Press the corre...

Page 255: ...reversing you must do the following Shift into position R apply the parking brake press the accelerator release the parking brake after the clutch has engaged If the symbol 1 with a message is shown when starting Shift to a lower gear or end the starting operation s G Risk of accidents when driving in neutral position Never switch into neutral position whilst driving In neutral position the truck ...

Page 256: ... 5 43 Downshifting To increase the braking force of the engine you can select a lower gear Press the gearshift lever downwards once Manual operating mode is switched on and if possible one gear is shifted down If you initiate a gear change which would cause the maximum permitted engine speed to be exceeded the transmission does not shift In that case slow the truck crane down until a permissible e...

Page 257: ...speed the higher the braking power H For long downhill stretches we recommend that you use level 2 When the transmission retarder is switched on you cannot regulate the speed with the accelerator Switching on the additional brakes Pull the switch back to the required level latch into place briefly at each level Switching off the additional brakes Press the switch upwards to level 0 When the additi...

Page 258: ...eversing you must do the following Shift into position R Release the parking and service brakes Apply the accelerator if you wish to accelerate Do not apply the accelerator if you wish to brake with the engine Driving On certain gradients the transmission may switch continuously back and forth between two gears In this event either release the accelerator slightly or downshift by one gear G Danger...

Page 259: ...u can override torque reduction up to 3 times If the level in the AdBlue tank falls to the reserve level then the symbol 1 is displayed Immediately fill up with AdBlue à AdBlue tank p 4 7 If the AdBlue tank is empty the light 1 will flash The engine torque is reduced the next time the engine is started The engine torque is reduced Push the button 1 upwards to override the torque reduction You can ...

Page 260: ...rrier Push the chock 2 behind the bracket 3 and hang it on the holder 1 A Folding out Push the latch 4 through the hole 5 The chock unfolds by spring force B Folding up Push the chock together until the latch 4 engages in the hole 5 1 Stop the truck crane 2 Apply the parking brake 3 Switch to neutral position à p 5 26 4 Turn off the engine à p 4 18 G Risk of accidents by truck crane moving uninten...

Page 261: ... the engine has been switched off Slide the guard 1 downwards and push the switch underneath it 2 in the battery master switch is now off Securing the truck crane against unauthorised use Secure the truck crane against unauthorised use by Stowing away the hand held control in the crane cab or in the driver s cab Removing the ignition key Locking the driver s cab and the crane cab G Danger due to u...

Page 262: ... unlocked position and fold the berth 2 down Place the supports 3 into the socket Folding up Turn the locking bar 1 to position Locked Fold out the berth 2 until the locking bar 1 engages in the berth Fold up the supports 3 Put up the back rests of the seats Bring the seats and the steering column into the desired position à Adjusting the driver s seat p 5 13 à Adjusting the passenger seat p 5 14 ...

Page 263: ...rting starting mode for load on Select the Manual operating mode This will allow you to drive carefully and promptly shift gears à p 5 29 Connections If the adjustments to the transmission are insufficient on their own you can additionally connect the following one after the other First you can switch on the off road gear in the transfer case à p 5 50 Then switch on the longitudinal differential l...

Page 264: ...e speed is limited to approx 20 km h 12 mph A Switching on Select symbol 1 and confirm it symbol 2 is displayed off road gear engaged B Switching off Select symbol 3 and confirm it symbol 4 is displayed off road gear is disengaged If neither the symbol 2 nor 4 is shown select a starting gear on the transmission and shift back into neutral or start up slowly If the error symbol is displayed contact...

Page 265: ...n and off the current speed needs to be under approx 5 km h 3 mph Open the Driving 1 menu Straighten the steering Stop the truck crane The symbols 1 and 2 indicate the current switching state and have the same colour Switching on Select and confirm the symbol 1 for the Longitudinal differential locks A or Transverse differential locks B Start moving slowly display first symbol 2 yellow then symbol...

Page 266: ...Select and confirm the symbol 1 for the Longitudinal differential locks A or Transverse differential locks B Display first symbol 2 yellow then symbol 3 green differential locks off If symbol 3 is not green then drive back and forth slowly If the error symbol is displayed contact Manitowoc Crane Care ...

Page 267: ... adjustment system menu when the current speed is less than about 5 km h 3 mph Open the Suspension level adjustment 1 menu Check that the symbol 1 is green suspen sion on If the symbol 1 is red then select and confirm the symbol 2 to switch the suspension on When the suspension has been switched on you can Set the on road driving level Pre select the suspension struts and change the vehicle level ...

Page 268: ... level has been reached Pre selecting suspension struts You can pre select the suspension struts for five different level changes For a uniform level change For inclination Select and confirm the desired symbol the symbol turns orange and the symbol 2 is also displayed Now the vehicle level can be changed with the 7 button 4 Overall level all suspension struts 1 Front level suspension strut for th...

Page 269: ... level is continuously changed until you release the button or the end position is reached Raise the level Press the button 4 the symbol 1 becomes orange the suspension struts extend Lower level Press the button 5 the symbol 2 becomes orange the suspension struts retract s G Risk of accidents by exceeding total permissible height Always bring the truck crane to on road level before driving on road...

Page 270: ...5 A When the truck crane is level the marking 1 is in the middle B In this example the carrier would be standing higher to the rear on the right hand side Exiting the menu You can exit theSuspension Level adjustment system menu at any time Press the button 1 once The Start menu opens or Press the button 2 once The next highest menu is opened The Suspension Level adjustment system menu automaticall...

Page 271: ... starting gear with the gearshift lever Press the accelerator as far as possible Start driving as far as you can as high as possible Release the accelerator The transmission declutches disengage Let the truck crane roll in the opposite direction as far as it will go Start driving again to the highest point Repeat driving and letting the truck crane roll back until it has rocked itself free H It do...

Page 272: ... the rear chassis wall using a shackle The rear towing coupling 1 is designed for a maximum tensile force of 100 kN about 10 t 22 480 lbf about 22 050 lbs if The direction of pull runs along the level of the longitudinal axle and The direction of pull runs along the longitu dinal axle towards the rear without diverting up or down Remove the spare wheel 2 if necessary à p 8 33 S Risk of damage to t...

Page 273: ...h separate steering Driving around corners When the separate steering is switched on the steering angle is larger than for normal steering mode the turning circle is smaller Crab travel mode When the separate steering is switched on the truck crane drives side ways if you turn the wheels of the front and rear axle lines in the same direction ...

Page 274: ...eparate steering is switched on the speed is limited to approx 20 km h 12 mph If the error symbol is displayed contact Manitowoc Crane Care à p 8 24 G Risk of accidents when driving on road with unlocked steering After driving with separate steering change over immediately to normal steering mode The locking status for normal steering mode is only restored once the on road driving symbol is displa...

Page 275: ...s are steered in line with the turning radius contrary to the steer ing angle of the 1st and 2nd axle lines B For crab travel mode The 3rd and 4th axle lines are steered in the same direction as the 1st and 2nd axle lines Steering with manual separate steering Steer the 1st and 2nd axle line with the steering wheel Steer the 3rd and 4th axle line with the button 1 The axle lines are steered as lon...

Page 276: ...ng manual GMK4100L 1 23 11 2017 A for driving around corners Steer the 3rd and 4th axle lines in the oppo site direction to the 1st and 2nd axle lines B For crab travel mode Steer the 3rd and 4th axle line in the same direction as the 1st and 2nd axle line ...

Page 277: ...peed of approx 5 km h 3 mph Select and confirm the symbol 1 The Driving menu opens Turn the wheels to the Straight ahead position current wheel position is displayed Select and confirm the symbol 2 display symbol 3 After the switchover to normal steering mode the symbols 1 turn green steering locked If the symbols 1 are yellow Depending on the steering mode steer using the steering wheel 5 or the ...

Page 278: ...1 23 11 2017 5 5 3 Switching units of measure You can display the crane control values in metric units or US units Open the Switch units menu 1 Select and confirm the symbol The symbol 3 shows the respective confirmed selection 1 To display metric units 2 To display US units ...

Page 279: ...he temperature Setting the fan Setting the fan You can regulate the air volume with the switch 1 for Turn the switch 1 to the desired level 1 to 4 Recommended level 2 Setting the temperature Turn the switch 2 to the desired position Press the switch 2 several times in succession at least once a month in order to prevent malfunctions s A Recirculated air air is sucked in from the driver s cab Chang...

Page 280: ...he air to flow out of various air vents Turn the switch 5 to the position for the required air vents You can adjust air vents 2 and 3 Adjusting the air vents A Air vents 1 2 front windscreen side B Air vents 1 to 4 C Air vents 2 3 4 side centre below D Air vents 2 3 side centre 1 To open Upwards To close Downwards 2 To direct the air flow ...

Page 281: ...Turn the switches to the positions shown If necessary open the air vents for the side and centre If necessary open the push up roof à p 3 71 B Defrosting the front windscreen Turn the switches to the positions shown Close the air vents for the side and centre Switching off Switching off the heating system Turn the switch 1 as far as it will go in a counter clockwise direction to Cold Switching off...

Page 282: ... the cooling output to your actual needs If the truck crane has been exposed to strong sunlight for a long period of time for example the air conditioning system should initially be operated at the highest blower level with the engine running The door or at least the windows should be left open for a short while to thoroughly air the cab The cooling down procedure can be accelerated by increasing ...

Page 283: ...ution with switch 2 open the air vents if necessary à p 5 66 Close the push up roof à p 3 71 Drying You can dry the air in the driver s cab Switch the air conditioning on the lamp 4 lights up Turn the switch 3 as far as it will go to Warm Turn the switch 1 to the desired level adjust the fresh air recalculated air setting to the current conditions humidity and temperature of the out side air Set t...

Page 284: ...ries at shorter intervals if you use the auxiliary heater frequently Further information on the operation of the auxiliary water heating system is provided at the address Webasto com You can use the auxiliary water heater to preheat the engine or pre heat the engine and driver s cab Preheating the engine If only the engine is to be preheated adjust the heating system as follows Switch 1 pushed in ...

Page 285: ...Check whether the auxiliary heater is allowed to be operated at the cur rent site of the truck crane before switching it on Find out whether there are any possible sources of danger that could result in an explosion s G Risk of explosion when operating the auxiliary heater The auxiliary heater is not allowed to be operated at service stations and tank farms At places where flammable gases or vapou...

Page 286: ...ton 1 Menu control The jog dial rotary push button 1 turn to select press to confirm Setting the temperature Turn switch 1 to the desired temperature If the switch 1 is turned as far as possible A cold the auxiliary heater is not switched on The auxiliary heater only supports the heating capacity of the standard heat ing system as long as the engine is cold If the engine is warm the heater is swit...

Page 287: ... 8 minutes You must reset the date and time Always set the current time and current day of the week These settings are required for the correct activation point of the automatic heating start Select and confirm the symbol Settings 1 display symbol Immediate start 2 Select and confirm the symbol Day of the week 1 display symbol 2 for instance MON for Monday Select and confirm the desired day of the...

Page 288: ...ng setting process they flash for 5 seconds The entry must be made within this period The value stops flashing after 5 seconds and is saved as the new value Select and confirm the symbol Timer 1 display symbol Add timer 2 Select and confirm the symbol Add timer 2 Select and confirm the desired day of the week for instance MON for Monday The Switch on time display flashes At the flashing display se...

Page 289: ...nfirm the desired temperature After the desired temperature has been input the set values are saved and shown in the display Day 1 Switch on time 2 Switch off time 3 Heating mode 4 Temperature 5 Confirm the set values Confirm the Activate symbol A heating start that is activated is shown by A white marking 1 The symbol T 2 in the main menu If the display is switched off the button 3 flashes green ...

Page 290: ...tlet 2 Switching on Before switching on the heating system check whether it is allowed to be operated at the current location of the truck crane Find out whether there are any possible sources of danger that could result in an explosion G Risk of explosion when operating the heating system The heating system may not be operated At service stations and tank farms At places where flammable gases or ...

Page 291: ...until the menu row 2 is displayed If you do not make settings within 10 seconds of switching on the control unit switches to idle mode Use button 1 or 2 to select the symbol 3 and confirm with button 4 The auxiliary heater switches on Setting the heating level You can preselect a heating level between 10 and 30 Use button 1 or 2 to select the symbol 3 and confirm with button 4 Change the heating l...

Page 292: ...day of the week using button 1 or 2 and confirm with button 4 The set time is shown in display row 3 Select the hour using button 1 or 2 and confirm with button 4 Select the minutes using button 1 or 2 and confirm with button 4 Setting the preselection time Heating is started automatically on schedule only if the time and the day of the week have been correctly set à Setting the day and time p 5 7...

Page 293: ...lect the hour or minutes and confirm with button 4 Use button 1 or 2 to select the Heating function 3 and confirm with button 4 You have now set the preselection time After setting the preselection time you can set the heating period Setting the heating period After an automatic start the auxiliary heater switches itself off as soon as the set heating period has elapsed The heating period applies ...

Page 294: ...Off display appears and confirm with button 3 The preselection time is deleted Switching off This section only describes how to switch off the heater manually If the aux iliary heater is switched on automatically it switches off after the set heating period has elapsed à Setting the heating period p 5 79 Use button 1 or 2 to select the symbol 3 and confirm with button 4 The auxiliary heater switch...

Page 295: ...r every 100 kg 220 lbs of drawbar load the axle loads on the 2nd and 3rd axle lines are reduced by 87 kg 192 lbs s G Risk of accidents by trailer moving unintentionally Before coupling or uncoupling the trailer it must be secured with the trailer parking brake as well as with chocks to prevent it rolling away Ensure that it is still possible to swivel the front axle of the trailer G Risk of accide...

Page 296: ...ar of the trailer is pushed into the coupling jaw The towbar coupling closes automatically and the lever 1 swings downwards H Make sure you check the prescribed condition of the coupling after each coupling procedure The pin 1 may no longer protrude from the guide bushing after the coupling procedure G Risk of injury when the automatic closing device is triggered Do not put your hand into the coup...

Page 297: ... Socket 2 is designed for special equipment Check the function of the trailer lighting Test the service brake and parking brake immediately after setting off s G Risk of accidents if the trailer is coupled improperly If the pin is protruding from the guide bushing the trailer is not coupled properly and could become disengaged from the towbar coupling while driving G Risk of accidents if the hoses...

Page 298: ...er Secure the trailer with the trailer parking brake and chocks as prescribed to prevent it from rolling away Open the towbar coupling Push the lever 1 up until it latches into place Drive the truck crane carefully away from the trailer G Risk of accidents due to trailer moving unintentionally Always first remove the hose from the supply line so that the trailer is braked This prevents the trailer...

Page 299: ...osing the towbar coupling by hand When closing the lever moves down with great force in the direction of the coupling jaw Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand If you hold the lever and move it down it may carry your hand with it and crush it G Risk of injury when the automatic closing device is triggered Always c...

Page 300: ...the lever in this position the parking brake on the trailer is released the parking brake on the truck crane remains applied This allows you to check whether the braking force of the parking brake on the truck crane alone is sufficient to brake the truck crane and the trailer Let go of the lever The lever latches into position and the parking brake of the trailer is applied S Risk of accident from...

Page 301: ...ured If country specific regulations allow the truck crane to be driven with axle loads greater that 12 t 26 500 lbs the crane driver operator bears the sole responsibility for driving in this condition and for any subsequent damage This also applies to damage due to premature wear G Risk of accidents from increased braking distance When driving with axle loads in excess of 12 t 26 500 lbs the bra...

Page 302: ...xt to Rigging mode Example of how to use the table Assuming your truck crane is equipped with 385 95 tyres 8 x 6 x 8 drive tans mission retarder and auxiliary hoist In this case the driving mode in the upper part next to equipment is 1 3 and 5 Assuming you are drive while in driving mode 3 according to the specifications in the bottom part next to the rigging mode the steel outrigger pad installed...

Page 303: ...el on rear Outrigger pad from steel Plastic outrigger pad Hook tackle hung on the bumper1 1 sheave hook block attached to the bumper1 1 0 t 2 205 lbs counterweight on the counterweight platform front 3 7 t 8 160 lbs counterweight on the counterweight platform rear 4 9 t 10 800 lbs counterweight on the counterweight platform rear Add on parts for lattice extension installed2 Hose drum for lattice e...

Page 304: ...erweight on the counterweight platform front 3 7 t 8 160 lbs counterweight on the counterweight platform rear 4 9 t 10 800 lbs counterweight on the counterweight platform rear Add on parts for lattice extension installed2 3 Hose drum for lattice extension installed2 AP switch cabinet with diesel generator or narrow storage compartment 1 The weight of the hook blocks is based on the information in ...

Page 305: ... mode 445 95 R25 spare wheel on rear Hook tackle hung on the bumper1 3 7 t 8 160 lbs counterweight on the counterweight platform rear 4 9 t 10 800 lbs counterweight on the counterweight platform rear Add on parts for lattice extension installed2 Hose drum for lattice extension installed2 AP switch cabinet with diesel generator or narrow storage compartment 1 The weight of the hook blocks is based ...

Page 306: ...ear Hook tackle hung on the bumper1 3 7 t 8 160 lbs counterweight on the counterweight platform rear 4 9 t 10 800 lbs counterweight on the counterweight platform rear Storage compartment on the rear with a capacity of 200 kg 441 lbs Add on parts for lattice extension installed2 Hose drum for lattice extension installed2 AP switch cabinet with diesel generator or narrow storage compartment 1 The we...

Page 307: ... note the information provided by the tyre manufacturer regarding the maximum permitted load duration G Risk of accidents from overloading tyres Never exceed the maximum permitted speed which is given for the current axle load and tyre size This prevents the tyres from becoming overloaded and bursting Tyre size Tyre pressure in bar psi Current Axle load in t lbs Maximum permissible speed In km h m...

Page 308: ...Driving modes 6 1 Driving modes 6 8 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 309: ...urer of the scales If multiple individual scales are used allowance must be made for the fact that the axle groups are hydraulically coupled For this purpose you will need wheel load scales of sufficient capacity and size Determining the total weight The weights of all the axle groups belonging to the crane must be recorded at the same time in a single weighing procedure In addi tion only one set ...

Page 310: ...belonging to an axle group must always be weighed In addition all the wheels must be on the same level If for instance only the axle group A1 is to be weighed then the axle groups A2 must be equalised on a support plate U which has the same height as the scales W1 and W2 Axle groups GMK4100L 1 Axle group 1 1 2 axle line Axle group 2 3 4 axle line ...

Page 311: ... In the next step drive at only a very low speed without any steering move ments and brake only very gently Drive the truck crane on to the scales W1 to W4 or on to the necessary support plates so that the axle groups stand centrally on the scales Do not apply the parking brake If the truck crane has to be braked while changing the level only use the service brake very gently 1 Use the level adjus...

Page 312: ...st determine the weight of the associated axle group and divide it by the number of axle lines Determine the weight of the axle group The axle group 2 was weighed with the scales W3 and W4 Add the weighing results Determining the axle load on the 2nd axle line Axle group 2 has 2 axle lines Divide the weight of the axle group by the number of axle lines Passenger side W1 10 t W3 12 t Driver s side ...

Page 313: ...king you can set the main boom onto a dolly when driving For this purpose the truck crane must be fitted with a slewing gear freewheel boom floating position and if necessary with a boom pre tensioning device Before driving with the dolly you must Switch on the slewing gear freewheel à p 6 14 Switch on the boom floating position à p 6 15 Switch on boom pre tensioning if necessary à p 6 16 Unrig th...

Page 314: ...5 Prerequisites The engine must be running The slewing gear brake must be released the lamp 1 must have gone out à Releasing the slewing gear brake p 11 116 Switching on Remove the lock 4 from the bore 2 Push the pin 3 inward as far as it will go Secure the pin with the padlock in the bore 1 and remove the key Insert and secure the pin 3 on the other slewing gear in the same way Open the valve 5 t...

Page 315: ...1 upwards Secure the lever 1 with the padlock 2 Switch the valve IV over Lever 3 points downwards The boom floating position is now switched on H Switching off the boom floating position à p 12 19 G Risk of accidents from the boom floating position being switched off Always switch on the boom floating position when the main boom is on a dolly This prevents the full weight of the dolly briefly beco...

Page 316: ...on the boom floating position à p 6 15 The valves II and III are under the pressure gauge 1 Close the valve II the lever 2 is horizontal Open the valve III the lever 3 points upward You can now fill the pressure accumulator Press button 4 in The pressure accumulator is now filled Fill up the pressure accumulator until the pressure stops rising on the pressure gauge 1 Close the valve III lever 3 po...

Page 317: ...arate vehicle Transport dimensions and weight à p 1 14 6 4 1 Slinging the auxiliary hoist Sling the auxiliary hoist at the slinging points 1 Use suitable lifting gear with the same length so that the auxiliary hoist hangs at the centre of gravity Remove the bolts from the connecting points 2 S Risk of damage to the auxiliary hoist and truck crane Only sling the auxiliary hoist onto the slinging po...

Page 318: ...vity and remove the bolts from the connection points à p 6 17 2 Lift the auxiliary hoist on to the turntable and make the connections à p 6 20 3 Make the hydraulic connections à p 6 21 Make the electrical connection à p 6 22 Establish the connection to the central lubrication à p 6 23 4 Check that the auxiliary hoist is functioning properly à p 6 25 Place the hoist rope on and reeve it 5 Fit the h...

Page 319: ...oist rope using the rigging aid if necessary à p 6 26 2 Disconnecting hydraulic connections à p 6 21 Disconnecting the electrical connection à p 6 22 Disconnect the connection to the central lubrication à p 6 23 3 Attach the auxiliary hoist at the centre of gravity à p 6 20 Disconnect the connection between the auxiliary hoist and turntable à p 6 20 4 Lift the auxiliary hoist onto the separate veh...

Page 320: ...o the turntable so that the connection points 2 are lined up Use a washer on each side and tighten the bolts 1 with the nuts 3 at all the connec tion points Tighten the bolts 1 to 200 Nm the bolts 2 to 1 800 Nm Undoing the connection Attach the auxiliary hoist on to an auxiliary crane Remove all the bolts 1 from the connecting points 2 Lift the auxiliary hoist off the turntable Lift the auxiliary ...

Page 321: ...5 Establishing disconnecting the hydraulic connections Making the connection The assignment is given by the size and colour designations Connect the hoses 1 to the ports 2 Undoing the connection Remove the hoses 2 from the connec tions 1 Close all hoses and connections Insert the hoses into the hoist frame 3 ...

Page 322: ...ng the electrical connection Making the connection Remove the plug 2 from the dummy socket 3 and plug it into the socket 1 Close the dummy socket 3 Undoing the connection Remove the plug 2 from the dummy socket 1 and plug it into the socket 3 Close the socket 1 Lay the cable 4 in such a way that it is not left hanging during removal ...

Page 323: ...K4100L 1 23 11 2017 6 4 7 Making breaking the connection to the central lubrication Making the connection Connect the hose 1 to the connection 2 Undoing the connection Remove the hose 1 from the connec tion 2 Close off the hose and the connection Insert the hose into the hoist frame 3 ...

Page 324: ...arate vehicle in such a way that the weight is evenly distributed Load the auxiliary hoist in such a way that no motorists and cyclists are put at risk Lift the auxiliary hoist onto the separate vehicle and remove the lifting gear Use a washer on each side and tighten the bolts 1 with the nuts 2 at all the connec tion points Check that the plug 2 is inserted into the dummy socket Lay the hoses and...

Page 325: ...ection is correct Slewing indicator Check the function of the slewing indicator when applying the hoist rope You should feel a pulse on the slewing indicator 1 when the auxiliary hoist is rotating If no pulse is present contact Manitowoc Crane Care G Risk of accidents due to incorrect slewing direction Check after each installation that the slewing direction is correct This prevents accidents caus...

Page 326: ... the auxiliary hoist Scope of delivery Making the connection Place the end of the hoist rope 1 in part 2 of the connector Screw part 2 and 3 of the connector together Attach the rope 4 to the connector 1 Connector two parts 2 Rope S Risk of damage to the hoist rope Always rig the hoist rope with the rigging aid This prevents slack rope Rope loops will form which can cause the load to slip and dama...

Page 327: ...ead sheave Slowly unreel the hoist rope Use the rope 1 to keep the hoist rope ten sioned so that no slack rope occurs When unrigging Slowly reel in the hoist rope Use the rope 1 to keep the hoist rope tensioned so that no slack rope occurs Undoing the connection Remove the rope 4 Disconnect part 2 and 3 of the connector and remove the hoist rope 1 Store the rigging aid so that it is safe for trans...

Page 328: ...Driving modes 6 4 Rigging the auxiliary hoist 6 28 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 329: ... on parts You will require the following equipment with a sufficient load bearing capacity An auxiliary crane Suitable lifting gear and guide ropes A chain hoist A separate vehicle Dimensions and weights of the outrigger beams à p 1 10 G Risk of truck crane overturning if not properly supported Loads may only be lifted when the truck crane is supported on all outrigger beams The lifting capacity t...

Page 330: ...ying operating instructions which are indicated by cross references Observe the warnings and safety instructions specified here 1 Preparing the truck crane à p 6 35 2 Label the outrigger beams retract release and bolt them to each other à p 6 34 3 If necessary remove the outrigger pads à p 6 36 4 Unscrew the spacer à p 6 40 5 Disconnecting hydraulic connections à p 6 38 Disconnect the electrical c...

Page 331: ...rigger box until it reaches the centre of gravity à p 6 42 8 Sling the outrigger beams in the centre of gravity and pull them out of the outrigger box Lift the outrigger beams onto the separate vehicle Attach the connecting elements on the outrigger box à Extending the outrigger beam p 6 42 à Transporting the outrigger beams p 6 46 9 Remove all necessary outrigger beams in the same way in accordan...

Page 332: ...s specified here 1 Preparing the truck crane à p 6 35 2 Remove the connection elements from the outrigger box Sling the outrigger beams at their centre of gravity Lift the outrigger beams into the outrigger boxes and remove the lifting gear à Inserting the outrigger beam p 6 44 3 Sling the outrigger beams and pull into the outrigger boxes until the connection points align à p 6 44 4 Establish the ...

Page 333: ...osition à p 6 36 8 Mount all necessary outrigger beams in the same way in accordance with this checklist 9 If the truck crane is at the site Extend the outrigger beams to the necessary outrigger span secure them and stabilize the truck crane 10 If the truck crane still has to be driven to the site Fully retract and secure the outrigger beams à Extending retracting outrigger beams p 12 47 ...

Page 334: ...gned for just one installation point If for exam ple you remove the outrigger beam on the rear left hand side you must mount the same outrigger beam on the rear left hand side again Before you remove all outrigger beams for the first time label them with the correct installation point and if necessary also with the serial number of the truck crane Release the outrigger beams All outrigger beams ar...

Page 335: ...ger beams All rigging work which involves slewing the superstructure has been completed The parking brake is engaged The truck crane has been levelled with the level adjustment system à p 5 53 The suspension is switched off blocked and the symbol 1 is red à p 5 16 The corresponding covers have been removed 1 If necessary the driver s cab may need to be tilted forward in order to reach the separato...

Page 336: ...own on the outrigger pad Removing the outrigger pads Handling is easier if you remove the outrigger pad before removing the outrigger beams A Move the outrigger pad into the oper ating position Extend the outrigger cylinder until the out rigger pad just touches the ground but is not yet under strain B Remove out the pin 1 Remove the bolts nuts 2 A Pull the outrigger pad off the outrigger cylinder ...

Page 337: ... far enough so that the bearing surface 3 is below the guide 4 B Push the outrigger pad onto the outrig ger cylinder Fasten the bolts nuts 2 Tightening torque 35 Nm 25 7 lbft Move the outrigger pad into required position On site move it to the working posi tion A If you need to drive to the site in driving position B Insert the pin 1 and secure it Securing pin Plug the pin with the peg 1 through t...

Page 338: ...f the valve block may differ from the drawings depending on the outrigger beam Undoing the connection Always disconnect all connections 4 Hold the hose 1 firmly Pull the lock 2 against the stop The hose is pushed out of the connection 3 Seal all connecting points Making the connection Always establish all connections 4 The assignment is specified by colour designations Insert the hose 1 into the c...

Page 339: ...the plugs 1 apart Protect the plugs against dirt and moisture B Establishing the connection Connect the plugs 1 together Protect the separating points against dirt and moisture H Some error messages can occur after disconnecting the electrical connec tions à Note on error messages with removed outrigger beams p 6 47 S Risk of malfunctions in the electronic system Always turn off the ignition befor...

Page 340: ...opposite side The illustrations show as an example the spacers for the outrigger beam on the front right hand side Unscrewing Before you pull out the outrigger beams you must unscrew the spacers At the outrigger box Undo the lug nuts 2 Unscrew the bolts 1 until the spacers 3 are screwed into the outrigger box 4 completely At the outrigger beam Undo the lug nuts 2 Unscrew the bolts 1 until the spac...

Page 341: ...x Screw in the screws 1 as far as possible until the spacers 3 are touching the outrig ger beam 4 at the top Ensure that the outrigger beam is aligned horizontally Lock the screws in place with the nuts 2 At the outrigger beam Screw in the bolts 1 Until the spacers 3 lie on top on the outrigger box 4 and Until the distance X to the supporting box 4 is an even 4 mm 0 16 in over the entire width Loc...

Page 342: ... plates 4 still have lateral play 6 5 11 Pulling out Inserting the outrigger beam Extending the outrigger beam Check that the outrigger beams are released and are secured between each other à Preparations for removal p 6 34 S Risk of damage to hydraulic lines Ensure that the hydraulic lines on the outrigger beam do not remain hang ing on the supporting box and become damaged G Danger of overloadin...

Page 343: ...r Fasten a guide rope 1 Lift the outrigger beam slightly to ease the load Lift the outrigger beam almost completely out of the outrigger box Fasten another guide rope 1 Lift the outrigger beam out of the outrigger box Lift the outrigger beam onto a separate vehicle à p 6 46 Fasten the connecting elements to the connecting points 1 of the supports s G Risk of being crushed by the swinging outrigger...

Page 344: ...sten two guide ropes 1 Set the outrigger beam in the outrigger box Remove the guide rope 1 G Risk of being crushed by the swinging outrigger beam Do not guide the outrigger beam with your hands when inserting it Always used guide ropes and keep a suitable distance This will prevent limbs from being crushed between the supporting box and the outrigger beam S Risk of damage to hydraulic lines Ensure...

Page 345: ...trigger beam as far as possible into the outrigger box Correct the height so that it does not remain hanging on the edges 1 Remove the lifting gear from the centre of gravity Fasten a chain hoist to the lifting gear 1 Pull the outrigger beam in so far until the connecting points 1 align Remove the chain hoist and lifting gear ...

Page 346: ...m so that it that does not endanger other traffic When the outrigger pads are mounted Place the outrigger beam onto a suitable fixture 1 Secure the outrigger beam from slipping When the outrigger pads are dismounted Lay the outrigger beam onto the side Secure the outrigger beam from slipping Lay the outrigger pads onto the separate vehicle and secure them for transportation S Risk of damage to the...

Page 347: ...e following error messages can occur after removal The error messages indicate only that the electrical connection between the outrigger beams and the crane control is disconnected They have no further effect on driving The error messages are displayed in the driver s cab on the CCS display until the outrigger beams are reinstalled 5801 7 33 2 5809 7 32 96 5801 7 33 98 5803 7 32 2 5807 7 32 96 580...

Page 348: ...Driving modes 6 5 Installing removing the outrigger beams 6 48 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 349: ...se only suitable lifting gear with sufficient lifting capacity for loading Use only trailers and vehicles with sufficient loading surface and carrying capacity for transport G Risk of accidents due to inadequate information Observe the information in the following sections concerning transport You can thus prevent unsecured parts from falling or components from being damaged due to improper handli...

Page 350: ...on I The boom must be resting in the boom rest The slewing gear is switched off à p 11 120 The superstructure is locked à p 11 15 Depending on the driving mode the counterweight must be unrigged à p 6 1 à p 12 69 If the base plate is being transported on the rear counterweight plat form lock the counterweight platform à p 12 96 2 On the outrigger All outrigger beams must be fully retracted and sec...

Page 351: ...he anemometer and air traffic control light must be removed à Anemometer and air traffic control light p 12 126 5 All railings must be folded in à p 12 129 6 The camera on the turntable must be retracted à p 12 132 7 The step at the crane cab must be retracted à p 12 137 8 All ladders are secured à p 3 77 s ...

Page 352: ...ok block must be attached to the bumper à p 12 99 or unreeved à Unreeving hoist rope p 12 113 11 The transverse differential locks must be switched on à p 5 51 7 1 2 Drive the truck crane on to the transport vehicle G Risk of accidents due to inadequate field of vision Always have a banksman on hand to help when driving onto a transport vehicle Maintain eye contact or radio contact with the banksm...

Page 353: ...mmediately and switch the engine off Close all the doors Lashing Secure the truck crane with the chocks 1 Lash the truck crane down at the slinging points 2 Ensure that no attachments cables or hoses are damaged in this process G Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided ...

Page 354: ...additional points as slinging points Under no circumstances exceed the set values G Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided S Risk of damage to the auxiliary hoist and main boom When lashing the truck crane under no circumstances exceed the set val ues This will avoid damage to the auxilia...

Page 355: ...emergency use Press an emergency stop switch 1 2 or 3 The switch latches The engine shuts down After activating an emergency stop switch à Resetting the emergency stop switch p 4 19 H The battery master switch cannot be used as an emergency stop switch for the engine The engine continues to run after the battery master switch has been switched off 1 On the carrier 2 On the hand held control unit 3...

Page 356: ... the traffic behind you Secure the truck crane in compliance with the legal regulations applicable in the country in which you are working If you are unable to repair the damage yourself notify Manitowoc Crane Care or have the truck crane towed à Towing the truck crane p 8 29 G Risk of accidents due to poor visibility If possible do not stop in a tunnel or directly after a curve G Risk of accident...

Page 357: ...Engine malfunction One or more systems have a malfunction Engine Engine cooling system Engine control Fuel system Drive on until you have a chance to stop Stop immediately and switch the engine off If necessary note the error messages and contact Manitowoc Crane Care or a qualified specialist repair shop The coolant temperature is too high the motor output is automatically reduced Reduce speed Dri...

Page 358: ...onic system will try to establish a secure operating condition with the remaining functions H Even if the transmission still shifts always notify Manitowoc Crane Care This avoid situations where another small error could lead to transmission failure A text message is also displayed in addition to a symbol on the on board computer display à Warning and malfunction messages on the on board computer ...

Page 359: ...lfunction message is active in the corresponding area Lamp goes out no message Lamp is red warning message Stop the truck crane immediately taking into account the traffic situation and identify the cause Lamp is orange malfunction message Identify the cause at the next opportunity If a symbol is displayed in red perform the following checks Battery charge indicator warning The voltage in the carr...

Page 360: ...k the hydraulic oil level à Maintenance manual Start the engine If all 3 lamps 1 light up Switch the engine off Contact Manitowoc Crane Care If at least 2 lamps 1 light up Drive at a speed greater than about 10 km h 6 mph If only one lamp is still lit drive slowly to the next repair shop The steering may be sluggish If two lamps are still lit stop immediately Contact Manitowoc Crane Care G Risk of...

Page 361: ...orrected at the next opportunity Steering system warning The lamp 1 lights up symbol 2 red The 3rd axle line stays on the current steering angle and can no longer steered Stop as quickly as possible taking account of the current traffic situation Briefly switch the ignition off and then on again If the error is still present then check the steering angle at the 3rd axle line Whether it is possible...

Page 362: ...ons in driving mode 8 3 Warning and error messages 8 8 3 302 690 en Operating manual GMK4100L 1 23 11 2017 AdBlue system Also check the control elements for the Adblue system à Faults on the Adblue system p 8 21 ...

Page 363: ...ormation Display 1 grey additional text and symbols Pay attention to the messages You can continue driving Message elements Messages consist of text and symbols abbreviations When the symbol 1 is shown you can display additional text by pressing the button 3 Follow the instructions that are displayed and perform the specified measures in good time Acknowledging a message Press 2 once the message d...

Page 364: ...Add oil if necessary If the error message is still displayed please contact Manitowoc Crane Care Oil level too low The oil level is far too low Stop the truck crane as quickly as possible while observing the traffic situation and switch off the engine If oil has run out Warn any vehicles on the road behind you Do not continue driving Contact Manitowoc Crane Care If no oil has run out Correct the o...

Page 365: ...malfunction Engine retarder fault The braking behaviour can change Stop the truck crane as quickly as possible while observing the traffic situation and switch off the engine Have the engine retarder immediately checked and repaired by a specialist workshop Transmission symbols The gear shifting has a malfunction driving can continue with restrictions If necessary note the error messages and conta...

Page 366: ...has been reached Shift to a lower gear for manoeuvring or starting or stop the manoeuvring or starting procedure The oil temperature of the fluid coupling is too high Shift to a lower gear the engine speed increases and the dry clutch closes The oil temperature of the retarder is too high Shift to a lower gear the engine speed increases and the engine braking effect increases ...

Page 367: ...alfunction message is active in the corresponding area Symbol yellow malfunction Symbol red warning message no symbol no malfunction or warning message If a symbol is displayed in red or yellow perform the following checks Symbols in the display area Voltage monitoring The voltage in the electrical system is too high or too low Display of the current voltage à p 4 17 s S Risk of damage if warning ...

Page 368: ...l level is correct then start the engine and check the warning messages that are present Air intake inhibitor triggered The air intake inhibitor was triggered because the maximum permissible engine speed was exceeded It is only possible to start the engine after the air intake inhibitor has been released manually à p 4 20 S Danger of overheating There is a fault if the hydraulic oil temperature ex...

Page 369: ...out 95 C Display of the current temperature à p 10 8 Possible cause and remedy à p 8 19 Transmission retarder too hot The retarder in the transmission is not working When the transmission retarder has cooled down the symbol reverts to grey and the transmission retarder is ready to function again Transmission oil too hot Stop the truck crane as soon as possible and try to find the cause à Malfuncti...

Page 370: ... height p 5 9 Emergency stop switch actuated à Resetting the emergency stop switch p 4 19 Engine malfunction Switch off the engine immediately and open the Engine transmission error menu à p 8 17 If necessary note the error messages and contact Manitowoc Crane Care CAN bus malfunction Switch off the ignition and wait about 15 seconds then switch it on again If the malfunction is still present cont...

Page 371: ...splayed 3 5 for example means Error 3 is shown there is a total of 5 errors Displaying errors Select and confirm the symbol 3 or 4 to show any additional errors Error message display For each error the display shows The error code 3 The symbols for the faulty components Always note the error code before contacting Manitowoc Crane Care Exiting the menu You can exit the Engine errors menu at any tim...

Page 372: ...Malfunctions in driving mode 8 3 Warning and error messages 8 18 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 373: ...e à p 5 46 Fuse F1 1 F1 2 blown Replace blown fuses à p 8 49 Emergency stop switch pressed Release the emergency stop switch à p 4 19 Engine does not start Starter turns Batteries insufficiently charged Charge the batteries à Maintenance manual The symbol is displayed Fuel tank empty 1 Refuel à p 4 5 2 Bleed the fuel system à Maintenance manual à Separate engine operating instructions provided by ...

Page 374: ...low the symbol is displayed Engine oil level too low Check oil level top up if necessary à Maintenance manual Engine cannot be switched off using the ignition key Malfunction in the electronics Switch off the engine with the emergency stop device à p 8 1 Engine transmission diagnostics plug not working Fuse F1 5 F6 6 blown Replace blown fuses à p 8 49 The engine power is reduced and the engine coo...

Page 375: ...does not start Starter turns Dual tank empty 1 Refuel à p 4 5 2 Bleed the fuel system à Maintenance manual à Operating manual of the engine manufacturer Malfunction Cause Solution Lights up Flashing AdBlue level in tank at reserve level AdBlue tank empty Fill up with AdBlue à p 4 7 Light up AdBlue tank sensor faulty Error on the AdBlue dosing unit AdBlue lines blocked Temperature sensor faulty Ope...

Page 376: ...air system insufficiently filled à Building up supply pressure p 5 10 Control unit fuse blown Replace blown fuses à p 8 49 Differential locks cannot be switched off Current speed above approx 5 km h 3 mph Slow down or stop the truck crane Drive train under tension Slowly drive truck crane back and forth à p 5 51 Malfunction Cause Solution Switching operations are not conducted Brake reservoir pres...

Page 377: ...ssion is not upshifting at speeds over about 20 km h 12 mph A locking procedure is not yet completed Switch off differential locks à p 5 52 Transmission not shifting the symbol is displayed Retarder switched on à Switching off the additional brakes p 5 43 The transmission does not respond to the controls Fuse F1 6 blown Replace blown fuses à p 8 49 Transmission cannot shift down as otherwise the m...

Page 378: ...circuit failure for example pump defective Stop and perform required inspections à p 8 6 Lights up yellow Steering malfunction Driving possible observe the subsequent informa tion for the next stop à p 8 7 lights up red Steering system warning The steering is defective stop as quickly as possible and observe the subse quent information à p 8 7 Symbol is displayed Hydraulic oil filter dirty Replace...

Page 379: ...Top up the compressed air supply on the filler connection à p 8 29 2 Tow the truck crane with the tow rod à p 8 29 Parking brake unable to be released Supply pressure too low à Building up supply pressure p 5 10 The retarder cannot be engaged Fuse F7 4 blown Replace blown fuses à p 8 50 Malfunction Cause Solution Suspension cannot be activated Current speed above approx 5 km h 3 mph Slow down or s...

Page 380: ...n Replace blown fuses à p 8 49 Malfunction Cause Solution Hydraulic oil temperature above 80 C 176 F fan in the hydraulic oil cooler running Symbol is displayed Hydraulic system is heavily loaded Stop the truck crane while taking the traffic situation into account and run the engine until the oil has cooled down Hydraulic oil temperature above 80 C 176 F fan in the hydraulic oil cooler not running...

Page 381: ...tarting the truck crane externally Start the engine of the auxiliary vehicle A Connect the cable 1 to the power supply 24 V of the auxiliary vehicle Insert the plug 2 into socket 3 Start the truck crane engine B Take out the plug 2 Close the socket 3 Remove the cable 1 from the auxiliary vehicle The socket 3 can also be used as a power source for another vehicle with a 24 V on board network ...

Page 382: ...ing eyes 4 Insert the plug 6 into the socket on the mains supply 230 V at the location The battery charger switches on The lamp 3 on the battery charger indicates the status Breaking Withdraw the plug 3 from the socket Take out the plug 1 from the socket 2 Close the socket 2 Return the battery charger to the storage compartment in the driver s cab G Risk of explosion when operating the battery cha...

Page 383: ... truck crane must be towed with a special breakdown truck The front towing coupling is designed for a maximum tractive force of 10 t 22 000 lbs Tensile force may be applied only forwards or at an angle of 45 to both sides of the longitudinal axis of the truck crane In the case of engine transmission damage The following information only applies to towing the truck crane out of the immediate hazard...

Page 384: ...ayed and the lamps 1 must not light up in the driver s cab when towing Electric power supply Switch on the battery master switch Switch on the ignition On the transmission Switch the transmission to neutral position N à p 5 26 Switching towing mode on off Open the main menu if necessary Switching on Select and confirm the symbol 1 Symbol 2 is displayed Towing mode is switched on Switching off Sele...

Page 385: ...r supply until the supply pressure has been built up à Building up supply pressure p 5 10 If the lamp 1 does not go out there is a malfunction on the parking brake system Contact Manitowoc Crane Care Towing the truck crane out of the danger area Once you have made all the adjustments as described in this section you can tow the truck crane away from the hazard area Ensure that the tractor vehicle ...

Page 386: ...nsmission is to be towed for a distance greater than 100 m 330 ft you must disconnect the Cardan shaft between the transfer case and transmission If you need to tow the truck crane further than 100 m 330 ft contact Manitowoc Crane Care Tow starting Tow starting is not possible for reasons related to the transmission G Risk of accidents due to sluggish steering At speeds less than 2 km h 1 2 mph th...

Page 387: ...elect as flat a place as possible to change the wheel Apply the parking brake s G Risk of accidents due to a wheel falling over If you temporarily lean a wheel against the truck crane while changing it secure it with a rope to prevent it falling over Move the outriggers only when no wheel is leaning against the truck crane G Risk of crushing due to turning wheels When you start the engine no perso...

Page 388: ...uck crane then Support the truck crane Enter and confirm the current rigging mode Lift the spare wheel using only lifting gear with sufficient load bearing capacity à Spare wheel p 1 10 G Risk of accidents due to a wheel falling over When unscrewing the final lug nuts the wheel can slip off the hub and fall toward you Secure the wheel and step back quickly if the wheel begins to tip G Danger of ov...

Page 389: ... the bearing surfaces of the wheel rim and hub are clean no paint grease or oil Lightly grease the wheel studs Place the wheel at the hub in an upright position Extend or retract the outrigger cylinders until the holes in the wheel rims are in line with the wheel studs Push the wheel on to the wheel studs Make sure the threads of the wheel studs are not damaged s G Risk of accidents Check the whee...

Page 390: ...1 and 2 finger tight to secure the wheel Tighten the remaining wheel nuts finger tight Always tighten the wheel nuts in the order 1 to 12 Tighten all wheel nuts first to 200 Nm 150 lbf ft Then all lug nuts to 400 Nm 300 lbf ft Finally tighten all wheel nuts to 650 Nm 480 lbf ft After 50 km 30 mi and 150 km 90 mi retighten all wheel nuts to 650 Nm 480 lbf ft ...

Page 391: ...ssure After you have inflated the tyres yourself always drive directly to a service station or repair shop and adjust the tyre pressure The filling hose has a tyre inflator connection 2 and a connection 1 Connecting the filling hose Remove the caps 2 and 4 Fasten the connection 3 to the filler connection 1 You can now inflate the tyres s S Risk of damage if the tyre pressure is too high Depending ...

Page 392: ...onnection and inflate the tyre Disconnect the tyre connection 1 from the tyre valve Remove the filling hose Before driving you must remove the tyre filling hose from the tyre inflator connection Remove the connection 3 from the filler connection 1 Close the filler connection and the connection with the caps 2 and 4 Stow the filling hose away Drive to a service station or repair shop and adjust the...

Page 393: ... emergency operation to the straight running position in order to enable a drive to the workshop Operating elements If need be lift the counterweight from the rear counterweight platform Remove the cover 1 Fasten the covering 1 after the emergency operation Performing emergency operation If the current situation allows it you can slightly lift the mobile crane with the support to relieve the 3rd a...

Page 394: ...ck valves switch on continuous operation Always switch on the continuous operation for all valves 1 A Remove the nut 2 Remove the magnets 3 Mark the magnet in such a way that you can put it back on the corresponding valve later B Turn the nut 2 as far as possible on the valve 4 do not tighten the nut Steering of the 3rd axle line The valves are labelled The valves are actuated by pressing the valv...

Page 395: ...he magnets 3 pay attention marking Tighten the nut 2 hand tight on the valve 4 Inserting the fuses After emergency operation you must insert the fuses again so that the 4th axle line can be steered while driving Turn off the ignition Insert the fuse F2 5 à Fuses in the driver s cab p 8 50 Insert the fuse F10 à Fuses in the battery box p 8 56 After emergency operation Drive directly to the workshop...

Page 396: ...Malfunctions in driving mode 8 5 Emergency operation and breakdown assistance 8 42 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 397: ... information on tilting Before tilting the driver s cab the following requirements must be met The truck crane must be level All loose objects must be removed from the driver s cab The main boom is raised to the extent about 1 5 m 4 9 ft that the driver s cab will not touch the main boom nor the hose drum when tilting Ensure that the hook block is outside the driver s cab slewing range and the win...

Page 398: ...d and lowered using a hand pump The lever for the hand pump is below the seats or in the tool box Insert the lever 1 into the hand pump 3 To tilt the driver s cab turn the lever 2 forward to position A To lower the driver s cab turn the lever 2 backwards to the B position Before tilting the driver s cab note the prerequisites specified at the beginning of the section à Prerequisites and informatio...

Page 399: ...b is tilted Close the doors This prevents e g liquids from getting into the instrument panels and doors from swinging open during tilting thereby injuring people G Risk of accidents due to driver s cab tilting When you are tilting the driver s cab forward and while it is actually tilted forward no one may be in front of the driver s cab S Risk of damage when the main boom angle is too small Only t...

Page 400: ... the fall back guard strut 1 Check that the lever is pointing 2 backwards B Use the lever to pump 1 the driver s cab is lowered Lower the driver s cab to its end position the lock closes audibly Switch on the ignition and check that the symbol 1 has gone out If necessary lower the driver s cab further until the symbol 1 goes out G Risk of accidents due to the driver s cab tilting back You may only...

Page 401: ...8 47 GMK4100L 1 23 11 2017 Remove the lever 1 and stow it away safely Close the front flap à Front flap p 3 73 G Risk of accidents if the driver s cab is not locked Ensure that the driver s cab is locked afterwards every time it is lowered This prevents the driver s cab tilting forward when braking ...

Page 402: ...Malfunctions in driving mode 8 6 Tilting lowering the driver s cab 8 48 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 403: ...e ignition whenever a fuse has to be replaced S Risk of damage if the ignition is switched on Switch off the ignition whenever a fuse has to be replaced This prevents the new fuse being blown immediately by the increased starting current after being installed S Risk of damage by overloading Replace blown fuses only with new fuses of the same amperage This prevents parts being overloaded and damage...

Page 404: ...esignations 1 to 8 in the tables correspond to their order from left to right fuse 1 is always the left fuse Observe the instructions for fuse changes à p 8 49 Designation Amperage A Function F1 1 3 Ignition lock F1 2 15 Control unit UB 2 CCM 11 F1 3 15 Control unit UB 2 CCM 11 F1 4 15 Permanent positive voltage terminal 30 F1 5 5 Engine transmission diagnostics plug F1 6 10 Electronic gear system...

Page 405: ...trol unit UB 2 IOL 31 F2 5 15 Control unit UB 1 IOL 32 Electronic steering system F2 6 15 Control unit UB 1 IOL 32 F2 7 15 Control unit UB 2 IOL 32 F2 8 15 Control unit UB 2 IOL 32 Designation Amperage A Function F3 1 15 Control unit UB 1 IOL 33 F3 2 15 Control unit UB 1 IOL 33 F3 3 15 Control unit UB 2 IOL 33 F3 4 15 Control unit UB 2 IOL 33 F3 5 10 ABS control unit F3 6 10 ABS control unit F3 7 ...

Page 406: ...F4 2 20 Dual tank switchover F4 3 5 CCS display F4 4 Unassigned F4 5 Unassigned F4 6 Unassigned F4 7 Unassigned F4 8 Unassigned Designation Amperage A Function F5 1 20 Auxiliary heater F5 2 3 Control unit UE CCM 11 Control unit UE 2 IOL 31 32 33 F5 3 10 Radio F5 4 5 Tachograph instrument panel F5 5 10 Fan F5 6 Unassigned F5 7 Unassigned F5 8 5 Power supply relay ...

Page 407: ...erse camera Radio F6 4 5 air intake inhibitor F6 5 10 Gearbox control F6 6 5 Engine transmission diagnostics plug F6 7 3 Outrigger control panel left right Inclination transmitter F6 8 3 Engine electronic control system AdBlue system Designation Amperage A Function F7 1 3 Alternator F7 2 3 Brake circuits 1 and 2 F7 3 3 Auxiliary heater time switch F7 4 15 Retarder F7 5 5 Horn Soot particle filter ...

Page 408: ...rication F8 2 15 Windscreen wiper F8 3 5 Steering coupling F8 4 3 ABS ABS trailer F8 5 10 Horn F8 6 15 Unassigned F8 7 10 Operating the mirror adjustment Window winder F8 8 Unassigned Designation Amperage A Function F9 1 2 Temperature gauge Fuel gauge F9 2 Unassigned F9 3 Unassigned F9 4 Unassigned F9 5 Unassigned F9 6 Unassigned F9 7 Unassigned F9 8 Unassigned ...

Page 409: ...mperage A Function F10 1 5 Turn signal indicators Light switch F10 2 10 Rotating beacon carrier superstructure F10 3 5 Parking light Side marker lights Side marker lights front F10 4 3 Instrument lighting F10 5 5 Brake lights Trailer brake lights F10 6 10 Light switch Warning blinkers F10 7 Unassigned F10 8 5 Reversing lamp ...

Page 410: ...49 S Danger from lead and lead compounds on batteries Battery poles battery terminals and parts of the battery itself contain lead and lead compounds Wash your hands after working on these parts or in these areas Designation Amperage A Function F7 50 Driver s cab central fuse F8 25 Battery charger socket F9 25 Superstructure central fuse F10 10 Steer by wire F11 20 Superstructure central fuse F12 ...

Page 411: ... are described in Chapter 3 9 1 Overview of the operating elements This section shows the position and designations of the operating elements for crane operation This also includes display elements such as lights or displays H Operating elements available only with additional equipment are desig nated accordingly These designations are made in this section only and are not repeated in the followin...

Page 412: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 2 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 1 Exterior of the truck crane ...

Page 413: ...verride Version A3 Key operated switch for overriding the RCL in an emergency RCL override Version B3 No function à p 9 143 à p 9 144 8 Spotlights1 à p 9 8 9 RCL status display à p 11 63 10 Lowering limit switch à p 11 84 11 Counterweight removed à p 12 69 12 Outriggers Operation Lighting Installing removing the outrigger beams à p 12 39 à p 12 43 à p 6 29 13 Shut off valves at the hydraulic tank ...

Page 414: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 4 3 302 690 en Operating manual GMK4100L 1 23 11 2017 ...

Page 415: ... à p 12 108 23 Hook block Separable hook block1 Hook block with ballast plates1 à p 12 99 à p 12 104 à p 12 106 24 Fuel tank auxiliary heater1 à p 11 5 25 Mirror for crane operation à p 12 130 26 Storage compartment Anemometer Hand held control à p 12 126 à p 12 23 27 Slewing gear Operation Switching off the slewing gear freewheel1 Switching on the slewing gear freewheel1 Turntable lock1 à p 11 11...

Page 416: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 6 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 2 Crane cab ...

Page 417: ...100 8 Windscreen washing system tank2 9 Adjusting the front panel à p 11 9 10 RCL control unit Rated Capacity Limiter à p 9 76 11 CCS control unit à p 9 16 12 Slewing gear brake pedal can be switched on off1 à p 9 119 13 Service brake1 14 Accelerator pedal 15 Left hand control panel à p 9 12 16 Right hand control panel à p 9 13 17 Handle 18 Crane cab seat Seat contact switch à p 11 8 à p 9 94 19 R...

Page 418: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 8 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Side panel ...

Page 419: ...erride Version B2 Overriding the RCL in an emergency à p 9 143 à p 9 144 4 Headlight on off à p 9 146 5 Slewable spotlights on off1 à p 9 147 6 Slew slewable spotlight1 à p 9 147 7 RCL override Version A2 Raise enable button after RCL shutdown RCL override Version B2 No function à p 9 121 à p 9 144 8 Windscreen wiper on off à p 9 148 9 Roof window wiper on off à p 9 148 10 Windscreen washing syste...

Page 420: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 10 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Crane cab rear ...

Page 421: ...3 Radio CD USB1 3 4 Loudspeaker1 5 Sockets 12 V à p 9 145 6 Fan with switch1 7 Rear window à p 9 154 8 Cover for Fuses Diagnostics CraneSTAR system1 à p 14 73 à p 9 156 à p 11 158 9 Rest 10 Air vents à p 11 152 11 Fire extinguisher2 12 Air vents à p 11 152 13 Door unlocking mechanism à p 9 155 14 Handle 1 Additional equipment 2 à Maintenance manual 3 à Separate operating manual ...

Page 422: ... Auxiliary hoist1 on off à p 11 79 5 Inclining the crane cab à p 9 128 6 Left hand control lever configuration varies depending on the version à p 9 14 7 Dead man s switch à p 9 94 8 Slewing gear freewheel à p 9 118 9 Depending on which function is switched on button for Derricking gear high speed mode Telescoping mechanism high speed mode Economy Mode step 3 switch on1 à p 9 121 à p 9 123 à p 9 9...

Page 423: ...t on off à p 9 114 3 Derricking gear on off à p 9 120 4 Telescoping mechanism on off à p 9 122 5 Lattice extension derricking gear1 2 6 Right hand control lever configuration depends on version à p 9 14 7 Dead man s switch à p 9 94 8 Horn à p 9 149 9 Hoist high speed mode on off à p 9 114 10 Main hoist slewing indicator à p 11 77 1 Additional equipment 2 à Lattice extension operating manual ...

Page 424: ...t control lever configura tions The current configuration of the control levers is indicated by symbols on the control levers Version 1 In version 1 the left control lever is configured with the Telescope function Left control lever Right control lever 1 Slewing to the left 5 Raising 2 Slewing to the right 6 Lowering the boom 3 Extension 7 Lower the main hoist 4 Retraction of the telescoping 8 Lif...

Page 425: ...ght control lever is configured with the Telescope function Left control lever Right control lever 1 Slewing to the left 5 Raise retract2 2 Slewing to the right 6 Lower extend2 3 Lower auxiliary hoist1 7 Lower the main hoist 4 Raise auxiliary hoist1 8 Lift the main hoist 1 Additional equipment 2 Derricking the lattice extension à Lattice extension operating manual ...

Page 426: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 16 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 5 CCS control unit ...

Page 427: ...g limit switch shutdown à p 9 115 6 Sensor for brightness à p 9 98 7 Menu control Select activate confirm à p 9 95 8 Display temperature warning display à p 9 99 9 Service diagnosis connection1 à p 9 156 10 Overview menu groups Operation Overview menu groups Overview à p 9 98 à p 9 22 11 Switch off the RCL buzzer à p 9 98 12 Slewing gear brake engaged released à p 9 119 13 Function only in the men...

Page 428: ...1 6 Menu independent displays 1 Slewing gear à p 9 118 2 Telescoping mechanism à p 9 122 3 Derricking gear à p 9 120 4 Main hoist à p 9 114 5 Auxiliary hoist1 à p 9 116 6 Lattice extension derricking gear1 2 7 Remote control display3 8 Display time 9 Jog dial display à p 9 98 10 Error display à p 14 7 11 Warning messages display à p 14 3 ...

Page 429: ... en 9 19 GMK4100L 1 23 11 2017 9 1 7 CCS Start menu s 1 RCL display à p 9 20 2 Engine speed display à p 10 8 3 AdBlue DEF filling level indicator à p 10 8 4 Coolant temperature display à p 10 8 5 Fuel level display à p 10 8 6 Voltage monitoring display à p 10 8 7 Hydraulic oil temperature display à p 10 8 ...

Page 430: ...splay à p 9 134 3 Current slewing angle display à p 9 134 4 Maximum permissible speed display Slewing gear à p 9 135 5 Maximum permissible speed display Main hoist à p 9 135 6 Maximum permissible speed display Auxiliary hoist1 à p 9 135 7 Maximum permissible speed display Derricking gear à p 9 135 8 Maximum permissible speed display Telescoping mechanism à p 9 135 9 Slewing range display à p 9 135...

Page 431: ...type Display of current slewing range divisions à p 9 133 1 Slewing range 1 à p 9 133 2 Slewing range 2 à p 9 133 3 Slewing range 3 à p 9 133 4 Slewing range 4 à p 9 133 5 Display of current slewing range limits à p 9 133 6 Current position display à p 9 134 Maximum permissible working radius display à p 9 134 1 1 In slewing range 1 à p 9 134 2 1 In slewing range 2 à p 9 134 3 1 In slewing range 3...

Page 432: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 22 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 8 CCS Overview menu groups ...

Page 433: ...automation menu Manual telescoping menu 4 Active working range limiter menu group à p 9 47 Overall height menu Working radius menu Slewing angle menu Hoist rope travel limitation menu 5 Information menu group 1 à p 9 52 Hydraulic pressure and fuel consumption menu Datalogger menu Menu opens on the display RCL 6 Heating Engine Additional equipment menu group à p 9 54 Economy menu Remote control men...

Page 434: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 24 3 302 690 en Operating manual GMK4100L 1 23 11 2017 ...

Page 435: ...ts menu Set control lever characteristic curve menu Power unit speeds menu 9 Information menu group 2 à p 9 70 Operating hours menu Engine transmission error menu Crane operation error menu Program version menu Disclaimer menu 10 Various controls à p 9 75 Preheating the hydraulic oil Camera on off Override torque reduction Switching the air traffic control light on and off Switching the rotating b...

Page 436: ...s for crane operation 9 1 Overview of the operating elements 9 26 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 9 Superstructure menu group 1 Superstructure lock sub menu à p 9 27 2 Counterweight menu à p 9 28 ...

Page 437: ...ay in the Counterweight menu à p 9 28 2 House lock locking status displays1 à p 9 131 3 Locking status displays à p 9 129 4 House lock on off1 à p 9 131 5 Display switch function for the slewing gear brake à p 9 119 6 Current slewing angle display1 à p 9 130 7 Slewing speed reduction on off à p 9 119 8 Display slewing direction to 0 180 à p 9 130 9 Locking unlocking the turntable1 à p 9 129 1 Addi...

Page 438: ...lewing direction for automatic mode à p 9 110 3 Current slewing angle display à p 9 113 4 Rear counterweight platform locked display à p 9 113 5 Extending Retracting the lifting cylinders à p 9 112 6 Lifting cylinder position display à p 9 112 7 Automatic mode rigging à p 9 111 8 Lifting cylinder position display à p 9 112 9 Automatic mode unrigging à p 9 111 10 Pre tensioning pressure display à p...

Page 439: ...peration 9 1 Overview of the operating elements Operating manual 3 302 690 en 9 29 GMK4100L 1 23 11 2017 9 1 10 Menu group outrigger driving s 1 Outrigger menu Outrigger cylinders menu à p 9 30 à p 9 32 2 Driving mode menu à p 9 34 ...

Page 440: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 30 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Outrigger menu ...

Page 441: ...4 1 Pre select front left outrigger à p 9 102 5 Pre select front right outrigger display à p 9 102 5 1 Pre select front right outrigger à p 9 102 6 Pre select rear left outrigger display à p 9 102 6 1 Pre select rear left outrigger à p 9 102 7 Pre select rear right outrigger display à p 9 102 7 1 Pre select rear right outrigger à p 9 102 8 Current inclination display à p 9 108 9 Exiting the menu à...

Page 442: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 32 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Outrigger cylinders menu ...

Page 443: ...à p 9 102 5 Pre select front right outrigger cylinder display à p 9 102 5 1 Pre select front right outrigger cylinder à p 9 102 6 Outrigger pressure display1 à p 12 66 7 Pre select rear left outrigger cylinder display à p 9 102 7 1 Pre select rear left outrigger cylinder à p 9 102 8 Pre select rear right outrigger display à p 9 102 8 1 Pre select rear right outrigger à p 9 102 9 Current inclinatio...

Page 444: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 34 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Driving mode menu l t r ...

Page 445: ...tatus display à p 9 164 10 Transverse differential locks display Transverse differential locks on off à p 9 159 à p 9 159 11 Longitudinal differential lock display Longitudinal differential lock on off à p 9 160 à p 9 159 12 Supply pressure brake circuits 1 and 2 display à p 9 161 13 Parking brake indicator lamp à p 9 162 14 Crane hydraulic system on off à p 9 157 15 Steering mode switched on indi...

Page 446: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 36 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 447: ...ng elements Operating manual 3 302 690 en 9 37 GMK4100L 1 23 11 2017 9 1 11 RCL Telescoping menu group s 1 Menu enter rigging mode telescope à p 9 38 2 Lifting capacity tables menu à p 9 44 3 Telescoping semi automation menu à p 9 45 4 Manual telescoping menu à p 9 46 ...

Page 448: ...nual GMK4100L 1 23 11 2017 Menu enter rigging mode telescope For the Standard slewing range type H Depending on the version the top view 2 is shown rotated by 180 The representation occurs in the same manner as in the RCL Monitoring menu à p 9 78 A For boom system main boom B For boom system lattice extension ...

Page 449: ...e length after the angle1 à p 9 138 7 Lattice extension input angle1 2 à p 9 138 8 Enter RCL code à p 9 140 9 Angle of the lattice extension display1 2 à p 9 138 10 Enter reeving Main hoist à p 9 137 11 Enter reeving Auxiliary hoist à p 9 137 12 Boom system display à p 9 138 13 Reeving input mode display à p 9 137 14 Counterweight display à p 9 136 15 Accept the measured outrigger span à p 9 139 1...

Page 450: ...ents 9 40 3 302 690 en Operating manual GMK4100L 1 23 11 2017 For the MAXbase slewing range type1 H Depending on the version the top view 2 to 5 is shown rotated by 180 The representation occurs in the same manner as in the RCL Monitoring menu à p 9 78 1 Additional equipment ...

Page 451: ...rigger width à p 9 139 5 Input rear right outrigger width à p 9 139 2 to 5 Outrigger span monitoring display à p 9 139 6 Enter counterweight à p 9 136 7 Enter reeving Main hoist à p 9 137 8 Enter reeving Auxiliary hoist à p 9 137 9 Reeving input mode display à p 9 137 10 Counterweight display à p 9 136 11 Accept the measured outrigger span à p 9 139 12 Pre selection telescoping menu à p 9 42 13 Pr...

Page 452: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 42 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Pre selection telescoping menu ...

Page 453: ... 3 Input main boom length à p 9 141 4 Input slewing range1 à p 9 141 Pre selection telescoping 5 Sort values à p 9 141 6 Selectable telescoping display à p 9 141 6 1 Associated maximum load à p 9 141 6 2 Associated maximum working radius à p 9 141 6 3 Associated telescoping duration à p 9 141 6 4 Associated main boom length à p 9 141 7 Overview of the table lengths 1 Display only with the MAXbase ...

Page 454: ...e slewing range type 1 Slewing range display 2 Permissible working range display range under the curve I Main hoist display Limitation due to reeving II Auxiliary hoist display Limitation due to reeving à p 11 59 1 Slewing range display Four slewing ranges marked in colour 2 3 4 5 Permissible working range display A coloured curve for each slewing range I Main hoist display Limitation due to reevi...

Page 455: ...9 124 3 Pre selection individual telescopic sections à p 9 124 4 Confirm pre selection à p 9 125 5 Current telescope status display à p 9 124 6 Telescoping permitted display Telescoping not permitted display à p 9 125 7 Locking status telescopic section display à p 9 123 8 Telescoping cylinder length display à p 9 124 9 Locking status telescoping cylinder display à p 9 123 10 Teleautomation direct...

Page 456: ...ay à p 9 126 2 Symbol lock release telescopic section à p 9 126 3 Telescoping cylinder in the telescopic section display à p 9 127 4 Locking status telescoping cylinder display à p 9 125 5 Locking releasing the telescoping cylinder à p 9 126 6 Locking point display à p 9 125 7 Telescoping cylinder length display à p 9 126 8 Telescoping direction display à p 9 127 9 Main boom length display à p 9 1...

Page 457: ...operating elements Operating manual 3 302 690 en 9 47 GMK4100L 1 23 11 2017 9 1 12 Active working range limiter menu group s 1 Overall height menu à p 9 48 2 Working radius menu à p 9 49 3 Slewing angle menu à p 9 50 4 Hoist rope travel limitation menu à p 9 51 ...

Page 458: ...ing elements 9 48 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Overall height menu 1 Switching monitoring function on off à p 11 146 2 Apply current overall height à p 11 140 3 Input maximum overall height à p 11 144 4 Maximum overall height display à p 11 140 ...

Page 459: ...g elements Operating manual 3 302 690 en 9 49 GMK4100L 1 23 11 2017 Working radius menu s 1 Switching monitoring function on off à p 11 146 2 Current working radius display à p 11 141 3 Maximum working radius display à p 11 144 4 Input maximum working radius à p 11 144 ...

Page 460: ... Slewing angle menu 1 Switching monitoring function on off à p 11 146 2 Maximum slewing angle A display à p 11 139 3 Current slewing angle A display à p 11 139 4 Input maximum slewing angle A à p 11 142 5 Maximum slewing angle B display à p 11 139 6 Current slewing angle B display à p 11 139 7 Input maximum slewing angle B à p 11 142 ...

Page 461: ...toring function on off à p 11 146 2 Input confirmation display top à p 11 142 3 Input confirmation display bottom à p 11 142 4 Current hoist rope position display à p 11 142 5 Hoist rope travel limitation input top Hoist rope travel limitation display top à p 11 142 à p 11 139 6 Hoist rope travel limitation input bottom Display hoist rope travel limitation bottom à p 11 142 à p 11 139 ...

Page 462: ...9 1 Overview of the operating elements 9 52 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 13 Information menu group 1 1 Hydraulic pressure and fuel consumption menu à p 9 53 2 Datalogger menu Menu opens on the display RCL à p 9 81 ...

Page 463: ... 23 11 2017 Hydraulicpressure and fuel consump tion menu 1 Angle gear temperature display à p 9 128 2 Slewing gear hydraulic circuit pressure display à p 9 128 3 Telescoping cylinder pressure display à p 9 128 4 Hydraulic circuit pressure display à p 9 128 5 Display of consumption in litres per hour1 1 Additional equipment ...

Page 464: ...the operating elements 9 54 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 14 Heating Engine Additional equipment menu group 1 Economy menu à p 9 55 2 Remote control menu à p 9 56 3 Heating air conditioning menu à p 9 57 4 Spotlights menu à p 9 58 ...

Page 465: ...on 9 1 Overview of the operating elements Operating manual 3 302 690 en 9 55 GMK4100L 1 23 11 2017 Economy menu s 1 Switching Economy mode on off à p 9 92 2 Set interval 1 à p 9 92 3 Set interval 2 à p 9 92 4 Average consumption à p 9 92 ...

Page 466: ...elements for crane operation 9 1 Overview of the operating elements 9 56 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Remote control menu 1 Remote control menu à p 9 132 2 Remote control display à p 9 132 ...

Page 467: ...ibution à p 11 152 3 Setting the temperature à p 11 151 4 Automatic air conditioning system à p 11 154 5 Defrosting the windscreen à p 11 151 6 Setting the fan à p 11 151 7 Air conditioning system on off à p 11 153 8 Cooling maximum à p 11 154 9 Recirculated air à p 11 151 10 Frost Guard1 2 11 Setting the auxiliary heating à p 11 155 12 Heating on display à p 11 151 1 Additional equipment 2 à Sepa...

Page 468: ...rating elements 9 58 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Spotlights menu 1 Switching automatic spotlights on off à p 9 147 2 Increase the slewing speed à p 9 147 3 Reduce the slewing speed à p 9 147 4 Opening closing the Settings submenu à p 9 147 ...

Page 469: ...Operating manual 3 302 690 en 9 59 GMK4100L 1 23 11 2017 9 1 15 Telescoping emergency program menu group s 1 Telescoping emergency program menu à p 9 60 2 Unknown telescoping menu à p 9 62 3 Swinging the swing away lattice emergency operation menu à p 9 63 1 Additional equipment ...

Page 470: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 60 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Telescoping emergency program menu ...

Page 471: ...ing status telescoping cylinder display Locking unlocking the telescoping cylinder à p 14 31 5 Locking status telescopic section display Locking unlocking a telescopic section à p 14 31 6 Display position of the telescoping cylinder in the foot section à p 14 31 7 Telescoping cylinder locked Telescopic section unlocked 8 Telescoping cylinder locked Telescopic section locked 9 Telescoping cylinder ...

Page 472: ...ode unknown telescoping à p 14 43 2 Input for telescopic section 1 à p 14 43 3 Input for telescopic section 2 à p 14 43 4 Input for telescopic section 3 à p 14 43 5 Input for telescopic section 4 à p 14 43 6 Input for telescopic section 5 à p 14 43 7 Input for telescopic section 6 à p 14 43 8 Input confirmation à p 14 43 9 Telescoping permitted not permitted display à p 14 43 ...

Page 473: ... manual 3 302 690 en 9 63 GMK4100L 1 23 11 2017 Swinging the swing away lattice emergency operation menu 1 Locked automatic slewing warning message 2 Enable disable telescoping 3 Telescoping cylinder length display 4 Extending retracting the swivel ram à Lattice extension operating manual ...

Page 474: ...90 en Operating manual GMK4100L 1 23 11 2017 9 1 16 Settings menu group 1 Crane cab menu à p 9 65 2 Set display brightness and date time menu à p 9 66 3 Switch units menu à p 9 67 4 Set control lever characteristic curve menu à p 9 68 5 Power unit speeds menu à p 9 69 1 Additional equipment ...

Page 475: ...dscreen interval duration selection display à p 9 149 2 Selection display of skylight interval duration à p 9 149 3 Retract extend step selection à p 12 137 4 Retract step à p 12 137 5 Extend step à p 12 137 6 Adjust interval selection à p 9 149 7 Adjust interval display à p 9 149 8 Windscreen selected display à p 9 149 9 Skylight selected display à p 9 149 ...

Page 476: ...ate time menu This is operated in the same way as in the driver s cab 1 Selection setting the display brightness à p 4 11 2 Increasing reducing the value à p 4 11 3 Display in percentage à p 4 11 4 Brightness display à p 4 11 5 Adjust time selection à p 5 24 6 Setting the time à p 5 23 7 Increasing reducing the value à p 5 24 8 Switching the display type à p 5 23 ...

Page 477: ...ion 9 1 Overview of the operating elements Operating manual 3 302 690 en 9 67 GMK4100L 1 23 11 2017 Switch units menu s 1 Display units in Metres Degrees Celsius Kilograms Bar à p 11 128 2 Display units in Feet Degrees Fahrenheit lbs Psi ...

Page 478: ...trol lever characteristic curve menu 1 Characteristic curve slewing gear à p 11 129 2 Characteristic curve telescoping mechanism 3 Characteristic curve derricking gear 4 Characteristic curve main hoist 5 Auxiliary hoist1 characteristic curve 6 Lattice extension1 characteristic curve 7 Setting Reset characteristic curve 1 Additional equipment ...

Page 479: ... GMK4100L 1 23 11 2017 Power unit speeds menu 1 Enter slewing gear speed à p 11 125 2 Enter telescoping mechanism speed 3 Enter derricking gear speed 4 Enter speed main hoist 5 Enter speed auxiliary hoist1 6 Enter speed derricking gear of lattice extension1 7 Reset power unit speed settings 1 Additional equipment ...

Page 480: ... elements 9 70 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 17 Information menu group 2 1 Operating hours menu à p 9 71 2 Engine transmission error menu à p 9 72 3 Crane operation error menu à p 9 73 4 Program version menu à p 9 74 5 Disclaimer menu à p 9 156 ...

Page 481: ...XXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX n XXXX n XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX n XXXX n 1 Keycode entry and confirmation à p 11 133 2 Slewing gear 3 Telescoping mechanism 4 Derricking gear 5 Main hoist 6 Transmission 7 Engine 8 Locking system 9 Auxiliary hoist 10 Carrier 11 superstructure 12 Lattice extension luffing jib1 13 Selection all 1 Additional equipment...

Page 482: ...3 302 690 en Operating manual GMK4100L 1 23 11 2017 Engine transmis sion error menu This is operated in the same way as in the driver s cab 1 Display of error total errors à p 8 17 2 Engine symbol display 3 Transmission symbol display 4 Error code display 5 Previous error 6 Next error ...

Page 483: ... Overview of the operating elements Operating manual 3 302 690 en 9 73 GMK4100L 1 23 11 2017 Crane operation error menu s 1 Display of error total errors à p 14 7 2 Error message display 3 To acknowledge the error 4 Previous error 5 Next error ...

Page 484: ...lements for crane operation 9 1 Overview of the operating elements 9 74 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Program version menu 1 Serial number display à p 14 3 2 Program version display à p 14 3 ...

Page 485: ...manual 3 302 690 en 9 75 GMK4100L 1 23 11 2017 9 1 18 Various controls 1 Preheating the hydraulic oil à p 9 128 2 Camera on off à p 12 136 3 Override torque reduction à p 11 132 4 Switching the air traffic control light on and off à p 12 127 5 Switching the rotating beacon on off à p 9 146 ...

Page 486: ...erating manual GMK4100L 1 23 11 2017 9 1 19 RCL control unit 1 RCL display 2 USB connection for data export à p 9 142 3 No function 4 Switch off RCL buzzer à p 9 98 5 RCL early warning à p 11 57 6 Sensor for brightness à p 9 98 7 RCL shutdown à p 11 57 8 Display temperature warning display à p 9 100 ...

Page 487: ... 9 1 Overview of the operating elements Operating manual 3 302 690 en 9 77 GMK4100L 1 23 11 2017 9 1 20 Menu independent displays 1 Warning messages display à p 14 9 2 Working range limiter displays à p 11 136 3 RCL status display à p 11 51 ...

Page 488: ...ting elements 9 78 3 302 690 en Operating manual GMK4100L 1 23 11 2017 9 1 21 RCL menus Monitoring menu H Depending on the version the top view in view A is shown or is shown rotated by 180 in view B This operating manual shows view A in the subsequent illustrations ...

Page 489: ... p 11 51 12 Maximum load display à p 11 51 13 Display of the currently raised load à p 11 50 14 Display of reeving used à p 11 46 15 Status display for current main boom angle à p 11 50 16 Counterweight display à p 11 45 17 Current working radius display à p 11 49 18 Current inclination display à p 9 108 19 Telescoping direction display à p 11 52 20 Current telescope status display à p 11 51 21 Te...

Page 490: ...90 en Operating manual GMK4100L 1 23 11 2017 Lifting capacity tables menu The same menu is displayed as shown on the CCS display à p 9 44 H Either the Monitoring menu or the Lifting capacity table menu is displayed Additionally the Datalogger menu can be manually opened from the CCS display ...

Page 491: ... operation 9 1 Overview of the operating elements Operating manual 3 302 690 en 9 81 GMK4100L 1 23 11 2017 Datalogger menu y 1 Export data à p 9 142 2 Display of export progress à p 9 142 3 USB connection for data export à p 9 142 ...

Page 492: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 82 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 493: ...3 302 690 en 9 83 GMK4100L 1 23 11 2017 9 1 22 Hand held control H Required connections for the various movements à p 9 150 1 Engine control panel à p 9 151 2 Pre select emergency operation1 à p 9 152 3 Function buttons à p 9 152 4 no function 5 no function 6 Horn à p 9 151 1 Additional equipment ...

Page 494: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 84 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 495: ...independent buttons This function of the illustrated buttons is the same in all the menus This function of the other buttons depends on the opened menu s 1 Outrigger display à p 9 103 2 Position lights for indicator lamps à p 9 103 3 Menu selection Outrigger menu Raise axle menu à p 9 103 à p 9 86 à p 9 88 4 START engine à p 12 27 5 Horn à p 9 104 6 STOP engine à p 12 27 ...

Page 496: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 86 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Outrigger menu ...

Page 497: ... Operating the right outriggers opposite side à p 9 104 4 Operating the right outriggers à p 9 104 5 Additional function F1 6 Retracting all supporting cylinders à p 9 105 7 Extending all supporting cylinders à p 9 105 8 Pre select high speed mode à p 9 103 9 Pre select normal speed Automatic alignment as additional function F1 à p 9 103 à p 9 105 1 1 Left hand outrigger pressure display à p 9 109...

Page 498: ... 302 690 en Operating manual GMK4100L 1 23 11 2017 Raise axle menu 1 to 4 Pre selection display à p 9 106 5 Directional indicator 6 Wheel load display opposite à p 9 107 7 Wheel load display operator s side à p 9 107 8 Pre selecting wheels à p 9 106 9 Lifting lowering wheels à p 9 107 ...

Page 499: ...ent Basic rule Directions always depend on whether the carrier or the superstructure is being operated On the carrier The driver s cab is always at the front which means that Forwards always means the driver s cab is to the front Backwards always means the rear lights on the carrier are leading On the superstructure The main boom head is always at the front which means that G Risk of accident by o...

Page 500: ...an be opened Symbols can be shown in different colours The colour of the symbol indicates the current switching state of the relevant power unit In these operating instructions we always refer to colours in terms of The symbol is red for instance regardless of whether the background 1 of a symbol is red or whether only parts 2 of a symbol are red This applies to all symbols and all colours If the ...

Page 501: ... must be off Set idling speed The engine is running Left control lever The engine must be off s 0 Ignition off engine off key can be removed 1 Ignition on and power supply on for instrument lighting CCS engine control system RCL à p 10 7 Press upwards once Engine starts Idling speed standard Press up Increase idling speed Press down Decrease idling speed engine cutout after about 6 seconds à p 10 ...

Page 502: ...e menu Select symbol and confirm for 9 2 4 AdBlue system CCS display AdBlue warning To open Select and confirm symbol 1 1 Switching Economy mode on off 2 Set interval 1 3 Set interval 2 4 Average consumption à p 11 126 1 Green AdBlue tank level sufficient Yellow Adblue DEF tank almost empty à AdBlue tank p 4 7 Red Adblue DEF tank empty symbol 2 displayed ...

Page 503: ...me the engine is started 1 Out Torque reduction off or overridden 2 On Torque reduction on Symbol 2 is displayed 1 Select and confirm Torque reduction overridden for 30 minutes symbol 3 displayed after 30 minutes 1 Select and confirm Torque reduction overridden for 30 minutes symbol 3 displayed after 30 minutes 1 Select and confirm Torque reduction overridden for 30 minutes symbol 3 displayed afte...

Page 504: ...down seat contact switch 2 on or Press at least one dead man s switch 1 Safety function on Get off seat seat contact switch off and Both dead man s switches 1 not pressed All operating elements for crane functions in the crane cab are locked Any crane movements are slowed down to standstill within 3 seconds and then locked Crane cab seat version 2 The seat contact switch is very sensitive It is re...

Page 505: ...a button on the jog dial or CCS control panel the overview of the menu groups 2 appears A symbol is selected with the jog dial or the selection buttons on the CCS control panel to call up a menu A selected symbol is shown in red A menu is opened by pressing the jog dial or the OK button on the control panel Menu control Buttons for selecting activating and confirming areas on the CCS display Selec...

Page 506: ...the input area For selecting and confirming values A field 1 with numbers or letters is marked Select a value Confirm value 1 Slewing or 2 Press The next symbol is marked 1 Press or 3 Press The corresponding menu is opened 1 Slewing1 or 2 Press 4 Value can be reduced increased 5 Highest value achieved 6 Lowest value achieved 1 Holding pressed and turning results in a quick value change 1 Press or ...

Page 507: ... e g outrigger cylinder 1 For turning on off and switching A symbol for a status is marked e g symbol 2 Executing a movement Select function Move function Turning on off and switching Selecting status Switch on state s 3 Press or 1 Slewing The marked function 4 or 5 is selected 2 Press The selected function is carried out 2 Press or 1 Slewing The marked state 4 or 6 is selected 1 Press or 3 Press ...

Page 508: ...l display Sensor for brightness Registers the brightness of the operating environment The brightness of all displays is automatically adjusted à Display setting the brightness p 10 6 Press the button once The opened menu closes the menu from the next higher level is opened Input mode is deactivated 1 Press After the first press Menu groups overview display After a subsequent press Next previous gr...

Page 509: ... the menu groups Select A symbol is selected such as symbol 2 Deselect A favourites symbol is selected Serial number and program version display s Blue flashing Temperature too low display will not be switched on Temperature too high Red lights up Brightness is reduced Yellow flashing Display is switched off Red flashing Control unit is switched off à Temperature on the display p 11 31 1 Press The...

Page 510: ...cylinders p 12 54 The display fields must be switched on for crane operation in the driver s cab in the Settings menu on the CCS display Control panels Short description on the CCS display Press Engine off crane functions stop immediately Switch latches Turn the latched switch Switch returns to initial position crane functions released à p 10 12 1 Lifting limit switch warning à p 9 118 2 Slewing g...

Page 511: ...ting on off s To open Select and confirm symbol 1 Red Slewing gear switched off symbol 1 out Green Slewing gear switched on outrigger movement disabled symbol 1 is displayed à p 12 43 Red Suspension is switched off Green Suspension switched on outrigger movement disabled symbol is displayed à p 12 43 Red Parking brake released outrigger movements locked Out Parking brake applied outrigger movement...

Page 512: ...g the outrigger An outrigger cylinder or outrigger beam is pre selected The movement stops after the button is released or when an end position is reached Switch on Select symbol 2 and confirm symbol 1 is grey Switch off Select symbol 1 and confirm symbol 2 is grey à p 12 43 1 Exiting the menu 2 Outrigger menu 3 Outrigger cylinders menu Pre selection on Press the required button 1 Pre selection of...

Page 513: ...ition lights for indicator lamps Light up when the ignition is on Outrigger display Menu selection Pre select high speed normal speed mode s Display field lighting off Ignition on and no button activated yet or no button activated within the last 10 seconds Display field lighting on Press any button à p 12 48 Display To display the outrigger and Raise axle menus Some of the buttons under the displ...

Page 514: ...d Movement stops after the button is released and when an end position is reached Operating the right outriggers next to control unit Operation is the same as on the button unit for Outriggers to the left of display field 1 Press Carrier horn on To open Press button 2 repeatedly until display 1 appears 1 Retract Press button outrigger beam retracts1 2 Extend Press button outrigger beam extends1 3 ...

Page 515: ...s pressed 1 Retract Press button all outrigger cylinders retract 2 Extend Press button all outrigger cylinders extend Movement stops after the button is released and when an end position is reached à p 12 55 Automatic alignment Press button 1 and button 2 together Truck crane is levelled horizontally The process stops as soon as the truck crane is levelled horizontally or the button is released à ...

Page 516: ...ve when the Raise axle menu is open Pre selection display Pre selected wheels are black e g all wheels on the operator s side Pre selecting wheels Only pre defined wheel groups can be selected Selectable wheel groups To open Press button 2 repeatedly until display 1 appears 1 Forwards Press button once next wheel group 2 Back Press button once previous wheel group A All wheel groups All wheels Opp...

Page 517: ...ble wheel load is exceeded Wheel load display The displays A to D show the sum of the wheel loads for the associated wheels Opposite the operator side operator s side The display is in tons or kilopounds depend ing on the setting 1 kilopound 1 000 lbs 1 Raise Press the button the selected axles are raised and the truck crane is lowered 2 Lower Press the button the selected axles are lowered and th...

Page 518: ...clination Switching over the measuring range A In the Monitoring menu B In the Outrigger menu C On the outrigger control units 1 Measuring range display 2 Inclination indicator 3 Directional indicator A In the Monitoring menu B In the Outrigger menu Changeover is automatic the current measurement range 1 is displayed 1 or 5 C On the outrigger control units Press 1 x button 2 the current measure me...

Page 519: ...y connected vmax maximum permissible reduced wind speed as shown in the lifting capacity table Unit of measurement Displayed depending on setting t tons or klbs kilopounds 1 kilopound 1 000 lbs Precision One decimal place à p 12 66 Unit of measurement Lights up depending on setting t tons or klbs kilopounds 1 kilopound 1 000 lbs Precision When in t one place of decimals When in klbs no places of d...

Page 520: ...rigging range the following rigging positions are displayed à p 12 87 Display of slewing direction for automatic mode Automatic mode is switched on To open Select and confirm symbol 1 1 White not in the rigging range 2 Green move the lifting cylinder position 3 Red intermediate position lifting cylin der movements blocked 4 Green lift lower the counterweight posi tion 0 position Arrow is displayed...

Page 521: ...ewing gear automatically Slewing in position Move lifting cylinders Extend lifting cylinders Move the control lever for slewing gear in indicated direction automatically Slewing in position Lift lower counterweight Lift counterweight Pre tension counterweight Automatic mode ends symbol yellow à p 12 88 Display Yellow Recognition that the counterweight is unrigged Flashing Automatic mode on Grey Au...

Page 522: ...1 Green extended 2 Green retracted 3 Yellow intermediate position 4 Violet error 5 Extended length in per cent 1 Extend Display 5 and symbol 3 yellow or Display 6 and symbol 4 yellow Select symbol and confirm slewing is disabled after extending 2 Retract Select symbol and confirm after reach ing the end position the counterweight is pre tensioned The movement stops after the button is released and...

Page 523: ...ed if no other shutdown has occurred 2 Red Slewing disabled by counterweight the corresponding warning is displayed The pre tensioning pressure is too low or the counterweight is not completely lifted à Extending retracting the lifting cylinders p 12 86 Displayed The rear counterweight platform has been locked The counterweight hoist unit is not operating and the slewing has been disabled Hidden T...

Page 524: ...he button Right control lever Hoist high speed mode on off The parking brake is engaged CCS display Power units display Press once Lamp bright main hoist on Lamp dim main hoist off à p 11 76 Back Lifting Forward Lowering à p 11 76 Left High speed mode on off when released Once to the right High speed mode on continuous operation Once to the right or once to the left High speed mode off à p 11 113 ...

Page 525: ... p 11 113 Symbol 1 lifting Symbol 2 lowering Red Lowering limit switch triggered main hoist stop Grey Lowering limit switch not triggered à p 11 82 1 On Lifting limit switch triggered movements which increase the load moment stops 1 Flashing Button 2 pressed 1 Out Lifting limit switch not triggered and not bridged à p 11 82 2 Press Shutdown functions of the lifting limit switch bridged Lamp 1 flas...

Page 526: ... button Left control lever Hoist high speed mode on off The parking brake is engaged CCS display Power units display Press once Lamp bright auxiliary hoist on Lamp dim auxiliary hoist off à p 11 79 Back Lifting Forward Lowering à p 11 80 Left High speed mode on off when released Once to the right High speed mode on continuous operation Once to the right or once to the left High speed mode off à p ...

Page 527: ...3 Symbol 1 lifting Symbol 2 lowering à p 11 113 Red Lowering limit switch triggered auxiliary hoist stop Grey Lowering limit switch not triggered à p 11 82 1 On Lifting limit switch triggered movements which increase the load moment stops 1 Flashing Button 2 pressed 1 Out Lifting limit switch not triggered and not bridged à p 11 82 2 Press Shutdown functions of the lifting limit switch bridged Lam...

Page 528: ...e button Left control lever Slewing gear freewheel Press once Lamp bright slewing gear on Slewing gear brake released Lamp dim slewing gear off Slewing gear brake applied à p 11 116 To the left Slewing to the left To the right Slewing to the right à p 11 117 Switch on Move control lever to zero position and press button slewing gear brake released lamp 1 goes out Switch off Release switch slewing ...

Page 529: ... on Red Slewing gear off 1 On Slewing gear brake applied 1 Out Slewing gear brake released à p 11 116 To switch Select symbol and confirm the function is displayed 1 Brake pedal function Brake slewing movement actuate slewing gear brake pedal 2 Control lever function Brake slewing movement control lever in the zero position Slewing gear brake pedal without function à p 11 115 Switch off Select sym...

Page 530: ...ver Derricking gear telescoping mechanism high speed mode on off The parking brake is engaged Press once Lamp bright derricking gear on power units with the same control lever configuration off Lamp dim derricking gear off à p 11 85 To the left Raise lift main boom To the right Lower lower main boom à p 11 86 Left High speed mode on off when released Once to the right High speed mode on continuous...

Page 531: ...1 GMK4100L 1 23 11 2017 CCS display Power units display High speed mode inspection derricking gear Side panel Green Derricking gear on Red Derricking gear off On High speed mode on Out High speed mode off à p 11 113 1 Raise enable button after RCL shutdown RCL override version A à p 9 143 RCL override version B à p 9 144 ...

Page 532: ... There is a lamp in the button Control lever The control lever configuration is depends on the version Version 1 Left control lever Version 2 Right control lever Press once Lamp bright telescoping mechanism on power units with the same control lever configuration off Lamp dim telescoping mechanism off à p 11 98 Back Retraction of the telescoping Forward Extension à p 11 98 To the left Retraction o...

Page 533: ...on menu Open menu Telescope diagram display Current relation of the telescopic sections to each other section of top view s On High speed mode on Out High speed mode off à p 11 113 Green Telescoping mechanism on Red Telescoping mechanism off To open Select symbol 1 and confirm menu is opened Locking pin Display 1 and 2 1 On the telescopic section Green Locked 2 On the telescoping cylinder Yellow I...

Page 534: ...lescopic sections Display Current extended length of the telescoping cylinder Unit of measure ment Displayed in per cent and depending on setting mm millimetres or ft feet à p 11 110 Display Current extended length of the main boom Unit of measure ment Displayed depending on setting mm millimetres or ft feet à p 11 110 1 6 Display of telescopic sections 1 to 6 1 6 Display of telescopic sections 1 ...

Page 535: ...g point display s 1 Confirm pre selected telescoping 2 Telescoping permitted display 3 Telescoping not permitted display à p 11 110 1 Start telescoping full automation with Retract 2 Start telescoping full automation with Extend à p 11 110 To open Select symbol 1 and confirm menu is opened Display Yellow Locking pins intermediate position Green Telescoping cylinder locked Red Telescoping cylinder ...

Page 536: ...nder is unlocked à p 11 103 Display Yellow Locking pins intermediate position Green Telescopic section locked Red Telescopic section unlocked To lock The telescoping cylinder is locked Select symbol 2 and confirm telescopic section locked To unlock The telescoping cylinder is locked Select symbol 1 and confirm telescopic section is unlocked à p 11 107 Display Current extended length of the telesco...

Page 537: ...ic section e g telescopic section 1 Telescoping direction display Telescope diagram display Current relation of the telescopic sections to each other section of top view 1 Extend telescoping cylinder 2 Retract telescoping cylinder 1 Start with Retract 2 Start with Extend à p 11 110 Locking pin Display 1 and 2 1 On the telescopic section Green Locked 2 On the telescoping cylinder Yellow Intermediat...

Page 538: ...n menu Current pressure in bar for movements of Preheating the hydraulic oil Press down Incline forward Press up Incline back à p 11 123 1 Angle gear oil temperature 2 Slewing gear 3 Telescoping mechanism 4 Hoist Derricking gear Counterweight hoist unit Inclining the crane cab Locking units Switch on Select symbol 1 and confirm symbol is red Switch off Select symbol 1 and confirm symbol is grey à ...

Page 539: ...ng status displays The current position of the locking pin is shown by different symbols Locking unlocking the turntable The superstructure must be in the 0 or 180 position s To open Select and confirm symbol 1 1 and 7 Red unlocked symbol 8 green 2 and 7 Yellow intermediate position 3 and 7 Violet error 4 and 7 Green locked symbol 8 hidden and 5 Unlocked 6 Locked à p 11 16 To unlock Symbol 1 locki...

Page 540: ...isplay Directional indicator Current position 20 in front of the locking point 0 Position 0 to the rear locking point 180 Position 180 to the front locking point 0 1 to 180 0 Turned to the right from 0 0 1 to 179 9 Turned to the left from 0 à p 11 115 Both arrows locking point reached One arrow direction of arrow turn ing direction towards the locking point à p 11 15 ...

Page 541: ...1 2017 Houselock à Switching the houselock on off p 11 17 Locking status displays The current position of the locking pin is shown by different symbols House lock on off 1 Unlocked 2 Intermediate position 3 Blocked locking pin in front of a tooth 4 Locked à p 11 17 Switch on Symbol 1 Pin extends Switch off Symbol 2 Pin retracts à p 11 17 ...

Page 542: ...ype Remote control menu Remote control display 1 Orange Remote control connected 1 Green Remote control switched on CCS operation from the cab is blocked Symbol 2 is shown green on all menus 1 Off Remote control deactivated Other information à Separate operating manual 1 Green Remote control switched on CCS operation from the cab is blocked Symbol 2 is shown on all menus 1 Off Remote control deact...

Page 543: ... range type For the MAXbase slewing range type Display Slewing ranges working radii Represents the defined slewing ranges and corresponding respective maximum per missible operating radii 5 for the confirmed rigging mode as a diagram Display of current slewing range divisions Shows the currently defined slewing ranges 1 to 4 as pillars 1 to 4 The pillar width represents the angular range Display o...

Page 544: ...e current position The display 3 moves a corresponding distance up or down à Slewing range type Standard p 11 53 à Slewing range type MAXbase p 11 55 1 Display area always corresponds to the largest maximum working radius 5 2 Maximum permissible working radius in the corresponding slewing range with the currently lifted load 3 White limit region for minimum permis sible working radius display only...

Page 545: ...the CCS display p 11 53 Slewing range display The function is identical to the display in the Lifting capacity table menu s 1 Slewing to the left 2 Slewing to the right 3 Lower the main hoist 4 Lift the main hoist 5 Lower the auxiliary hoist 6 Lifting the auxiliary hoist 7 Lowering the boom 8 Raising 9 Extension 10 Retraction of the telescoping 11 Lower the lattice extension 12 Raise the lattice e...

Page 546: ...ng range type à Enter rigging mode p 11 32 Enter counterweight Counterweight display Select and confirm the symbol 1 the menu opens and opens automati cally after Ignition on 1 Display for a slewing range of 360 or for working position1 e g 0 to the front 2 Display for restricted slewing range e g 0 30 After confirmation Menu display 3 1 To accept switch off the slewing gear 4 MAXbase After confir...

Page 547: ...oist In input mode select and confirm current reeving 2 Auxiliary hoist functions as with 1 à Enter rigging mode p 11 32 1 Telescope status display in percentage 2 Preselected main boom length 1 in metres m or in feet ft à Enter rigging mode p 11 32 1 Orange Select and confirm Rigging mode and preselected telescope status are adopted lifting capacity table is confirmed Display 2 Monitoring menu on...

Page 548: ...gle In input mode select and confirm length Input lattice extension the length after the angle In input mode select and confirm length Lattice extension input angle Only for manually inclinable lattice extensions In input mode select and confirm the angle à Enter rigging mode p 11 32 A Main boom display B Lattice extension display C Heavy load lattice extension display 1 Angle of the lattice exten...

Page 549: ...d individually for outrig ger beams 1 to 4 In input mode select and confirm the indi vidual widths Outrigger span monitoring display MAXbase à Enter rigging mode p 11 32 Enter outrigger span Standard The selection occurs simultaneously for all outrigger beams selected outrigger widths are orange In input mode select and confirm the outrig ger span à Enter rigging mode p 11 32 s 5 Measured outrigge...

Page 550: ...de In input mode select and confirm the RCL code The corresponding rigging mode is displayed à p 11 40 A Measured outrigger width required width B Measured outrigger span of required span query menu 2 Required outrigger width for RCL code 1 3 Measured outrigger width 4 Outrigger width not OK for RCL Code 1 red 5 Confirmation Rigged outrigger span outrigger span 2 Crane operation enabled 6 Confirma...

Page 551: ...During the telescoping duration the required telescoping times are compared and provided with values between 1 shortest time and 5 longest time Preselect the telescope status select and con firm the desired line for example line 3 The Pre selection telescoping menu closes The Enter rigging mode telescope status menu opens à Pre selecting telescoping p 11 40 s 1 Selection of numerical values 2 Sele...

Page 552: ... when a USB stick is connected to the RCL control unit Starts the data export to the USB stick Display of export progress There are no short descriptions for these displays In the Lifting capacity tables menu à Displaying the lifting capacity tables p 11 59 In the Monitoring menu à Checks before operating the crane p 11 45 à Display during the crane operation p 11 49 To open Select and confirm sym...

Page 553: ...y operated switch for overriding the RCL in an emergency s 1 Press once RCL shutdown overridden crane functions ena bled up to 110 utilisation Crane functions can be started within the next 10 seconds Speed of movements increasing load moment max 15 à RCL override version A p 11 63 1 Press once Release the raise function to the permitted working range If the degree of utilisation is less than 100 ...

Page 554: ...int only applies to RCL programming deviating from EN 13000 For RCL programming in accordance with EN 13000 à p 9 143 Overriding the RCL in an emergency No function No function 1 Press once RCL shutdown overridden crane functions enabled Crane functions can be started within the next 10 seconds Speed of movements increasing load moment max 15 à RCL override version B p 11 67 ...

Page 555: ...nual 3 302 690 en 9 145 GMK4100L 1 23 11 2017 9 2 23 Electrical system Voltage monitoring warning Sockets 12 V Only connect electrical devices with the matching specification to the socket Display symbol Engine on power failure switch off engine Out Engine on no fault à p 10 8 1 Socket 12 V max 15 A ...

Page 556: ...light on off Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed à p 12 127 Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed Switch on Select symbol 1 and confirm symbol ON is displayed Switch off Select symbol 2 and confirm symbol OFF is displayed à p ...

Page 557: ...atic spotlights The spotlights are switched on Cab lighting s Switch on Push down lamp in the button on Switch off Push up lamp in the button off à p 11 130 Down Push down Up Push up à p 11 130 1 Switch on symbol 2 display 2 Switch off symbol 1 display 3 Increase the slewing speed 4 Reduce the slewing speed 5 Submenu speed opening closing à p 11 130 1 Always on 2 Always off 3 On off via door conta...

Page 558: ...er washing system Windscreen wiper on off Roof window wiper on off Windscreen washing system 1 On 2 Off Off Middle position Interval Push up wiper goes to end position Continuous operation Push down Off Middle position Interval Push up wiper goes to end position Continuous operation Push down Windscreen Push down Skylight Push up No additional wiping function is performed ...

Page 559: ...cab menu Adjusting the wiper stroke interval Wiper interval in seconds for à p 11 124 Horn The ignition must be switched on To open Select symbol 1 and confirm menu is opened 1 Windscreen wiper selection display 5 2 Skylight wiper selection display 6 7 Changing the interval duration 3 Windscreen wiper 4 Roof window wiper 1 Press superstructure horn on ...

Page 560: ...eld control The following applies to all sockets The hand held control is only active when it is connected to the sockets 1 or 2 Pull plug Engine off ignition off Insert plug Switch the ignition on à p 12 23 Enabled operations 1 Emergency operation for crane movements except for telescoping mechanism Derrick lattice extension1 2 Emergency mode for crane operations 1 Additional equipment ...

Page 561: ...Switch the ignition off 2 CAN monitoring On Hand held control connected no malfunction goes out after 20 seconds Flashing Hand held control connected malfunction 3 Emergency stop switch May only be used in an emergency Press Engine off crane functions stop immediately Switch latches Turn the latched switch Switch returns to initial position crane functions released 4 START engine Press once Engine...

Page 562: ...shown in black Pre selected function on Press the required button combination Pre selected function off Release one or both the buttons Press a non assigned button combination pre selection off 1 Main hoist 2 Telescoping mechanism 3 Derrick lattice extension1 4 Auxiliary hoist 5 Derricking gear 6 Slewing gear 1 Lattice extension derricking gear Pre select Press button once lamp 1 lights up pre sel...

Page 563: ...53 GMK4100L 1 23 11 2017 à Emergency operation with the hand held control p 14 45 Pre selected power unit Button combination Telescoping mechanism Derricking gear Slewing gear Hoists Lattice extension c e f a b d No Lower No lowering Lower Retract raise No lifting raise No No slew to right No No No No slew to left No No ...

Page 564: ...ws and doors Window The handles on the windscreen and the rear window have the same function Open window A Turn both handles 1 inward Push the window forward Close window B Pull the window closed Turn both handles down pegs 2 located behind the clamp 3 Rear window Opening Raise the handle 1 Push window outwards Closing Pull in window Push down the handle 1 ...

Page 565: ...3 11 2017 Crane cab door From outside Unlocking Turn the key in direction A Locking Turn the key in direction B Open close Pull the handle 1 Slide the door From inside Closing Pull unlocking lever 3 push door forwards by handle 1 engages Locking from inside not possible Opening Pull unlocking lever 2 push door back by handle 1 latches ...

Page 566: ...ic and service connections are present on the CCS and RCL control units 5 Do not connect external devices e g a mobile phone to these connections 9 2 28 Other Disclaimer menu 1 CCS diagnostics serial interface 2 CCS diagnostics CAN bus 3 RCL diagnostics S Risk of damage to the crane control system Do not connect external devices to the diagnostic connections This prevents severe malfunctions in th...

Page 567: ...rm menu is opened To close Crane cab Applying the carrier parking brake Press button 2 or 3 once main menu is displayed à p 13 18 Green Driver s cab Ignition key in position 1 Crane cab Operating elements for driving active with released parking brake Red Driver s cab Ignition key not in position 1 Crane cab Operating elements for driving without function Red Crane cab Accelerator not functioning ...

Page 568: ...rom the crane cab operating the transmission when driving a rigged truck crane à Operating the transmission p 13 27 Neutral position N Transmission mode DM Transmission mode RM Switch on Select and confirm symbol letter is white No gear engaged Switch off Shift to DM or RM letter is blue Switch on Select and confirm symbol letter is white When at a standstill Select forwards starting gear When dri...

Page 569: ...s are switched on or off Transverse differential locks display The current status is shown using different symbols Longitudinal differential lock on off s To open Select symbol 1 and confirm menu is opened Switch on Select symbol 1 and confirm symbol is red Switch off Select symbol 1 and confirm symbol is green 1 Green locks off 2 Red locks on 3 Yellow intermediate position 4 Violet error à p 13 2...

Page 570: ...ing elements driving from the crane cab 9 160 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Longitudinal differential lock display The current status is shown using different symbols 1 Green lock off 2 Red lock on 3 Yellow intermediate position 4 Violet error à p 13 29 ...

Page 571: ...K4100L 1 23 11 2017 9 3 4 Brakes Service brake pedal Affects the carrier brakes the braking force can be steplessly adjusted CCS display Supply pressure brake circuits 1 and 2 display Parking brake indicator lamp s Red Supply pressure less than approx 5 bar Green Supply pressure greater than 5 5 bar Red Parking brake applied Grey Parking brake released ...

Page 572: ...arking brake indicator lamp Applying releasing the parking brake On Parking brake applied Out Parking brake released Press up once Parking brake released When the driver s cab ignition key is in position 1 The Driving mode menu opens Steering control lever function on Press down once Parking brake applied The Driving mode menu closes High speed control lever function on à After driving p 13 31 ...

Page 573: ...l 3 302 690 en 9 163 GMK4100L 1 23 11 2017 9 3 5 Steering CCS display Changing the steering direction Depending on the superstructure position the display 1 changes automatically to the appropriate steering direction à p 13 22 Current wheel position display à p 13 22 s 1 Straight ahead 2 Driving around corners 3 Crab travel mode ...

Page 574: ...in 2 seconds otherwise the type of steering remains unchanged Automatic separate steering for driving around corners on off Automatic separate steering for crab travel mode on off Manual separate steering on off 1 Green locked 2 Red unlocked 3 Yellow intermediate position 4 Violet error à p 13 22 Switch on Select symbol 1 and confirm Symbol 2 is displayed Switch off Select a different steering mod...

Page 575: ...steering driving around corners Symbol 1 or 2 is displayed Press button 3 and keep it depressed Steering in normal steering mode The 1 symbol is displayed Steer the 1st and 2nd axle lines with the button 2 Switch on Select symbol 1 and confirm Symbol 2 is displayed Switch off Select a different steering mode Symbol 3 à p 13 22 To the left 2 and 3rd axle lines turn to the left To the right 2 and 3r...

Page 576: ...Operating elements for crane operation 9 3 Short description of the operating elements driving from the crane cab 9 166 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 577: ...e day Start the engine from the crane cab à p 10 3 Start the engine with the hand held control à p 10 10 10 1 When starting the engine for the first time in the day The first start of the day should always be made from the driver s cab as all the displays for monitoring the engine can only be accessed there Carry out all the required tasks and checks for starting the engine à CHECKLIST Starting th...

Page 578: ...GMK4100L 1 23 11 2017 When not driving from the crane cab Remove the ignition key If you want to drive from the crane cab Turn the ignition key to position 1 Driving from the crane cab is enabled and the steering lock is prevented from engaging while driving à Preparing to drive p 13 18 H Lock the driver s cab for protection against unauthorised use ...

Page 579: ... 1 indicates the current filling level in per cent 100 corresponds to about 400 ltr 105 6 gal 1 The display changes colour depending on the filling level AdBlue The display 1 indicates the current filling level in per cent 100 corresponds to about 40 ltr 10 6 gal The display changes colour depending on the filling level Green Over 10 over 40 ltr 10 6 gal Yellow 5 to 10 20 to 40 ltr 5 3 to 10 6 gal...

Page 580: ...ugs are inserted into all sockets for the hand held control à p 9 150 Hand held control connected to the superstructure After starting the engine you can use the hand held control to execute all functions which are provided from this socket At the hydraulic tank Before you start the engine all valves on the hydraulic tank must be open The valve is located behind the ladder 1 Open the flap 1 Check ...

Page 581: ...e CCS display shows a menu usually the Enter rigging mode menu Turn the ignition key to position 1 The ignition is switched on The vehicle parking brake must be engaged The lamp 1 lights up symbol 2 red The transmission must be switched to neutral position symbol 1 If the symbol 1 is grey then switch the ignition off and on again After switching on the ignition a lamp test is performed and switchi...

Page 582: ...s and the separate steering are compared Differential locks The state last saved is retrieved In the Driving menu the corresponding symbols 1 are shown and the electronics system triggers the switching operations Steering When you switch the ignition on the steering is always set to On road driving 2 irrespective of what setting was last saved 10 2 5 Display setting the brightness Open the Setting...

Page 583: ...ards Let go of the button after the engine starts After starting the idling speed corresponds to the standard value If the engine does not start release the ignition key after approx 15 seconds and wait one minute before trying again H To set the idling speed à p 10 9 If the engine does not start after several attempts à Malfunctions on the engine p 8 19 S Danger of explosion when using starter fu...

Page 584: ...splay 1 on the CCS control unit immediately after starting the engine When a symbol is displayed in the display area 1 à Malfunctions on the engine p 8 19 Also check the displays 1 Engine speed display in rpm 2 AdBlue DEF filling level indicator in per cent 3 Coolant temperature display in C F 4 Fuel level display in per cent 5 Voltage monitoring display in volts 6 Hydraulic oil temperature displa...

Page 585: ...dling speed increases continuously until you release the button or the maximum value is reached or Push the button 1 up once The idling speed is increased by one step Reduces the idling speed Push the button 1 down once The idling speed is reduced by one step or Press the button 1 in at the bottom and hold it pressed After about 3 seconds the idling speed will be at the standard value After a furt...

Page 586: ...so start the engine if the ignition in the driver s cab or crane cab is switched on Wait until the lamps 1 and 2 light up If the lamp 2 does not light up or flash after about 20 seconds there is a malfunction à p 8 19 Press the 3 button once the engine starts H If the hand held control is connected to the superstructure you cannot drive the power units from the crane cab G Risk of crushing due to ...

Page 587: ...fter switching off Refer to the instructions in the respective sections for each type of stopping work à In case of short work breaks p 11 149 à In case of work breaks of more than 8 hours p 11 150 10 4 2 With the idling button Push the button 1 down and hold it there After about 3 seconds the idling speed will be at the standard value After a further about 3 seconds the engine will switch off the...

Page 588: ...u can restart the engine only after you have reset the emergency stop switch Switch off the ignition Turn the actuated emergency stop switch until it unlatches again If an air intake inhibitor is present this must be loosened à Releasing the air intake inhibitor p 4 20 G Risk of overloading if used improperly Use the emergency stop switches only in an emergency i e if the crane functions no longer...

Page 589: ...ing instructions which are indicated by cross references Observe the warnings and safety instructions there H This checklist only applies to working with a rigged truck crane supported and rigged with counterweight If the truck crane is not yet rigged à CHECKLIST Rigging p 12 1 1 The truck crane has been rigged for the operation to be carried out as described in the CHECKLIST Rigging à p 12 1 2 In...

Page 590: ...sary à p 11 130 4 Crane cab heater check the fuel level à p 11 5 5 Earth the load if necessary à p 11 13 6 Adjust crane cab seat and front panel à Crane cab seat p 11 8 à Front control panel p 11 9 7 Start the engine for crane operation à p 10 7 8 Check RCL lifting limit switch seat contact switch and dead man s switch emergency stop switch for correct operation Have faulty units repaired à p 11 1...

Page 591: ...with the RCL display enter and confirm current rigging mode if necessary à p 11 32 11 Check telescoping à Inspections prior to starting operations p 11 97 12 Switch off the slewing gear for 0 and 180 working positions symbol 1 red à p 11 120 Switch off houselock if fitted for other working positions symbol 2 red à p 11 19 13 Check the electrical system for correct operation à p 11 7 s ...

Page 592: ...ck hydraulic oil temperature preheat if necessary à p 11 14 15 Adjust the brightness of the CCS display if necessary à p 10 6 H Additional information on inspections during crane operation on permissi ble working positions and on how to operate the individual power units à Crane operation with main boom p 11 73 ...

Page 593: ...and seal the tank 1 with the cap Visual inspection Walk around the truck crane and look out in particular for leaking oil fuel or coolant s S Danger of fire due to flammable gases Turn off the engine and heating systems before refuelling G Danger if the crane cannot be unrigged If oil is lost you may no longer be able to move the crane Not even in emergency mode O Risk of environmental damage due ...

Page 594: ...ope has moved over a complete width X of the rope drum The rope must be evenly wound The rope turns on the drum must be evenly spaced 0 to 2 mm 0 to 0 08 in apart The cross over points must be offset by approximately 180 H The top rope lines are laid over the next lower rope lines at the cross over points G Risk of crushing due to turning rope drum Keep away from the rope drum while it is turning ...

Page 595: ...ng manual 3 302 690 en 11 7 GMK4100L 1 23 11 2017 Checking the electrical system Check the following functions and have faulty parts repaired Working area spotlight Air traffic control light rotating beacons Windscreen wipers windscreen washing system Horn ...

Page 596: ...t angle 4 Seat height 5 Seat longitudinal adjustment With control panels 6 Seat longitudinal adjustment Without control panels 7 Seat cushion angle 1 Control panel right height 2 Control panel left height 3 Back rest angle 4 Seat heating1 on off 5 Seat height1 6 Seat longitudinal adjustment With control panels 7 Adjust suspension stiffness to body weight 8 Seat longitudinal adjustment Without cont...

Page 597: ... 690 en 11 9 GMK4100L 1 23 11 2017 Front control panel You can adjust the height and inclination Pull and hold the handle 1 Adjust the front panel to suit your requirements Release the handle 1 In addition the inclination of the display can be adjusted Press either 2 or 3 ...

Page 598: ... hook block is lifted off the ground Slowly perform the Raise movement until the hook block lifts the lifting limit switch weight Now check whether the Raise movement is switched off and lamp 1 lights up Check whether the Lower and Extend movements are also switched off The lifting limit switch is working correctly at this point in time if the lamp 1 lights up and the Raise Lower and Extend moveme...

Page 599: ...the emergency stop switch 3 so that it engages Check whether the engine stops Turn the emergency stop switch until it disengages again Release the air intake inhibitor if required à Air intake inhibitor p 4 20 Repeat the checks with the emergency stop switches 1 and 2 If the emergency off switch is not working correctly do not start work with the crane but notify Manitowoc Crane Care s ...

Page 600: ...go of the right dead man s switch and check whether the crane movement comes to a standstill within about 3 seconds Repeat the check with the dead man s switch on the left control lever Seat contact switch Do not press any dead man s switch 1 Sit down on the crane cab seat and slowly lift the hook block With the control lever actuated stand up and check whether the crane movement comes to a stands...

Page 601: ...tion of at least 16 mm2 0 025 in2 Clamp the other end of the cable 3 to a metal rod 2 with an insulated handle 1 Hold the metal rod firmly by its insulated handle 1 To earth touch the load with the metal rod B Risk of accident due to electric shock Always earth the load before operating the crane Near strong transmitters radio transmitters radio stations etc Near high frequency switchgears If a th...

Page 602: ...C 50 F to 32 F You can carry out crane movements with loads only at normal speed at average engine speed and at average operating speed From 0 C to 15 C 32 F to 5 F To preheat only carry out crane movements without a load Only operate at normal speed at medium engine speed and medium working speed Below 15 C 5 F You must preheat the hydraulic oil before carrying out crane movements Prerequisites T...

Page 603: ... Locking points The locking points are at 0 and at 180 Open the Superstructure lock menu 1 if necessary The display 1 will show the current super structure position Slew to locking point at 0 or 180 The display 1 shows positive and negative values For an overview à p 11 118 At the locking point both arrows 2 are shown In the range of 20 around the locking point an arrow 3 indicates the slewing dir...

Page 604: ...d contact Manitowoc Crane Care Unlocking the superstructure The RCL shutdown procedure will be triggered and slewing disabled if you unlock the superstructure during a rigging mode for 0 to the rear has been entered To acknowledge the shutdown procedure you must either lock the superstructure or set down the load and enter a rigging mode for a working range of 360 Select the symbol 5 Press the but...

Page 605: ...re to the position in which it is to be locked and then stop the slewing movement Open the Superstructure lock menu 1 if necessary Switching off the slewing gear The slewing gear brake must be engaged when operating the houselock Press the button 1 once The slewing gear will be switched off and the slewing gear brake applied Symbol 2 is red The lamp 3 lights up s S Risk of damage during slewing Al...

Page 606: ...orrect the position of the superstructure as follows Select the symbol 6 Press the button until the symbol 1 is displayed Houselock switched off Apply the slewing gear brake Switch on the slewing gear and slew the superstructure a little further minimally Switch off the slewing gear Select the symbol 5 Press the button until the symbol 4 is displayed Houselock switched on If symbol 3 is still show...

Page 607: ...lewing gear p 11 17 Select the symbol 4 Press the button until the symbol 3 is displayed Houselock switched off The display first shows the symbol 1 then symbol 2 in the intermediate position and then symbol 3 when the houselock is switched off S Risk of damage during slewing Always switch off the slewing gear before you operate the houselock The system will be damaged if the superstructure is sle...

Page 608: ...Crane operation 11 1 Before operating the crane 11 20 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 609: ...the rigged outrigger span Slewing with a rigged counterweight is not per mitted with all outrigger spans à Slewing with rigged counterweight p 12 97 Working position 0 to the rear Support the truck crane with the outrigger span required according to the Lifting capacity table Slew the superstructure to the rear into the 0 position Lock the turntable à p 11 15 Enter an RCL code for the 0 to the rea...

Page 610: ...Crane operation 11 2 Standard slewing range type 11 22 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 611: ...tables with different variable outrigger spans are available for the MAXbase slewing range type These additional lifting capacity tables are supplied in digital form with the truck crane and can be shown as a dia gram on the display in the crane cab The designation of the slewing angle always relates to the starting point 0 to the rear A full turn from this working position is divided into two sem...

Page 612: ...ucture position is the starting point for the enabled slewing range A com plete turn is always divided in four slewing ranges The size of the slewing range is defined via an angular region around the start ing point e g 60 for the slewing range 1 This results in the enabled slewing range 1 between the slewing angles of 30 to 150 The size of the enabled slewing range depends on the rigged outrigger...

Page 613: ... applies only to a symmetrical outrigger span with a span of 7 200 m 23 6 ft Smallest individual width 3 125 m 10 3 ft This case applies when one or more outrigger beams is extended to a span of 3 125 m 10 3 ft and all other outrigger beams are extended to larger spans s Positional reference Angular range Enabled slewing range 1 To the right 55 145 to 35 2 Backwards 35 35 to 35 3 To the left 55 35...

Page 614: ...t individual width 1 900 m 6 2 ft This case applies when one or more outrigger beams is extended to a span of 1 900 m 6 2 ft and all other outrigger beams are extended to larger spans Positional reference Angular range Enabled slewing range 1 To the right 65 155 to 25 2 Backwards 25 25 to 25 3 To the left 65 25 to 155 4 Forwards 25 155 to 155 Positional reference Angular range Enabled slewing rang...

Page 615: ...idual width 1 170 m 3 8 ft This case applies when one outrigger beam is extended to a span of 1 170 m 3 8 ft and all other outrigger beams are extended to larger spans Positional reference Angular range Enabled slewing range 1 To the right 85 175 to 5 2 Backwards 5 5 to 5 3 To the left 85 5 to 175 4 Forwards 5 175 to 175 ...

Page 616: ...trigger beam retracted left e g for the outrigger span I Outrigger span type Right left Lifting capacity tables are only provided for the combination Right greater than left e g for the outrigger span II When the truck crane is on outrigger beams with a mirrored outrigger span then the same lifting capacities are enabled in the correspondingly mirrored slewing range Example Assuming that the truck...

Page 617: ... the overload range G Risk of accidents due to an incorrectly set RCL Ensure that the current rigging mode is correctly entered Before starting crane operation An incorrect entry will give you a false sense of security This may result in the truck crane overloading and causing an accident Acquired via measurements Acquired via manual entry Main boom length Main boom angle Current load Lattice exte...

Page 618: ...refer to Manitowoc Crane Care Brightness of the displays The brightness of the CCS and RCL is adjusted automatically Do not cover the sensors 1 and keep them clean to avoid contamination that can affect the brightness adjustment You can set a common minimum brightness for both displays at the CCS control unit This is operated in the same way as in the driver s cab à p 4 11 G Risk of accidents in t...

Page 619: ... that can affect the brightness adjustment After completing the test program The lamps 1 light up All power units are disabled The CCS display shows the last confirmed rigging mode and the RCL display shows the corresponding lifting capacity table The symbol 1 indicates that a rigging mode has not been confirmed If the current rigging mode is displayed then you can conform the rigging mode à p 11 ...

Page 620: ...es slewing ranges and telescopings that are enabled with this rigging mode H You can only change the rigging mode when all crane movements have stopped control lever in the initial position If necessary open the Enter rigging mode telescope status menu 1 on the CCS display The RCL display shows the Lifting capacity table menu The CCS shows the Enter rigging mode telescope status for the last riggi...

Page 621: ...listed there can be entered The rigging mode can be specified via entry of the reeving and RCL code or via the individual components In the case of individual components the outriggers are always entered as complete outrigger span In the case of individual components the slewing range is entered according to the lifting capacity table MAXbase slewing range type The MAXbase tables apply which are o...

Page 622: ... components à p 11 34 For the MAXbase slewing range type Select and confirm the display 1 Select and confirm the symbol 2 After confirming the menu 3 is displayed for further rigging mode entry Enter the rigging mode à p 11 34 Entering indi vidual compo nents Only enabled rigging modes can be selected For this reason the selection possibilities for the individual components are based on the alread...

Page 623: ...ewing range 2 for example working position 0 to the rear Confirm the selection The corresponding RCL code 3 is displayed You can only confirm rigging modes for slew ing ranges other than 360 When the selected working position is reached and the slewing gear is switched off When the superstructure is in the selected slewing range If necessary first enter the 360 slewing range and slew the superstru...

Page 624: ...rent display 1 At the same time the current telescoping is adopted and shown on the display 3 Always check that the currently rigged out rigger span is displayed before confirming the rigging mode Enter outrigger span Standard Select and confirm the display 1 Select the rigged outrigger span for example symbol 2 for 8 660 x 5 300 m 28 4 x 20 5 ft Confirm the selection The selection and the corresp...

Page 625: ...ary you must re enter the outrigger widths in the sequence 1 to 4 Select and confirm the display 1 for the desired outrigger beam Select the rigged individual width 2 for example 3 600 m 11 8 ft Confirm the selection If the outrigger span measured by the outrig ger width monitoring differs from the entered value then the value 3 is displayed in red The symbol 4 becomes grey the rigging mode cannot...

Page 626: ...ndard slewing range type only Select and confirm the display 1 Select the symbol for the rigged boom system Confirm the selection When selecting lattice extension additional displays 4 to 6 are shown selection and confirmation is performed in the same manner as with display 1 Display 4 Select an confirm the current length Z before the angle Display 5 Select an confirm the current length Y after th...

Page 627: ...017 The confirmed boom system 1 or 2 is displayed Reeving A Select and confirm the display for the hoist to be used for lifting the load for example display 1 for the main hoist symbol 3 is orange B Select the currently rigged reeving 2 for example 8 fall Confirm the selection and leave the display 1 symbol 3 grey s ...

Page 628: ...he necessary RCL code 3 for example 1100 Confirm the selection The other displays will show the correspond ing rigging mode 11 4 3 Pre selecting telescoping First enter the current rigging mode Select and confirm the symbol 1 The Pre selection telescoping menu opens Enter the desired parameter 2 à p 9 42 The table shows all permissible telescop ings 4 and the associated parameter 3 for the entered...

Page 629: ...ging modes if necessary The displayed lifting capacity table 9 applies to the RCL code 5 in the corresponding slew ing range 8 and for the preselected telescope status 7 If the actual rigging mode is displayed correctly and the planned operation can be performed within the displayed working range 8 then you can confirm the rigging mode s G Risk of accidents due to an incorrectly set RCL If the cur...

Page 630: ...ting the crane p 11 45 If a deviation in the outrigger span is detected A query menu opens The display 2 shows the outrigger span corresponding to the RCL code 1 The display 3 shows the acquired outrigger span deviating outrigger widths 4 are red Check the currently rigged outrigger span If an incorrect outrigger span is rigged Select and confirm the symbol 5 the menu closes and the rigging mode i...

Page 631: ...en you can confirm the rigging mode s S Risk of accident due to incorrectly supported truck crane A shutdown is not initiated as standard when an outrigger span monitoring error message is issued When an error message is displayed compare the rigged outrigger span with the required outrigger span and rig the required outrigger span This prevents the truck crane from tilting due to an inadequate ou...

Page 632: ...e RCL display shows the Monitoring menu The CCS display shows the Start menu The crane movements are released if there is no error à Checks before operating the crane p 11 45 If a deviation in the outrigger span is detected The symbol 2 is grey The rigging mode cannot be conformed crane operation is not enabled If the value for an outrigger width is red then a deviating outrigger span has been det...

Page 633: ... if necessary Display RCL code For the Standard slewing range type only Shows the RCL code corresponding to the confirmed rigging mode accord ing to the lifting capacity table Outrigger span display Numerical values show the individual widths of the outrigger beams for the confirmed rigging mode in metres m or feet ft Visual display shows the required outrigger span in orange For the Standard slew...

Page 634: ...attice extension after the angle according to the confirmed rigging mode in metres m or feet ft Angle of the lattice extension display Only for manually inclinable lattice extensions Shows the required angle of the lattice extension for the confirmed rigging mode Display of reeving used A Main boom B Swing away lattice extension1 boom extension1 C Heavy load lattice extension 1 1 For the Standard ...

Page 635: ... Switching over the display A Switch off both hoists both symbols become grey B Switch on the hoist with which you wish to lift the load The corresponding symbol becomes orange for example the symbol 1 for the main hoist If you wish to also lift a load with the other hoist during subsequent crane operation then you must first switch over the display appropriately G Risk of accidents due to incorre...

Page 636: ...Crane operation 11 4 Operation of the rated capacity limiter 11 48 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 637: ...length in metres m or feet ft Current working radius display Shows the current working radius horizontal distance between the turnta ble axis and hook block axis in metres m or feet ft The displayed value is calculated on the basis of the telescoping and the main boom or lattice extension angle Current overall height display Overall height vertical distance between the lower edge of the outrigger ...

Page 638: ... in degrees Current slewing angle display Shows the angle of the current superstructure position 180 means that the superstructure is slewed to the front 0 means that the superstructure is slewed to the rear A full turn from this working position is divided into two semi circles When slewing clockwise the slewing angle is displayed as a positive value 0 to 180 0 When slewing anticlockwise the slew...

Page 639: ...the weight of the current load as a percent age of the maximum possible load degree of utilisation 100 x current load maximum load The display has three coloured regions Depending on the equipment the degree of utilisation is shown on a display 4 with coloured lamps RCL status display The green yellow and red displays 1 are identical to the status displays 2 on the outside of the truck crane Curre...

Page 640: ...he display is only active when telescoping with teleautomation and shows the direction in which you must move the control lever for each respective telescoping direction Current wind speed display Shows the current wind speed in metres per second m sec or miles per hour mph The display flashes in colour in the vicinity of the maximum permissible value vmax 1 Start with Retract 2 Start with Extend ...

Page 641: ...0 m 100 ft The current position of the boom head is shown using the symbol 4 and defined by two displays The shutdown range for the maximum work ing radius 2 is shown in colour and if active the shutdown range for the minimum work ing radius 6 is displayed When telescoping or derricking The displays 2 move up and down to show the current working radius for example 25 m 20 ft In a shutdown range 1 ...

Page 642: ...d 4 remain at the current position The diagram 1 and the displays 3 move to the left or right Immediate before the slewing range limits 3 the movement leading towards a shutdown limit is continuously reduced until reaching a standstill The corresponding display 5 shows the current speed reduction for example for slewing to the right Working position The diagram 1 shows the working range for exampl...

Page 643: ... the definition for the slewing angle display 0 to the rear the slewing range limits would be 30 30 150 and 150 The RCL display shows an angular range of approx 200 The range of the diagram is always in the middle corresponding to the current slewing angle 6 for example the range 3 for 120 When slewing The displays 2 3 and 6 remain at the current position The diagram 4 and the displays 5 move to t...

Page 644: ...e manner as with the Standard slewing range type à p 11 54 Special case disabled range A slewing range can be disabled in certain cases If for example an outrigger span 1 is rigged and operations are to be performed at the right side with large counterweight combina tions a small working radius and a small load it is possible for the stability towards the rear to become endangered within the slewi...

Page 645: ...ound After five seconds you can switch off the buzzer tone using button 3 or 4 The lamp 2 lights up The display 1 is in the yellow range H If the current crane continues to move in the same direction there will be an RCL shutdown 11 4 8 RCL shutdown There are different types of RCL shutdowns shutdown due to overload Shutdown due to an error à p 14 7 Shutdown due to overload If approx 100 of the ma...

Page 646: ...zer tone if necessary Leave the shutdown range by moving the crane according to the following table H The crane movements are released when you have left the shutdown area lamps 1 and 2 go out Switched off crane movements Permitted crane movements Lift loads Lower loads Lower the main boom Raising the main boom1 Extend the main boom Retracting the main boom1 Slewing to the left Slewing to the righ...

Page 647: ...unit once the Start menu opens Slewing range type Standard If the MAXbase slewing range type has been entered à p 11 61 Permissible working range display The curve 3 applies to the displayed RCL code and the displayed telescope status The working range ends at the maximum pos sible working radius 2 Reduction of the working radius increases the enabled load along the curve 3 up to the maximum possi...

Page 648: ...d does not move The symbol 2 for the carrier rotates to the position corresponding to the slewing angle Examples I Display for main hoist for example maximum load 12 t II Display for main hoist for example maximum load 18 t 1 Coloured Enabled slewing range 2 Yellow red Shutdown range for maximum working radius 3 White Shutdown range for minimum working radius display only when the lifting capacity...

Page 649: ...colour for example the curve 3 The working range in slewing range 1 ends at the maximum possible working radius 4 Reduction of the working radius increases the enabled load along the curve 3 up to the maximum possible load 2 There has to be enough reeving for this load The speed reduction due to reeving occurs in the same manner as with the Standard slewing range type à p 11 60 s 1 Slewing range d...

Page 650: ...e symbol 2 for the carrier rotates together with the display of the slewing range division to the position corresponding to the slewing angle Examples 1 Coloured Enabled slewing range for example blue 2 Yellow red Shutdown range for maximum working radius 3 White Shutdown range for minimum working radius display only when the lifting capacity table specifies a limitation A Current slewing angle 0 ...

Page 651: ...work à When rigging p 11 64 You can release the raise boom function to leave the shutdown area à To raise the boom p 11 65 In an emergency you can override the RCL shutdown completely à In emergencies p 11 66 Overview status display The lamps 5 to 7 of the status display 4 light up or flash depending on the RCL degree of utilisation and button confirmations s Switch pressed Degree of utilisation 0...

Page 652: ...d Now a degree of utilisation of up to 110 is enabled If you do not trigger a control lever move ment within 10 seconds after the override you must press the button 1 again The speed of the movements which increase the load moment is reduced to 15 Cancelling the override The override will be cancelled when you press button 1 again or do not activate the control lever for 10 seconds or switch off t...

Page 653: ...tton 1 once the information message 2 is displayed Raising is enabled The speed is reduced to 50 Raise the main boom until the degree of utilisation is less than 100 The crane movements will then be enabled again The button 1 has no function H The raising of the main boom will be shut down if the main boom angle is too great Then all you can do is set the load down Switch off function For degree o...

Page 654: ...e cancelled when you Switch off the ignition Press the key operated switch again The override will automatically be cancelled 30 minutes after the key operated switch has been pressed G Risk of accidents due to overridden or faulty RCL It is not permitted to work with an overridden or faulty RCL Set down the load immediately and stop operating the crane if the RCL is faulty You may only override t...

Page 655: ... The crane movements are enabled If you do not trigger a control lever move ment within 10 seconds after the override you must press the button 1 again The speed of the movements which increase the load moment is reduced to 15 Cancelling the override The override will be cancelled when you press button 1 again or do not activate the control lever for 10 seconds or switch off the ignition G Risk of...

Page 656: ... 0 FAT32 file system approx 500 MB free capacity is recommended Export data Plug the USB stick into the connection 3 on the RCL control unit The symbol 1 is activated Select and confirm the symbol 1 The display 2 shows the export progress All exported files are named with the serial number start time and end time Files with various different suffixes are exported xxx mcd Contains all exported data...

Page 657: ...t window with various settings is displayed Confirm the selection via the symbol 6 the display 5 shows the import progress A graphical selection window opens If you do not wish to select a graph you can simply close the window symbol 1 à Displaying tables p 11 71 s 1 Import the data is imported for display in the program 2 Convert the data is saved in a log file that can be opened for example with...

Page 658: ...Events and actuates switches are shown as narrow framed bars 3 Errors are shown as symbols 4 The legend 5 defines the assignments of the colours and symbols You can hide and reveal symbols in the graphic by clicking in the legend Clicking with the left mouse button provides more details 6 on an element Use the symbol 1 to open the graphic selec tion window 1 Crane use offers the greatest variety o...

Page 659: ... When the Crane use graphic is also open an element is displayed and marked in the respective other window when clicked Display the error list Select the symbol 2 a table showing all imported errors is displayed Other Select the command 1 for further information 2 List with all lifts 3 List with all events 4 List with all actuated switches 1 Graphical marking 2 Tabular marking ...

Page 660: ...Crane operation 11 4 Operation of the rated capacity limiter 11 72 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 661: ... the 0 or 180 position you must immediately determine the cause and eliminate it and if necessary realign the crane Observe the position of the superstructure when doing so à Levelling the truck crane on outriggers horizontally p 12 58 Safe distances During crane operation always ensure that the truck crane and the load are at a sufficiently large distance to objects and persons Pay particular att...

Page 662: ...t available or in the event of a fault you can find out which speeds are forecast by contacting the relevant weather stations The lifting capacity table contains an overview of the wind strengths wind speeds and their effects If the maximum permissible wind speed is exceeded No automatic shutdown occurs if the maximum permissible wind speed is exceeded Immediately stop crane operation Put the truc...

Page 663: ...e switch off point of the lowering limit switch shifts in the course of the Raise movement The lowering limit switch will lose its function as a safety device G Risk of accidents when raising loads at an angle Loads can cause the main boom to bend resulting in the hoist rope no longer being aligned in a vertical position Compensate for the bend by lowering the boom so that the load will be lifted ...

Page 664: ...eck that the current reeving of the main hoist is displayed for example 4 Correct the reeving if necessary à p 11 39 Lifting and lowering You can adjust the sensitivity of the control levers to suit the operating conditions à Setting the characteristic curves for the control levers p 11 129 G Risk of accidents due to gaps in monitoring Operation of the hoist will only be monitored fully if The lif...

Page 665: ...gine speed idling speed with button 1 à p 10 9 Maximum permissible hoist rope speed The maximum permissible hoist rope speed is limited automatically depending on the degree of utilisation of the lifting capacity and reeving The scale of the limitation is specified in the supplied lifting capacity table The current speed reduction is displayed in the start menu à p 9 19 You can limit the maximum t...

Page 666: ...ating manual GMK4100L 1 23 11 2017 Switching off the main hoist If you no longer require the main hoist you should switch it off to avoid unintentional use Press the button 1 once The lamp in the button 1 will light up dimly Symbol 2 is red when the main hoist is switched off ...

Page 667: ...ed Press the button 1 once The lamp in button 1 will light up brightly Symbol 2 is green when the auxiliary hoist is switched on s G Risk of accidents when operating the auxiliary hoist Read and observe all of the safety instructions in the section titled Main hoist p 11 75 before operating the auxiliary hoist All safety instructions for the operation of the main hoist also apply to the auxiliary ...

Page 668: ...ol lever and changing the engine speed with the accelerator You can switch on high speed mode for a higher speed à p 11 113 G Risk of accidents due to gaps in monitoring Operation of the hoist will only be monitored fully if The lifting limit switch is correctly rigged à p 12 120 The lifting limit switch is not overridden à p 11 82 The lowering limit switch is correctly set à p 11 82 G Risk of acc...

Page 669: ...ion of the lifting capacity and reeving The scale of the limitation is specified in the supplied lifting capacity table The current speed reduction is displayed in the start menu à p 9 19 You can limit the maximum telescoping speed in the Power unit speed menu à p 11 125 Switching off the auxiliary hoist If the auxiliary hoist is not required it should be switched off to avoid unintentional use Pr...

Page 670: ... the lifting limit switch weight is not attached The lifting limit switch will not trigger if it is locked The lamp 1 will light up if the lifting limit switch has been triggered At the same time all movements which would increase the load moment will be switched off Lifting Lowering Extending and Derricking the lattice extension if necessary To cancel the shutdown leave the shutdown range by perf...

Page 671: ...n Cancelling the override Release the button 2 or leave the shutdown range The lamp 1 goes out The buzzer tone is switched off s G Risk of accidents if the lifting limit switch is overridden You may override the lifting limit switch only if this is specified in the oper ating instructions for carrying out maintenance or rigging work With the lifting limit switch overridden you may drive only at th...

Page 672: ...that the lowering limit switch is set correctly and always complete the lowering operation before the lowering limit switch is triggered This prevents the hoist rope becoming damaged due to complete unreeling or switching off at high speeds and the load being dropped as a result G Risk of accidents due to adjustments made to the lowering limit switch Always re adjust the lowering limit switch if y...

Page 673: ... if the load lifted is too heavy You can have the operating hours of the derricking gear displayed à p 11 133 Switching on the derricking gear After the ignition is switched on all of the power units will be switched off and the lamps in the corresponding buttons will light up only dimly Press the button 1 once The lamp in button 1 will light up brightly Symbol 2 will be green if the derricking ge...

Page 674: ... when the main boom is being set down a symbol 1 is displayed Correct the position of the slewable spotlights until the symbol 1 goes out à p 11 130 You can switch on high speed mode for a higher speed à p 11 113 G Risk of accident due to unexpected crane movements If assigned more than one function check whether the Derricking control lever function is switched on before you move the control leve...

Page 675: ...urrent speed reduction is displayed in the start menu à p 9 19 You can limit the maximum derricking speed in the Power unit speed menu à p 11 125 Re enable raising function RCL override version A If the RCL has switched off the raising function due to an overload you can re enable the raising function with button 1 The speed will then be reduced to 50 Push the 1 button down once Use the control le...

Page 676: ...tion The main boom can be set down by referring to the working curves within the working range specified in the lifting capacity tables This section supplements the information 1 in the lifting capacity tables supplied for the main boom intermediate lengths To prevent any overloading of the derricking cylinder the derricking cylinder pressure is also monitored here In area Z of the main boom inter...

Page 677: ...h pre selection When telescoping with pre selection you can enter several parameters for lifting the load and the CCS suggests corresponding telescopings that you can use as the starting point for semi automatic teleautomation Tel escoping with pre selection has no independently selectable menu The parameters are entered when entering the rigging mode at the RCL and the telescope status displays a...

Page 678: ...Crane operation 11 5 Crane operation with main boom 11 90 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 679: ...cking pins 7 are pushed into the cutouts 4 of the telescopic section above at the locking points the telescopic section is locked The telescoping cylinder is attached to the basic section 9 with the piston rod 8 The telescoping cylinder has two locking pins 5 at the bottom and a mechanism at the top 10 When the telescoping cylinder is positioned at a locking point The locking pins 5 can be extende...

Page 680: ...a telescoping process A telescop ing processes consist of 4 steps 1 Unlocking the telescoping cylinder The locking pins 5 retract the telescoping cylinder is unlocked 2 Moving and locking the telescoping cylinder The telescoping cylinder moves into the sec tion to be telescoped for example telescopic section III 3 The locking pins 5 extend the telescoping cylinder is locked ...

Page 681: ...n is unlocked 4 Telescoping locking and setting down a telescopic section The telescoping cylinder pushes the telescopic section to a locking point The weight is taken off the mechanism 10 The locking pins 7 extend into the cutouts 4 The telescopic section is automatically set down The telescoping cylinder retracts until the locking pins 7 are positioned on the above telescopic section 1 The weigh...

Page 682: ...r display The CCS display shows a sectional view of the main boom in the menus The following elements are displayed 0 Basic section 1 Telescopic section I 2 Telescopic section II 3 Telescopic section III 4 Locking pin on the telescopic section 5 Locking pins on the telescoping cylinder 6 Cutouts external 7 Cutouts internal ...

Page 683: ...g capacities A main boom fixed length is reached if All telescopic sections are locked to a fixed length All telescopic sections are set down Main boom intermediate length A main boom intermediate length is reached if not all telescopic sections are locked to fixed lengths Extend the main boom to the required length before hoisting the load You cannot telescope the boom with the specified lifting ...

Page 684: ...s telescoping lengths Telescoping sequence The telescopic sections can only be telescoped individually one after the other When extending the telescopic section 1 to 6 with the highest number must always be extended first then the telescopic section with the next lower number and so on e g IV III II I The telescopic sections are always retracted in the reverse order of extending Telescopic section...

Page 685: ... the current telescoping if the current telescoping is not displayed correctly à Current telescoping p 11 102 Checks for folded swing away lattice This section is only valid for the swing away lattice which is automatically swivelled during telescoping in this case the menu 1 is available à CCS Overview menu groups p 9 22 Check whether the slewing connection is separated and whether the con nectin...

Page 686: ...er Before telescoping a number of prerequisites need to be fulfilled as well Before manual telescoping à p 11 101 Before telescoping with teleautomation à p 11 110 You can adjust the sensitivity of the control levers to suit the operating con ditions à Setting the characteristic curves for the control levers p 11 129 G Risk of accident due to unexpected crane movements In the case of multiple conf...

Page 687: ...ation With telescoping assigned to the right hand lever With telescoping assigned to the left hand lever Telescoping will only start if arrow 1 or 2 for the selected telescoping direction is green You can regulate the speed by moving the control lever and changing the engine speed with the accelerator H With certain telescoping states the RCL will switch telescoping off for example when you leave ...

Page 688: ...s menu à p 11 125 Switching off the telescoping mechanism If the telescoping mechanism is not required it should be switched off to avoid unintentional use Press the button 1 once The lamp in the button 1 will light up dimly The symbol 2 red if the telescoping mechanism is switched off If the control lever is assigned more than one function the telescoping mechanism will also be switched off if yo...

Page 689: ...ck the telescoping cylinder à p 11 106 Unlocking the telescopic section à p 11 107 Telescoping the telescopic section à p 11 108 Locking the telescopic section à p 11 109 H The operating order depends on the current initial position For an overview of a telescoping process example à p 11 92 H The lengths given in the following illustrations are purely sample values and may differ from the current ...

Page 690: ...n boom length The display 3 shows the corresponding telescopic section for example telescopic section 3 Position of the telescoping cylinder The display 1 shows how far the telescoping cylinder is extended for example 98 If the telescoping cylinder is near a locking point The display 3 shows the corresponding telescopic section for example telescopic section 3 The display 2 shows one or two arrows...

Page 691: ...e tel escoping cylinder Unlocking the telescoping cylinder is required for the telescoping cylinder to be moved separately without telescopic section The telescoping cylinder and the telescopic section cannot be unlocked simultaneously Prerequisites Telescoping mechanism on symbol 3 green Telescoping cylinder locked symbol 2 green Telescopic section locked symbol 1 green s 1 On the telescopic sect...

Page 692: ...1 5 Crane operation with main boom 11 104 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Unlocking Select the symbol 1 Confirm the selection the locking pins 2 will retract Yellow Intermediate position Red Unlocked ...

Page 693: ...ymbol 1 green Telescoping cylinder unlocked symbol 2 red Extending retracting Move the control lever in the corresponding telescoping direction The telescoping cylinder 2 extends retracts The display 1 shows the currently extended length for example 80 Near a locking point the symbols 3 show The direction of travel to the locking point s Extend Extension Retract Retraction of the telescoping 1 Ext...

Page 694: ...Prerequisites Telescoping mechanism on symbol 3 green Telescopic section locked symbol 1 green Telescoping cylinder unlocked symbol 2 red Locking Move the telescoping cylinder to the desired locking point for example to telescopic section 1 Wait until the display shows the desired telescopic section 1 and the symbols 4 are shown Select the symbol 3 Confirm the selection the locking pins 2 will ext...

Page 695: ...nder and the telescopic section cannot be unlocked simultaneously Prerequisites Telescoping mechanism on symbol 3 green Telescopic section locked symbol 1 green Telescoping cylinder locked symbol 2 green Unlocking Select the symbol 1 Confirm the selection the locking pins will retract Symbol 2 red If symbol 2 is not rot after about 10 seconds this means that the locking pins are under load To reli...

Page 696: ...nism on symbol 3 green Telescoping cylinder locked symbol 2 green Telescopic section unlocked symbol 1 red Telescoping If the requirements for telescoping are met the symbol 3 flashes Move the control lever in the desired telescoping direction The display 1 shows the current extended length telescoping in metres The current telescope diagram on the display 2 will change continually S Risk of damag...

Page 697: ...fixed lengths à p 11 95 Prerequisites Telescoping mechanism on symbol 3 green Telescopic section unlocked symbol 1 red Telescoping cylinder locked symbol 2 green Locking Telescope to the desired fixed length for example telescopic section 1 1 to 100 If the symbol 4 is displayed the telescopic section must be locked Select the symbol 3 Confirm the selection the locking pins will extend symbol 2 gre...

Page 698: ...telescoping cylinder à p 11 106 Telescoping with semi automaton When telescoping with semi automation you enter the desired fixed lengths and then move the control lever in the required direction Switching between the telescopic sections is carried out automatically by CCS H If the desired telescoping status is not a fixed length you can first telescope to the next closest fixed length with the se...

Page 699: ...reached symbol 1 go out Move the control lever to its initial position teleautomation off Cancel telescoping semi automation Release the control lever If the telescopic sections are at a fixed length the current telescoping can be entered as the telescoping destination The display 8 shows the current telescoping Enter the current telescoping 1 to 6 and confirm the selection with 7 s 2 Extension 3 ...

Page 700: ...ameters can be entered for the load ing case The table shows all permissible telescop ings 6 and the associated parameter 7 for the entered rigging mode A preselected telescope status 8 is shown on the display 9 after confirmation After confirming the rigging mode the display 1 in the Monitoring menu shows the pre selection Telescoping Switch on the telescoping mechanism Move the control lever for...

Page 701: ...gh speed mode will be enabled until you press the button again The symbol 1 indicates the current status H When lowering the boom high speed mode only supports the start of the derricking procedure from steep boom positions It does not increase the derricking speed High speed mode is disabled for raising when performing operations with the lattice extension Hoists High speed mode is always switche...

Page 702: ...k of accidents due to overloading Make sure the lifted load is no more than 50 of the maximum load accord ing to the Lifting capacity table maximum degree of utilisation of 50 before operating the hoists in high speed mode S Danger of slack rope with a lightweight hook block If you switch on high speed mode at high speeds a light hook block will not be able to keep the hoist rope taut if it is hoi...

Page 703: ...of overturning when slewing with a rigged counterweight Always check before slewing whether slewing is permitted in the truck crane s current rigging mode counterweight outrigger span working radius Correct the rigging mode if necessary à Slewing with rigged counterweight p 12 97 G Risk of accidents due to switched off operating elements Always check that the slewing gear brake function is switche...

Page 704: ...ledge the shutdown you must either switch off the slewing gear or set down the load and enter an rigging mode for the 360 working range Releasing the slewing gear brake With the brake pedal function The slewing gear brake is released when you switch on the slewing gear With the control lever function The slewing gear brake is released as soon as you move the control lever 2 Lamp 1 will extinguish ...

Page 705: ...ng gear will be locked You can adjust the sensitivity of the control levers to suit the operating con ditions à Setting the characteristic curves for the control levers p 11 129 s G Danger of overturning when slewing with an incorrectly set RCL Before slewing always check that the current rigging mode is shown on the RCL display This prevents slewing operations being enabled within the impermissib...

Page 706: ... in the Start menu and in the Superstruc ture lock menu 0 means that the superstructure is slewed to the rear Angles in the right semi circle are displayed as positive values 0 to 180 Angles in the left semi circle are displayed as negative values 0 to 179 9 Permissible slewing speed The current speed reduction is displayed in the start menu à p 9 19 The maximum permissible slewing speed is limite...

Page 707: ...movement will be stopped At the same time the slewing gear brake will be applied and lamp 1 will light up Slewing gear freewheel The slewing gear freewheel is required if the slewing gear needs to be slewed by means of external forces for example when operating with two cranes With the brake pedal function switched on Switch on the slewing gear The slewing gear brake is released lamp 1 lights up S...

Page 708: ...lamp in the button 1 will light up dimly Symbol 2 will be red if the slewing gear is switched off The slewing gear brake is applied lamp 3 lights up S Risk of damage to the main boom Brake the slewing movement down to a standstill before you switch off the slewing gear The slewing gear brake is automatically applied when the slewing gear is switched off This prevents excessive lateral forces affec...

Page 709: ...ng message display 3 blue The slewing speed is not reduced automatically If the maximum permissible slewing speed is exceeded the buzzer tone sounds once and the warning message 3 is displayed red H The entered limitations for the power unit speed of the slewing gear are still valid and the continuous speed reductions due to the working range limiter are still active s G Risk of accidents due to e...

Page 710: ...oping mechanism derricking gear and slewing gear can be operated in almost any combination simultaneously Restrictions are specified for the respective power units The auxiliary power units Superstructure lock tilt crane cab counter weight lifting unit cannot be operated with the Telescoping out movement Moving the auxiliary power units in combination with other power units can result in reduction...

Page 711: ...rane cab to the rear in order to attain a better sitting position when working at great heights A Incline to the rear Close the crane cab door Press the button 1 in at the top B Incline to the front Close the crane cab door Push the button 1 down The crane cab will tilt as long as you hold the button down or until its end position is reached G Risk of accidents due to objects overturning in the cr...

Page 712: ...er stroke interval H The higher the selected value is the longer the pauses between the strokes of the wiper are Open the Datalogger 1 menu The displays 1 and 2 show the current values Select and confirm the symbol Select and confirm the symbol 7 Symbol is orange input on To cancel the input press button 9 once Change the value using buttons 8 or 10 Confirm the changed value 3 Interval for windscr...

Page 713: ...ply if they are lower than the automatically limited values The automat ically limited values are not displayed The symbol 5 is only active when the auxiliary hoist is connected With the preselection symbol for Symbol 9 resets all values without prior selection Changing values Select and confirm the symbol for the relevant power unit symbol red Change the value using switch 2 or the buttons 3 To c...

Page 714: ...lso equipped with APS Auxiliary Power Supply there is a further third step in which the engine is shut down and an external generator started You can adjust the time inter val between the steps Open the Economy menu 1 Switching on Select and confirm the symbol 2 Symbol 1 is displayed Adjusting the time interval Select and confirm the symbol 1 or 2 Change the value of the time intervals using switc...

Page 715: ...ate step 3 manually Press and hold the button 1 for 3 seconds The engine for crane operation is switched off APS is started Economy Mode display Depending on which Economy Mode is activated the crane controller shows the following background image s Step 1 The engine speed is reduced Step 2 The superstructure drive is shut down Step 3 The engine is switched off APS1 is started automatically 1 Addi...

Page 716: ...e accelerator pedal move a control lever switch on a power unit Switching off Select and confirm the symbol 2 symbol 1 is displayed 11 6 6 Switching units of measure You can display the crane control values in metric units or US units Open the Switch units menu 1 Select and confirm the symbol The symbol 3 shows the respective confirmed selection 1 To display metric units 2 To display US units ...

Page 717: ...ves to the power units Open the Settings 1 menu The symbols 2 show the set characteristic curves of the power units 1 Select the power unit for which you would like to change the characteristic curve Set the desired characteristic curve Select and confirm symbol 3 to reset all power units to characteristic curve 1 There are five characteristic curves The higher the number of the characteristic cur...

Page 718: ...witching on Push the switch 1 in at the bottom the lamp 2 lights up Switching off Push the switch 1 in at the top the lamp 2 goes out S Risk of damage to the slewable spotlights Make allowances for the position of the slewable spotlights before setting down the main boom This is prevent a collision between the working spotlights and the engine cover G Risk of accidents due to dazzling during on ro...

Page 719: ...osition The automatic load tracking can be switched on via the Spotlights menu Open the spotlight 1 menu Automatic load tracking The pivoting spotlights must be manually aligned onto the load You can then switch on the automatic load tracking The spotlights automatically follow the load You can adjusting the pivoting speed of the spotlights Switch on the automatic load tracking symbol 2 You can ad...

Page 720: ...the torque reduction function for a limited time while working with the crane Select and confirm the symbol 1 symbol 3 appears The torque reduction function is overridden for 30 minutes After 30 minutes the torque is automatically reduced again You can override this reduction three times The torque is reduced continu ously with each override starting at 80 down to 20 After the third override the s...

Page 721: ...recorded as follows The value 1 indicates the total operating hours for example 1 680 hours The value 2 shows the operating hours which can be reset Exception The value below the symbol 3 indicates how often the cycle Unlock telescopic section has been performed for example 13 750 times The value 4 shows the cycles this can be reset Reset The displayed operating hours cycles 3 can be reset Select ...

Page 722: ...Crane operation 11 6 Settings and displays for crane operation 11 134 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 723: ...eliberately move into the shutdown range You the crane opera tor are still responsible for monitoring the working range so that you can react appropriately if situations arise which cannot be monitored electron ically G Risk of accidents due to limits set too low When entering the limits bear in mind that even after switching off the engine movements can still occur that would bring the load into ...

Page 724: ...displays The corresponding symbol is shown when a monitoring system is switched on The display shows 5 if the power unit speed has been reduced There are three displays 1 Hoist rope travel limitation monitoring 2 Overall height monitoring 3 Slewing angle monitoring 4 Working radius monitoring 1 Red Movement disabled 2 Yellow Speed reduced1 3 Green Speed not reduced 1 The maximum enabled power unit...

Page 725: ...us monitoring systems Display examples for switched on slewing angle and working radius monitoring systems 11 7 2 Opening the working range limiter menu Open the main menu if necessary and select the corresponding symbol 1 to 4 The corresponding Working range limiter menu opens s 1 Permissible working range according to the lifting capacity table shown darkened 2 Limited working range shown lighte...

Page 726: ...g range limiter values are displayed graphically and numerically Limit values current values for height The symbols show values for Limit values current values for working radius The symbols show values for 1 Current overall height 2 permissible overall height 1 current working radius 2 permissible working radius ...

Page 727: ...80 Angles in the left semi circle are displayed as negative values 0 to 179 9 Hoist rope limit values The symbols show The displayed values are purely numeric values from the rotary encoder and can be positive or negative The values have no relationship to the actual hook height and are only used for limit value acquisition during the current lift 1 current slewing angle A 2 permissible slewing an...

Page 728: ...6 Overall height Move the main boom head to just before the shutdown point without a load for example up to 17 5 m value 1 Press the button 3 or 4 once The current value 1 will be accepted as the limit value 2 Switch monitoring on à p 11 146 G Risk of accidents due to limits set too low When entering the limits bear in mind that even after switching off the engine movements can still occur that wo...

Page 729: ...ce The current value 1 will be accepted as the limit value 2 Switch monitoring on à p 11 146 Slewing angle Display of the slewing angles The slewing angle A limits slewing to the left The slewing angle B limits slewing to the right The permissible slewing range is repre sented by the angle working counter clock wise from A to B Press the button 3 or 4 once The current value 1 will be accepted as t...

Page 730: ...alue 3 will be accepted as the limit value 4 Switch monitoring on à p 11 146 Hoist rope limitation The values for the hoist rope limitation may not be entered until the tele scope status and the boom position for the application have been rigged If you change the telescope status or boom position after entering values for hoist rope limitation then the RCL display will show an error message à Erro...

Page 731: ...Press the button 6 or 7 once The current numerical value 5 is set at the symbol 2 as the upper limit value symbol 1 confirms the entry Limiting lowering Lower the load to the necessary height Select the symbol 4 Press the button 6 or 7 once The current numerical value 5 is set at the symbol 4 as the lower limit value symbol 3 confirms the entry Switch monitoring on à p 11 146 ...

Page 732: ...limit values for the overall height the working radius and the slewing angle are entered in the same way For the overall height Select and confirm the symbol 1 symbol is red Set the limit value for example 17 5 m and confirm with button 2 or 3 The value is adopted Switch monitoring on à p 11 146 For working radius Select and confirm the symbol 1 symbol is red Set the limit value for example 10 0 m...

Page 733: ... Set the respective limit value and confirm with button 3 or 4 The value is adopted The symbol 1 for the slewing angle A symbol is red The symbol 2 for the slewing angle B symbol is red Switch monitoring on à p 11 146 For the hoist rope travel For hoist rope travel limitation the values 1 and 2 cannot be entered manually ...

Page 734: ... currently enabled speed range is displayed visually à p 11 136 Select the symbol for switching the desired monitoring on off Confirm the selection with button 5 or 6 Monitoring on off display 1 Slewing angle 2 Overall height 3 Working radius 4 Hoist rope travel limitation 7 switch on 8 Switch off Displayed Monitoring switched on Hidden Monitoring switched off G Danger of accident due to incorrect...

Page 735: ...ill be overridden and all movements enabled RCL display Shutdown point reached for Disabled movements Overall height Raising Extension Lowering the hoist Derricking the lattice extension Working radius Lowering the boom Extension Lifting the hoist Derricking the lattice extension Slewing angle A Slewing to the left Slewing angle B Slewing to the right Rope travel limitation Lifting Lifting Rope tr...

Page 736: ...Crane operation 11 7 Working range limiter 11 148 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 737: ...itched off Lamp 3 must light up slewing gear brake applied Switch the engine off turn the ignition key to position 0 and remove it Ensure that no unauthorised persons can operate the truck crane à To secure the truck crane p 11 150 G Risk of accident by suspended loads Never switch off the engine whilst a load is suspended You must have the control levers at hand in order to intervene at any time ...

Page 738: ...ch the engine off turn the ignition key to position 0 and remove it Switch off all current consumers Switch off the battery master switch This will not interrupt the run down period of the heater To secure the truck crane Secure the truck crane against unauthorised use by Stowing away the hand held control in the crane cab Removing the ignition key Locking the crane cab G Danger due to unauthorise...

Page 739: ... Start the engine The heating output is only provided when the engine is running Open the Heating 1 menu Heating You must set the fan fresh air recirculated air and the temperature Setting the temperature Select and confirm the symbol 1 symbol is red Setting the fan Select and confirm the symbol 2 symbol is red Fresh air recirculated air mixed air Select and confirm the symbol 3 symbol is red Chan...

Page 740: ...sponding symbol 1 for the desired air vents Adjusting the air vents Switching off Switching off the heating system Reduce the temperature symbol 1 Switching off the ventilation Switch off the ventilation symbol 2 A Top only B Top and bottom C Bottom only 1 To open Press in and position lengthwise To close Position crosswise To direct the air flow In intermediate position 2 To direct the air flow S...

Page 741: ...ver to fresh air mode to ensure a fresh supply of oxygen at the same time Adjust the cooling output to your actual needs If the truck crane has been exposed to strong sunlight for a long period of time for example the air conditioning system should initially be operated at the highest blower level with the engine running The door or at least the windows should be left open for a short while to tho...

Page 742: ...et the desired air distribution symbol 3 Open the air vents if necessary Set the desired fan setting symbol 4 Change and confirm the respective values using the controls 5 or 6 Cooling maximum You can also manually cool the crane cab without regulation The air condi tioning operates at maximum power and at the highest fan level Select and confirm the symbol 1 symbol is red Set the desired air dist...

Page 743: ...k crane Find out whether there are any possible sources of danger that could result in an explosion The engine in the carrier is switched off and the ignition in the driver s cab is switched off à Switch off the engine p 4 18 Switch on the ignition in the crane cab à Switch the ignition on p 10 5 Select and confirm the symbol 1 the submenu opens s G Risk of explosion when operating the heating sys...

Page 744: ...d confirm the respective values using the controls 3 or 4 Setting the heating start heating duration Select a weekday symbol 1 Set the starting time for the heating symbol 3 You can set up to three starting times Set the desired heating duration symbol 4 You can set a maximum heating duration of 2 hours Set the desired temperature symbol 2 Change and confirm the respective values using the control...

Page 745: ...g on Select a storage location for example 1 symbol 1 red You can also selected other storage locations The auxiliary heating now starts at the times stored in the corresponding column Switching off Select a storage location e g 1 symbol 1 grey You can also selected other storage locations Change and confirm the respective values using the controls 2 or 3 ...

Page 746: ...ts The CraneSTAR system will be activated only at the request of the crane operator Information on viewing the transmitted data in the Internet can be found in the separate CraneSTAR Operating instructions and at www cranestar net here you will find all the information about activating the CraneSTAR system 11 10 2 Position of the components The CraneSTAR system includes an antenna and a TCU contro...

Page 747: ...ing instructions which are indicated by cross references Observe the warnings and safety instructions there 12 1 1 CHECKLIST Rigging 1 Choose a suitable site à Choice of a suitable positioning site p 12 11 2 Check that the parking brake is engaged if necessary engage the parking brake 3 If the main boom is resting on a dolly Switch off the boom floating position à p 12 19 Switch off the slewing ge...

Page 748: ...t and axle loads p 1 9 à Determining the required load bearing area p 12 11 5 Align the truck crane horizontally with the level adjustment system à Operating the level adjustment system p 5 53 6 On the outriggers Extend all outrigger beams as far as possible à p 12 47 Move all outrigger pads into the working position à p 12 51 Extend all outrigger cylinders far enough so that the outrigger pads ar...

Page 749: ...ue the checklist at point 12 8 Check whether the ground will support the maximum occurring outrig ger pressures à Determining the required load bearing area p 12 11 9 Deactivate Lock the suspension symbol red suspension off à p 5 17 10 Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise until none of the wheels is touching the grou...

Page 750: ...13 Earth the truck crane if necessary à Earthing the truck crane p 12 15 14 Inspect the truck crane while looking out in particular for any leaking fluids oil fuel or water 15 Start the engine for crane operation à p 10 3 16 Unlock the turntable and if necessary switch off the houselock à Unlocking the superstructure p 11 16 à Switching off the houselock p 11 19 ...

Page 751: ... p 12 137 18 Pick up the hook block and re reeve the hoist rope if necessary à Hook block on a separate vehicle p 12 101 à Hook block on the bumper p 12 99 à Reeving and unreeving the hoist rope p 12 108 19 Install lifting limit switch à p 12 120 20 Install the anemometer and if necessary the air traffic control light à Anemometer and air traffic control light p 12 126 s ...

Page 752: ...form all the required checks prior to crane operation à CHECKLIST Checks before operating the crane p 11 1 24 Enter and confirm the current rigging mode à Enter rigging mode p 11 32 25 With the rigging mode adjusted accordingly rig the counterweight combination required for the operation according to Lifting capacity table à CHECKLIST Rigging the counterweight p 12 76 26 Enter the current rigging ...

Page 753: ...terweight à CHECKLIST Unrigging the counterweight p 12 78 2 Enter the current rigging mode with the new rigged counterweight combination at the RCL display à Enter rigging mode p 11 32 3 Depending on transport Attach the hook block to the bumper à p 12 100 or Set down the hook block and unreeve the hoist rope à Setting down the hook block p 12 102 à Unreeving hoist rope p 12 113 4 Retract the main...

Page 754: ...ensioning if necessary à p 6 16 Switch off the houselock à p 11 17 Unrig the counterweight on the rear counterweight platform à p 12 74 8 Turn off the engine for crane operation à p 10 11 9 If necessary remove the anemometer and air traffic control light à Anemometer and air traffic control light p 12 126 10 If necessary remove the camera from the main boom à Cameras for crane operation p 12 132 1...

Page 755: ...00L 1 23 11 2017 12 Retract the step à p 12 137 13 Retract the outriggers à CHECKLIST Retracting the outriggers p 12 41 14 Switch on suspension release locking symbol green suspension on à p 5 17 15 Switch off the engine 16 When the truck crane is no longer being used à In case of work breaks of more than 8 hours p 11 150 ...

Page 756: ...Rigging work 12 1 Rigging work checklists for crane operation with the main boom 12 10 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 757: ...site such that the unevenness of the ground can be compen sated for by adjusting the outrigger cylinders Maximum hoist of the out rigger cylinders à p 1 17 Choose a location where it is possible to keep the working radius to a min imum and where no obstacles are within the slewing range of the crane 12 2 1 Determining the required load bearing area The stability of the truck crane depends in the f...

Page 758: ... CAPACITY OF THE GROUND Load bearing capacity t m2 lbs ft2 Backfilled not artificially compacted ground 0 to 10 0 to 2 050 Natural apparently undisturbed ground Mud peat marsh 0 Non cohesive ground which is sufficiently firm Fine to medium sand 15 3 070 Coarse sand to gravel 20 4 100 Cohesive ground Mushy 0 Soft 4 820 Stiff 10 2 050 Semi solid 20 4 100 Hard 40 8 200 Rock with minimal fissures in s...

Page 759: ... for calculating the required load bearing area If the outrigger pressure is 25 t and the ground has a load bearing capacity of 40 t m2 Then the required ground bearing area for this supporting cylinder is 0 625 m2 6 250 cm2 If the outrigger pad has a surface of 2 000 cm2 you would need to enlarge the ground bearing area by packing the outrigger pads à p 12 53 G Danger of overturning if the load b...

Page 760: ...re not supported Rule of thumb If you are working on non cohesive or filled in ground the safety distance a must be twice as large as the pit depth b a 2 x b If you are working on cohesive undisturbed ground the safe distance a must be as great as the depth of the pit b a 1 x b The safe distance is measured from the base of the pit 3 In addition to this the safe distance d between the outrigger pa...

Page 761: ...conductivity dampen the soil around the metal rod 3 Clamp an insulated cable 2 to the metal rod 3 cross section of at least 16 mm2 0 025 inches2 Connect the free end of the cable using a clamp 1 Attach the clamp to the main boom or the superstructure B Risk of accident due to electric shock Earth the truck crane before you start to work with it Near strong transmitters radio transmitters radio sta...

Page 762: ...rhead power lines within the working range of the truck crane have these overhead power lines de energised if possible If this is not possible you must at least observe the prescribed safe distance A Different safe distances are recommended by the respective national regulations B Risk of accident due to electric shock The truck crane is not insulated If the truck crane its equipment its load lift...

Page 763: ...ntact with you check that you are observing the safe distance A If the load has to be guided use only guide ropes of non conductive material If you do touch the overhead power cable Keep calm Do not leave the crane cab Tell anyone standing outside not to touch the truck crane the load or the lifting tackle Move the main boom out of the hazard area Voltage Safe distance A Up to 1 000 V 1 m 3 3 ft o...

Page 764: ...Rigging work 12 2 Choice of a suitable positioning site 12 18 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 765: ...om pre tensioning if necessary à p 12 21 12 3 1 Switching off the boom floating position You must switch off the boom floating position before you raise the main boom off the dolly Remove the padlock 2 Switch over valve I lever 1 horizontal and pointing outward Secure the lever 1 with the padlock 2 Switch the valve IV over lever 3 points forwards The boom floating position is now switched off G Ri...

Page 766: ...re 1 Pull the pin 3 out as far as possible Secure the pin with the padlock in the bore 2 and remove the key Pull and secure the pin 3 on the other slewing gear in the same way Close the valve 5 the slewing gear freewheel is switched off Before slewing Support the truck crane with the necessary outrigger span enter the corre sponding rigging mode and derrick the main boom to an angle permissible wi...

Page 767: ...e accumulator Switch off the boom floating position à p 12 19 The valves II and III are under the pressure gauge 1 Open valve II the lever 2 is vertical The pressure accumulator is emptied The pressure on the pressure gauge 1 must drop to 0 bar 0 psi The valve III stays closed lever 3 is horizontal S Danger of the hydraulic oil overheating Always switch the valve IV à p 12 19 over lever in horizon...

Page 768: ...Rigging work 12 3 Rigging work after driving with a dolly 12 22 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 769: ...ontrol Operating manual 3 302 690 en 12 23 GMK4100L 1 23 11 2017 12 4 Connecting disconnecting the hand held control For operation Remove the hand held control 1 from the clamp 2 For transport Hang the hand held control 1 in the clamp 2 Close the covering 3 s ...

Page 770: ...hen it is connected to the sockets 1 or 2 H Switch off the engine Pulling a bridging plug will shut the engine off but this action is only designed for emergencies The ignition can be switched on or off Socket Enabled operations 1 Emergency operation for crane movements except for telescoping mechanism Derrick lattice extension1 2 Emergency mode for crane operations 1 Additional equipment ...

Page 771: ... If the lamp 4 does not light up or if it flashes there is a malfunction à p 14 21 Disconnecting the hand held control Open the cap 2 Remove the plug 5 from the socket 1 the lamps 4 will go out Insert the bridging plug 3 into the socket 1 and secure it with the cap 2 The ignition is switched off unless it is switched on at an ignition lock G Danger due to unauthorised use Always stow the hand held...

Page 772: ...Rigging work 12 4 Connecting disconnecting the hand held control 12 26 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 773: ...trol units The ignition in the driver s cab must be switched on The ignition in the crane cab must be switched off Starting the engine All activities and inspections required to start the engine must be carried out before starting the engine à p 4 1 The lamp in the button 1 lights up Press the 1 button once the engine starts Turning off the engine Press the button 1 once the engine will switch off...

Page 774: ...Rigging work 12 5 Starting the engine for rigging 12 28 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 775: ... outrigger spans are symmetrical All outrigger beams are extended and all outrigger beams are extended to the same outrigger span à Enabled outrigger spans p 12 30 12 6 1 Representation in the lifting capacity tables The outrigger span is always specified in this form in the Lifting capacity table Outrigger length xxxx outrigger width yyyyy Outrigger length The outrigger length I has a fixed value...

Page 776: ...table for the Free on wheels working position The cover pages of the individual lifting capacity tables provide a brief overview in per cent G Risk of overturning when slewing the superstructure With some outrigger spans slewing is only permissible with certain counterweight combinations and boom positions à Slewing with rigged counterweight p 12 97 1 7 200 m 23 6 ft 2 6 250 m 20 5 ft 3 5 300 m 17...

Page 777: ...ral different types of outrigger spans each with several permissible combinations Separate lifting capacity tables for the variable outrigger spans are provided in digital form Observe all the specifications and definitions in these tables before commencing operation 12 7 1 Definitions Specific terms and graphical illustrations are used in the description Directional information The directional in...

Page 778: ...s the outrigger widths 3 The outrigger width is specified as an individual width II or overall width III depending on the type of the outrigger span Individual widths Overall widths The tables show the values for the outrigger widths 1 to 5 The individual widths and overall widths are specified in metres feet in the lifting capacity tables The cover pages of the lifting capacity tables provide a b...

Page 779: ...g ger beams The overall width is entered once For example Right Left The outrigger span is the same at the left side and the same at the right side but different between the right and left sides The individual widths for the front and for the rear are entered For example Front rear The outrigger width is the same at the front and the same at the rear but different between the front and rear The ov...

Page 780: ...7 3 Enabled outrigger spans Particular combinations are enabled for each type of outrigger span This section shows all released combinations with the associated individual widths of the outrigger beams Symmetrical The outrigger width is the same for all outrig ger beams The table shows the released combinations Front outrigger span 7 200 m 23 6 ft Rear outrigger span 3 600 1 170 m 11 8 3 8 ft FL F...

Page 781: ...is type The lifting capacities for the Right greater than left type are enabled in a corre spondingly mirrored slewing range à Lifting capacities and slewing ranges for outrigger spans without separate lifting capacity tables p 11 28 s FR RR FL RL I 3 600 m 11 8 ft 3 125 m 10 3 ft II 3 600 m 11 8 ft 2 650 m 8 7 ft III 3 600 m 11 8 ft 1 900 m 6 2 ft IV 3 125 m 10 3 ft 2 650 m 8 7 ft V 3 125 m 10 3 ...

Page 782: ...than front The rear outrigger beams are extended further than the front outrigger beams The table shows the permissible combinations FR FL RR RL I 3 600 m 11 8 ft 3 125 m 10 3 ft II 3 600 m 11 8 ft 2 650 m 8 7 ft III 3 600 m 11 8 ft 1 900 m 6 2 ft IV 3 125 m 10 3 ft 2 650 m 8 7 ft V 3 125 m 10 3 ft 1 900 m 6 2 ft FR FL RR RL I 3 125 m 10 3 ft 3 600 m 11 8 ft II 2 650 m 8 7 ft 3 600 m 11 8 ft III 1...

Page 783: ...side is retracted The table shows the released combinations There are no separate lifting capacity tables for this type The lifting capacities for the One outrigger beam retracted left type are enabled in a correspondingly mirrored slewing range à Lifting capacities and slewing ranges for outrig ger spans without separate lifting capacity tables p 11 28 VR VL HR HL I 3 600 m 11 8 ft 1 170 m 3 8 ft...

Page 784: ...Rigging work 12 7 Outriggers Overview MAXbase slewing range type 12 38 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 785: ...he level adjustment system and lower it as far as possible à p 5 53 2 Deactivate Lock the suspension symbol red suspension off à p 5 17 3 Engage parking brake à p 5 46 4 Extend all outrigger beams to the required span For the Standard slewing range type à p 12 30 For the MAXbase slewing range type à p 12 34 à Setting the outrigger spans p 12 44 à Extending retracting outrigger beams p 12 47 s G Da...

Page 786: ...he load bearing area p 12 53 7 Extend the supporting cylinders until none of the wheels are touching the ground à p 12 54 8 Level the truck crane horizontally with the outriggers The lamp 1 lights up in the measuring range 1 à p 12 58 9 Check that none of the wheels are touching the ground Raise the wheels if necessary à Operating the axle raising system p 12 64 10 Switch off the engine After oper...

Page 787: ...es Observe the warnings and safety instructions specified here 1 Retract the outrigger cylinders as far as possible à p 12 54 2 Move the outrigger pads into the driving position and secure them à Moving into driving position p 12 51 3 Fully retract and secure all supports à For on road driving p 12 47 à Extending retracting outrigger beams p 12 47 4 Stow away packing material safely if applicable ...

Page 788: ...ith the level adjustment system à Operating the level adjustment system p 5 53 Locking the suspension Switch off the suspension à Switching the suspension on off p 5 16 The control elements for the outriggers are only released if the suspension is switched off If the suspension is switched off the wheels are lifted when the crane is put on outriggers Crane cab The outriggers can be moved from the ...

Page 789: ...rol units on Select and confirm the symbol 1 symbol 1 red symbol 2 grey The outriggers cannot now be operated via the CCS display Switch the control units off Select and confirm the symbol 2 symbol 2 red symbol 1 grey The outriggers can now be operated via the CCS display Outrigger lighting on off You can switch the outrigger lighting on and off from the crane cab Switching on Select symbol 1 and ...

Page 790: ... 11 8 ft A Prerequisite Pins 1 and 2 must be pulled out B Setting and securing Extend the outrigger beam up to the marking 3 Secure the outrigger beam with the pins 1 and 2 For the overall width Set the same outrigger span in the same way at the opposite outrigger beam G Danger of overturning if the outrigger beams are not correctly extended Extend the outrigger beams only as far as the permissibl...

Page 791: ...utrigger beam with the pins 1 and 2 For the overall width Set the same outrigger span in the same way at the opposite outrigger beam Outrigger span 60 Overall width 8 660 x 5 300 m 28 4 x 17 4 ft Individual width 8 660 x 2 650 m 28 4 x 8 7 ft A Prerequisites Pin 1 must be removed Pin 2 must be inserted B Setting and securing Extend the outrigger beam up to the marking 3 Secure the outrigger beam w...

Page 792: ...ng 3 Secure the outrigger beam with the pin 1 The pin 2 remains inserted For the overall width Set the same outrigger span in the same way at the opposite outrigger beam Outrigger span 0 Overall width 8 660 x 2 340 m 28 4 x 7 6 ft Individual width 8 660 x 1 170 m 28 4 x 3 8 ft A Prerequisites Pins 1 and 2 must be pulled out B Setting and securing Completely retract the outrigger beam Secure the ou...

Page 793: ...nd causing seri ous accidents G Risk of accidents if outrigger beams cannot be seen Cordon off the area where you intend to extend and retract the outrigger beams Nobody is allowed to be in this area Observe the moving outrigger beams or have them observed by a banks man who is in visual contact with you G Danger of overturning if improperly supported Always extend all outrigger beams to the requi...

Page 794: ...are switched on Moving the outrigger beams H You can only operate the outrigger beams to the left and right of the control unit on the operator s side Observe the safety instructions for operating the outriggers à p 12 47 Press the button Additionally press the button for the desired outrigger beam The outrigger beams move until you let go of the respective button or until the respective end posit...

Page 795: ...g brake is engaged Starting the engine Start the engine from the crane cab à p 10 3 Switch off the slewing gear à p 11 120 Open menu Open the Outrigger menu 1 Select and confirm the symbol 2 Move outrigger beams Extending Press the button for the desired outrigger beam Press the button 5 in at the top the selected outrigger beam extends s 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 796: ...2 50 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Retracting Press the button for the desired outrigger beam Press the button 5 in at the bottom the selected outrigger beam retracts 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 797: ...handle 2 Secure the outrigger pad with the pin 1 Secure the pin 1 Move the other outrigger pads into operat ing position in the same way Securing pin Plug the pin with the peg 1 through the cutout 2 Turn the grip 3 downwards Moving into driving position A Pull out the pin 1 B Pull the outrigger pad by the handle 2 onto the holder 3 Secure the outrigger pad with the pin 1 Secure the pin 1 Move the ...

Page 798: ...Rigging work 12 8 Outrigger operation 12 52 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 799: ...f the packing has several layers each layer must be placed below the other offset by 90 The packing must lie flat on the ground Consult your supervisor if you are in doubt H If the truck crane is equipped with plastic outrigger pads then the uppermost layer of the packing must be a steel plate 1 of sufficient strength G Risk of accidents if the packing is insufficient Only use materials of suffici...

Page 800: ...nd the resulting outrigger pressure This prevents the ground under the outrigger pad giving way and causing the truck crane to tilt and overturn G Risk of accidents if the supporting cylinders are out of sight No one is allowed to be in the area of the supporting cylinders Observe the moving supporting cylinders or have them observed by a banksman who is in visual contact with you S Risk of damage...

Page 801: ...p 12 54 The operation is the same for all supporting cylinders Press the button Also press the button for the desired supporting cylinder e g for 4 1 You can also operate several supporting cylinders at the same time The supporting cylinders move until you let go of the respective button or until the respective end position has been reached s 1 Supporting cylinder 1 1 2 Supporting cylinder 2 1 3 S...

Page 802: ... menu Starting the engine Start the engine from the crane cab à p 10 3 Switch off the slewing gear Open menu Open the Outrigger menu 1 Select and confirm the symbol 2 Move outrigger cylinders Extend Press the button for the desired outrigger cylinder Press the button 5 in at the top the selected supporting cylinder extends 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 803: ...ting manual 3 302 690 en 12 57 GMK4100L 1 23 11 2017 Retracting Press the button for the desired outrigger cylinder Press the button 5 in at the bottom the selected supporting cylinder retracts 1 Front left 2 Front right 3 Rear left 4 Rear right ...

Page 804: ...asuring ranges You can change the measuring range between 1 and 5 Press the button 2 once The current measuring range 1 is displayed The measuring range is automatically switched in the Outrigger menu and the Monitoring menu Read the display Only the lamp 1 at the centre is on if the truck crane is level The other lamps show the sides of the truck crane which are higher RCL CCS display The assignm...

Page 805: ...uisites apply to manual and automatic alignment The main boom must be resting in the boom rest Or The main boom must be raised and the load must have been set down and the superstructure must be in the 0 or 180 position s G Risk of overloading the main boom Always slew the superstructure to the 0 or 180 position and set down the load before levelling the truck crane In other positions the deformat...

Page 806: ...e ground that the ground has not given way under any of the outrigger pads that the packing is correct for the enlarged load bearing area If slewing is permissible in the current rigging mode Slew the superstructure within the permissible slewing range Perform the specified checks again Check the horizontal alignment on the inclination indicator Automatic alignment During the automatic alignment p...

Page 807: ...er pads touch the ground 2 All the supporting cylinders are extended simultaneously so that none of the wheels is touching the ground any more 3 The truck crane is automatically levelled horizontally This procedure is performed until horizontal alignment is reached the lamp 1 in the centre is the only one lighting up in measuring range 1 or until you let go of a button or until horizontal alignmen...

Page 808: ... until all wheels are just above the ground Levelling the truck crane Level the truck crane with the outriggers until only lamp 1 is illuminated in the measuring range 1 G Danger of overturning if the supporting cylinders are operated unevenly Extend or retract the supporting cylinders as evenly as possible This prevents the truck crane overturning while retracting individual outrigger cylinders G...

Page 809: ... is switched on Now all wheels are lowered to the ground and are in the right position for the horizontal alignment Switching off the suspension Select and confirm the symbol 1 once The symbol 2 is red if the suspension is switched off To secure the truck crane Retract the supporting cylinders until the outrigger pads are about 5 to 10 cm 2 to 4 in above the ground Leave the outrigger beams extend...

Page 810: ... locked suspension without first supporting the truck crane on outriggers Open menu The Raise axle menu can only be opened when the suspension is switched off locked à Switching the suspension on off p 5 16 Press button 2 repeatedly until the Raise Axle menu 1 is displayed The assignment to the carrier corresponds to the top view The operation is same on both sides Only certain wheel groups can be...

Page 811: ...n Operating manual 3 302 690 en 12 65 GMK4100L 1 23 11 2017 Press the button for the desired movement Lifting lowering wheels Aligning the truck crane 1 Lifting wheels 2 Lowering wheels 1 Lowering the truck crane 2 Lifting the truck crane ...

Page 812: ...n the outrigger pressure table always determines the load on the ground The set unit t or klbs is shown next to the displays H Outrigger cylinders retracted or extended as far as possible will lead to an incorrect outrigger pressure display The display will show the most accurate reading if the movement per formed last was Extend outrigger cylinders In the Outrigger menu The assignment of the disp...

Page 813: ...1 23 11 2017 On the outrigger control units The assignment of the displays to the carrier corresponds to the top view 1 Display for the supporting cylinder 1 1 2 Display for the supporting cylinder 2 1 3 Display for the supporting cylinder 3 1 4 Display for the supporting cylinder 4 1 ...

Page 814: ...Rigging work 12 8 Outrigger operation 12 68 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 815: ...ctions and instruct the crane operator When the engine is running for crane operation the rigging personnel may only climb on the truck crane when the slewing gear is switched off and the slewing gear brake is applied The crane operator and rigging personnel must maintain visual contact during the rigging process The rigging process for a single counterweight section is described Proceed in the sa...

Page 816: ... range of the counterweight and the load As the crane operator Perform the Raise hoist movement at the lowest possible speed until the lifting gear is free When unrigging As the crane operator Lift the lifting gear over the counterweight section Now inform the rigging personnel that they can climb on the truck crane As the rigging personnel Do not climb on the truck crane until permitted by the cr...

Page 817: ...K4100L 1 can be equipped with a counterweight mass of 4 5 t 9 920 lbs or 26 2 t 57 761 lbs There are various counterweight sections depending on the rigging of the truck crane one 0 8 t plate 9 or the auxiliary hoist 10 one 2 7 t base plate 1 one 1 0 t plate 2 one 2 1 t section 3 one 7 1 t section 4 one 1 5 t block 5 one 2 2 t section 6 one 4 t section 7 two 2 4 t blocks 8 ...

Page 818: ...Rigging work 12 9 Rigging unrigging the counterweight 12 72 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 819: ...te and the counterweight sections are labelled with the serial number 1 Depending on the version other counter weight sections e g blocks are labelled with a serial number 1 S Danger if counterweight sections are interchanged Operate the truck crane only with the counterweight sections that belong to it The truck crane and counterweight sections are labelled with the same serial number Other or ad...

Page 820: ... of sufficient load bearing capacity Weights à Counterweight parts p 1 14 Sections Attach the counterweight sections at the slinging points 1 Blocks Sling the blocks at the slinging points 1 G Risk of accident if used improperly Attach the lifting gear to various counterweight section only at the appro priate slinging points Ensure the lifting gear has sufficient load bearing capacity ...

Page 821: ...erweight Operating manual 3 302 690 en 12 75 GMK4100L 1 23 11 2017 Multiple sections You can lift the assembled counterweight mass max 17 t as a single item The 2 1 t section 1 must be at the bottom Attach the lifting gear as shown in the diagram ...

Page 822: ... Standard slewing range type à p 12 30 For the MAXbase slewing range type à p 12 34 2 Enter and confirm the current rigging mode à p 11 32 3 If necessary unlock the rear counterweight platform à p 12 95 4 Assemble the required combination of counterweights à Slinging points on the counterweight sections p 12 74 à Assembling counterweight combination p 12 80 5 If necessary unlock the 2 7 t base pla...

Page 823: ...rstructure p 11 15 7 Open Counterweight menu Correct the rigging mode if necessary à p 12 87 Slew the superstructure into the rigging range and lift counterweight to the turntable automatic and pre charge à p 12 89 8 Enter the current rigging mode with the new rigged counterweight combination at the RCL display à p 11 32 9 Only switch on the slewing gear if slewing is permissible for the current o...

Page 824: ...d slewing range type à p 12 30 For the MAXbase slewing range type à p 12 34 2 Slew the superstructure into the 180 to the forwards position and lock it à Braking the slewing movement p 11 119 à Locking unlocking the superstructure p 11 15 3 Unlock the rear counterweight platform à p 12 95 4 Open Counterweight menu Correct the rigging mode if necessary à p 12 87 Use the automatic system to lower th...

Page 825: ...g on the driving mode lift the necessary counterweight sections on to the front counterweight platform à Slinging points on the counterweight sections p 12 74 à Driving modes p 6 1 from the rear counterweight platform à Slinging points on the counterweight sections p 12 74 à Driving modes p 6 1 If the base plate is being transported on the rear counterweight platform lock the counterweight platfor...

Page 826: ... by the RCL G Risk of crushing when setting down the counterweight sections Make sure the helpers keep a sufficient distance away from the counter weight sections with any parts of their body when setting down the coun terweight sections Remove all objects from the counterweight platform that could become jammed or crushed G Risk of crushing when slewing the superstructure The access ladders are l...

Page 827: ... plate in such a way that the holders 1 grip into the recesses 2 You may need to lock the counterweight platform area à p 12 95 Always position the 4 0 t section 7 or the 7 1 t section 4 at the top Only then can the lifting cylinder be rotated into the 2 7 t base plate s S Risk of damage to the counterweight Always position the 4 0 t section or the 7 1 t section at the top This prevents the liftin...

Page 828: ...stration and the table show all counterweight sections and all counterweight combinations which can be rigged The table specifies which counterweight sections are needed for the respective counterweight combination Lift the counterweight sections onto the base plate à Slinging points on the counterweight sections p 12 74 ...

Page 829: ...ination in t lbs 2 7 5 950 1 1 0 2 204 2 2 1 4 630 3 7 1 15 650 41 1 5 3 307 5 2 2 4 850 6 4 0 8 818 71 2 4 5 291 2 x 8 0 8 1 764 92 0 8 1 764 4 5 9 920 5 7 12 566 6 7 14 770 8 5 18 739 9 7 21 385 11 6 25 573 13 1 28 880 14 9 32 848 17 4 38 360 19 9 43 872 21 4 47 179 24 0 52 911 26 2 57 761 1 Section 7 or 4 must always be at the top 2 0 can be used instead of 9 ...

Page 830: ...Rigging work 12 9 Rigging unrigging the counterweight 12 84 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 831: ...To lift and lower the counterweight the lifting cylinders are screwed into the 2 7 t base plate 2 Counterweight menu To operate the counterweight hoist unit you must open the Counterweight menu Open menu Open the Counterweight menu 1 s G Risk of crushing when lifting and lowering the counterweight Make sure nobody is on the counterweight platform while the counterweight is being lifted or lowered ...

Page 832: ...ift and lower the counterweight in automatic mode otherwise slewing with extended lifting cylinders will be blocked à Automatic mode rigging p 12 88 à Automatic mode unrigging p 12 90 1 Slewing blocked pre clamp the counter weight à p 12 88 2 Slewing and counterweight hoist unit blocked Lock the rear counterweight platform à p 12 95 3 Contact Manitowoc Crane Care 4 If the pre tensioning pressure c...

Page 833: ...mode as follows Slew the superstructure out of the rigging range so that the lifting cylinders can be freely extended Assuming the symbol 4 is yellow with the counterweight unrigged Press the override button 3 in at the top A Fully extend the lifting cylinders symbol 1 Release the override button 3 B Fully retract the lifting cylinders button 2 The symbols 4 become green You can now use the automa...

Page 834: ...matic mode rigging While the automatic mode is being executed you can always Cancel the automatic mode à Cancel automatic mode p 12 91 Interrupt the automatic mode by letting go of the control lever After moving the lever in the displayed direction once more the automatic mode is continued Prerequisites The counterweight combination must be assembled The lifting cylinders must be fully retracted s...

Page 835: ... lever in the dis played direction 1 or 2 the automatic mode starts The superstructure turns into position A The lifting cylinders are extended B Release the control lever Move the slewing control lever in the dis played direction 1 or 2 the automatic mode continues The superstructure turns into position C The lifting cylinders are retracted D The counterweight is pre charged symbol 3 green Releas...

Page 836: ... the displayed direction once more the automatic mode is continued Prerequisites The lifting cylinders must be fully retracted symbol 3 green The slewing gear is switched symbol 1 green The superstructure must be in the rigging range Symbol 4 active Symbol 2 displayed Switch on automatic mode Select and confirm the symbol 3 Execute automatic mode Move the slewing control lever in the dis played di...

Page 837: ...atic mode You can cancel the automatic mode any time Press the override button 1 in at the top the automatic mode is can celled If you have cancelled the automatic operation then you must In position A Fully retract the lifting cylinders symbol 1 In position B Turn the superstructure into position A Fully retract the lifting cylinders symbol 1 S Risk of damage to the counterweight With the overrid...

Page 838: ...t platform The Rear counterweight platform is available in two versions Version A with lock Version B without lock For driving with axle loads up to 10 t or dolly operation No counterweight sections must be placed on the rear counterweight platform For version A Lock the pins on the counterweight platform à p 12 95 S Risk of damage during dolly operation Before you start driving in dolly mode make...

Page 839: ...or 4 9 t 10 800 lbs Set the 2 2 t section 6 down on the 2 7 t base plate For driving with axle loads greater than 12 t Place the 2 7 t base plate on to the counter weight platform à p 12 81 For version A Lock the counterweight platform à p 12 96 Depending on the driving mode you can also place the 1 0 t plate 2 the 2 2 t plate 6 and the 4 0 t plate 7 on to the 2 7 t base plate s G Risk of accident...

Page 840: ... the 7 1 t plate can be placed on the front counterweight platform Position the 2 1 t plate in such a way that the holders 1 grip into the recesses 2 Position the 7 1 t plate in such a way that the holders 1 grip into the recesses 2 S Risk of damage to the derricking cylinder Set down only the 7 1 t plate on the 2 1 t plate In this way you can prevent the derricking cylinder being pushed against a...

Page 841: ...nterweight combination on to the turntable before you set down or pick up the 2 7 t base plate if no counterweight is to be transported on the counterweight platform The procedure is applicable irrespective of whether A no counterweight is set down or B a counterweight is set down Remove the pins 1 from the connecting points 3 and insert them into the holders 2 Secure the pins s S Risk of damage A...

Page 842: ...st lock the rear counterweight platform after the counterweight has been set down for transport Remove the pins 1 from the clamps 2 and insert them into the connecting points 3 Secure the pins If the counterweight platform is not correctly mechanically locked then a warning will show in the driver s cab à Counterweight p 8 16 ...

Page 843: ...set RCL The RCL only disables the slewing operation if you have entered the RCL code correctly and if the RCL is not overridden Before slewing always check that the current rigging mode is shown on the RCL display This prevents slewing operations from being enabled within the impermis sible ranges which would cause the truck crane to overturn G Risk of overturning when slewing in emergency operati...

Page 844: ...Rigging work 12 9 Rigging unrigging the counterweight 12 98 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 845: ...t bumper à Driving modes p 6 1 The main boom must be fully retracted Enter and confirm the current rigging mode Slacken the hoist rope and raise the main boom simultaneously Raise the main boom until the boom head is in a vertical position above the hook block Detach the hook block from the retaining rope 1 s S Risk of accidents if the view is obstructed Have someone instruct you when raising the ...

Page 846: ...and pull the hoist rope tight only to the extent that the hook block is stabilised in its position H If the lifting limit switch is deactivated while you tighten the hoist rope you can override the shutdown of the lifting limit switch à p 11 83 G Risk of accidents if the view is obstructed The reeved rope lines obstruct the view of the runway The number of legally permissible rope lines can vary d...

Page 847: ...ndard slewing range type enter a rigging mode for the 360 working range or for the MAXbase slewing range type enter a working radius for which slewing is enabled This prevents slewing into impermissible areas and the truck crane tipping over as a result S Risk of damage to the separate vehicle Raise the hook block from the separate vehicle only when the main boom head is directly above the hook bl...

Page 848: ... the boom head is directly above the hook block 1 Unreel the hoist rope Reeve the hoist rope into the hook block 1 à Reeving and unreeving the hoist rope p 12 108 Raise the hook block off the separate vehicle Setting down the hook block Depending on the driving mode the hook block must be set down on a separate vehicle à Driving modes p 6 1 With the RCL set accordingly fully retract the main boom ...

Page 849: ...k 1 for transport Set down the main boom on the boom rest Fastening the hoist rope to the bumper Do not attach the rope end clamp to the front towing coupling The towing coupling must be free for a tow rod in emergencies Attach the rope end clamp to the retaining rope 1 Pull the hoist rope slightly taut Fasten the lifting limit switch weight to the hoist rope The hoist rope and lifting limit switc...

Page 850: ...on a separate vehicle Rigging for on road driving A Remove the retaining pin and pull out the pins 3 B Raise the block hook 1 an Insert the pins 3 and secure them in the hook Stow away the hook 2 so that it is safe for transportation Raise the block hook 1 vertically above the holding ropes 2 Lower the block hook 1 and fasten it using the holding ropes 2 Set down the main boom onto the boom rest a...

Page 851: ... hoist rope and raise the main boom simultaneously Raise the main boom until the boom head is in a vertical position above the block hook 1 Detach the block hook from the retaining ropes 2 A Pull the pin 3 out B Raise the hook block 1 above the hook 2 until the connecting points are aligned Insert the pins 3 and secure them with the retaining pins ...

Page 852: ...ok block weight to the weight required according to the Lifting capacity table Weight version A à p 1 13 Weight version A à p 1 13 Removing Remove the securing plugs and pull out the pins 2 Remove the ballast plates 1 In this way remove the ballast plates alter nately from both sides If all ballast plates have not been removed make sure that the number of remaining ballast plates are equal on both...

Page 853: ...Check that the hook blocks have room to move freely especially for two hook operation G Risk of accident due to falling ballast plates Always secure the ballast plates with the pins and the securing plugs Always check the completeness and condition of the securing plugs before operating the crane This prevents ballast plates from falling down during crane operation S Risk of damage to the hook blo...

Page 854: ...n boom p 12 114 To reeve and unreeve the hoisting rope you must remove the pocket lock After reeving you must reattach the pocket lock Removing Remove the linchpin 4 Release the locknuts 3 and pull out the pins 1 Remove the bracket 2 Slide the padlock 5 back and remove it from the hoist rope 6 Positioning Insert the padlock 5 and slide it onto the hoist rope as far as it will go 6 Fasten the brack...

Page 855: ... necessary à p 6 26 For hook blocks with ballast plates you can achieve the required weight by installing or removing ballast plates à p 12 106 s S Risk of damage to the hoist rope Always install the pocket lock as it is described in the following paragraph This will prevent the hoist rope rubbing against the locknut and being damaged G Danger due to slack rope Only use hook blocks and lifting gea...

Page 856: ...he plates 3 Positioning the hoist rope Pull out the rods 1 and 4 Feed the main hoist rope 2 under the rope grab 1 If two hoist ropes are reeved you must feed the auxiliary hoist rope 5 over the rope grab Feed the main hoist rope to the head sheave 3 Feed the auxiliary hoist rope to the head sheave 4 Use the rope grab also when working with the lattice extension ...

Page 857: ... Reeve the hoist rope with the required number of lines Possible reevings à p 12 114 Fastening the hoist rope The fixed point used depends on the number of reeved rope lines Depending on the version the centre fixed point 2 may be present on main booms with 5 head sheaves Fixed points for an even number of lines The rope end clamp is fastened to a fixed point 1 or 2 for 2 fall 4 fall 6 fall reevin...

Page 858: ... pin 2 A If there is an even number of lines to a fixed point 1 of the main boom head B If there is an uneven number of lines to a fixed point 1 of the hook block Secure the pin 2 with the safety hinged pin Securing the hoist rope Insert the rods 1 and 4 Secure all the rods Closing the hook block Fold up the plates 3 on both sides Insert the rods 2 and secure them ...

Page 859: ...3 Fold down the plates 1 Remove the rope end fitting from the fixed point 2 or 4 Unreeve the hoist rope Insert the rods 5 and 3 and secure them Depending on the driving mode you can fasten the hoist rope to the bumper à p 12 103 or pull out the rods 1 2 and roll the hoist rope 3 on to the drum Insert the rods 1 2 and secure them Secure the hoist rope 3 ...

Page 860: ...on the main boom Possible reevings on lattice extensions and the auxiliary single sheave boom top à Lattice extension operating manual H The maximum lifting capacity is specified in the supplied lifting capacity table With 5 head sheaves If 6 head sheaves are provided à p 12 117 5 sheave hook block Reeving A 10 fall B 9 fall C 8 fall ...

Page 861: ...ting manual 3 302 690 en 12 115 GMK4100L 1 23 11 2017 3 sheave hook block On version with centre fixed point 3 sheave hook block On version without centre fixed point s Reeving A 7 fall B 6 fall C 5 fall D 4 fall Reeving A 7 fall B 6 fall C 5 fall D 4 fall ...

Page 862: ...Rigging work 12 10 Rigging work on the main boom 12 116 3 302 690 en Operating manual GMK4100L 1 23 11 2017 1 sheave hook block Hook tackle Reeving A 3 fall B 2 fall C 1 fall Reeving A 1 fall ...

Page 863: ...e main boom Operating manual 3 302 690 en 12 117 GMK4100L 1 23 11 2017 With 6 head sheaves If 5 head sheaves are provided à p 12 114 7 sheave hook block 5 sheave hook block s Reeving A 12 fall Reeving A 11 fall B 10 fall C 9 fall D 8 fall ...

Page 864: ... 12 10 Rigging work on the main boom 12 118 3 302 690 en Operating manual GMK4100L 1 23 11 2017 3 sheave hook block 1 sheave hook block Reeving A 7 fall B 6 fall C 5 fall D 4 fall Reeving A 3 fall B 2 fall C 1 fall ...

Page 865: ...1 23 11 2017 Hook tackle With 7 head sheaves The 7th head sheave of the auxiliary single sheave boom top 1 is used for this version 7 sheave hook block Reeving A 3 fall Reeving A 14 falls2 B 13 fall 1 Additional equipment à Lattice extension operating manual 2 Only with special equipment à p 1 7 ...

Page 866: ...head Install the switch on the side that is closer to the last rope line leading upwards There can also be one lifting limit switch installed on each side On the left side Plug the lifting limit switch 3 onto the bracket 2 and secure it with the retaining pin Lay the cable 4 so that it will not be damaged during crane operation and insert the lifting limit switch into the socket 1 On the right sid...

Page 867: ...mit switch weight has been attached If the lifting limit switch weight has for exam ple been attached to the left lifting limit switch 1 you must lock the right lifting limit switch 2 à Locking p 12 125 Otherwise the movements Raise hosting gear Telescope out and Lower the boom will be locked s S Risk of damage if the lifting limit switch is locked The lifting limit switch must not be locked Remov...

Page 868: ... safety pin 1 out and fold the two halves of the weight back together Make sure the safety pin locks into place and the two halves of the weight are securely attached to each other If two hoist ropes are reeved you must also place a lifting limit switch weight around the second hoist rope H If you place the lifting limit switch weight around the last rope line leading upwards less rope will run th...

Page 869: ... around the hoist rope again before driving Removing the lifting limit switch weight Pull the safety pin 1 out and fold the two halves of the weight apart Remove the halves of the weight from the rope line Pull the safety pin 1 out fold the two halves of the weight back together and let the safety pin engage Remove the lifting limit switch weight 2 Remove the lifting limit switch weight on the oth...

Page 870: ...02 690 en Operating manual GMK4100L 1 23 11 2017 Removing the right lifting limit switch Pull out the plug and close the socket with the protective cap 1 Remove the lifting limit switch 4 from the bracket 2 Attach the retaining pin 3 to the lifting limit switch ...

Page 871: ...iggered B Secure the rope 2 in this position using the cap 1 the lifting limit switch is locked Removing the lock You must always release the locking before you place a lifting limit switch weight around the hoist rope A Pull the rope 2 down and take off the cap 1 the locking is released B Fit the cap 1 onto the lifting limit switch S Risk of damage if the lifting limit switch is locked If the lif...

Page 872: ...pins Remove the cable from the holders 2 and connect The anemometer to socket 4 The air traffic control light to the socket 5 Lay the cables in such a way that they will not be damaged during crane operation Check that the anemometer is able to swing so that it hangs vertically even when the main boom is raised S Risk of damage during on road driving Always remove the anemometer and air traffic co...

Page 873: ... lighting modes Select the desired lighting mode using the switch 2 Switching on off Removing You must remove the rod with the anemometer air traffic control light before driving on the road Switch off the air traffic control light Remove the plug and close the sockets 5 and 4 with the protective caps Wind the cables on to the holders 2 Take the rod 1 out of clamp 3 s Switch on Select symbol 1 and...

Page 874: ...Rigging work 12 10 Rigging work on the main boom 12 128 3 302 690 en Operating manual GMK4100L 1 23 11 2017 For transport Place the rod 1 in the holder 2 Secure the rod 1 using the retaining pins ...

Page 875: ...the railings before driving A Sliding out Fold the handrail 1 upwards until the bolt 2 latches into place B Sliding in Open the locking bolt 2 Fold the handrail 1 in until the bolt 2 latches into place G Risk of accidents if railings are not pushed out The railings provide protection from falling Always fold out the railings before stepping on to the turntable G Risk of accidents due to exceeding ...

Page 876: ...perstructure Folding out and adjusting the mirror Fold out the mirror 1 Adjust the mirror 1 so that the rear right outrigger beam can be observed clearly from the crane cab when the main boom is raised Folding in the mirror Fold in the mirror 1 until it does not protrude over the side of the carrier G Risk of accidents due to exceeding the permissible dimensions Fold the mirror in for driving The ...

Page 877: ...23 11 2017 12 11 3 Slinging points for personal protective equipment The approved slinging points for personal safety equipment are marked with special labels 2 Always secure yourself using your personal protective equipment for rigging work e g on the main boom at the slinging points 1 ...

Page 878: ...nsmitter nor the receiver should be removed or installed they remain together on the truck crane at all times In the event of a defect both transmitter and receiver must always be replaced even if only one part is defective When spare parts are ordered both transmitter and receiver are always delivered together Switch off the ignition in the crane cab G Risk of accidents if an incorrect transmitte...

Page 879: ...Insert the camera 2 into the clamp 1 and secure it with the retaining pin Insert the plug 4 into socket 3 Lay the cable 5 so that it will not be damaged The camera and the connecting cable Insert the camera 2 into the clamp 1 and secure it with the retaining pin Insert plug 3 in socket 4 Lay the cable 5 so that it will not be damaged s G Risk of accidents due to falling camera Always use a retaini...

Page 880: ...ket 3 and close it with the cap Remove the camera 2 from the clamp 1 and put the retaining pin in the holder 1 Wind the cable 5 on to the clamp The camera and the connecting cable Withdraw the plug 3 from the socket 4 and close it with the cap Remove the camera 2 from the clamp 1 and put the retaining pin in the holder 1 Wind the cable 5 on to the clamp ...

Page 881: ...end the camera symbol 3 B For crane operation you must retract the camera symbol 2 Camera on the driver s cab A camera 1 allows viewing of the non visible area in front of the driver s cab Depending on the version the camera image is shown on the CCS display or on a separate monitor Adjust the camera 1 to show the area 2 in front of the bumper on the display or monitor s G Risk of accidents due to...

Page 882: ... separate monitor Switching on Switch on the ignition A Select and confirm the symbol 1 or B Press the button 3 once The lamp 4 lights up The image appears on the display after a few seconds Switching the representation A with symbol 1 or B with the buttons or If no image appears à p 14 15 Switching off A Press the button 1 or 2 once or B Press the button 3 once The image will disappear ...

Page 883: ...rane cab menu Select extend retract access ladder as neces sary 1 Extending Select and confirm the symbol 3 the step extends Retracting Select and confirm the symbol 2 the step retracts On the outrigger control unit Extend Press the buttons 1 and 3 the step extends Retract Press the buttons 1 and 2 the step retracts G Risk of accidents by exceeding the permissible overall width Always retract the ...

Page 884: ...Rigging work 12 11 Other rigging work 12 138 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 885: ...rial e g wooden planks on it G Risk of accidents due to partially obstructed view of the truck crane When driving the truck crane always stay in visual or radio contact with a banksman who can observe the parts you are unable to see e g the raised main boom in 0 to the rear G Risk of overturning by slewing superstructure When driving the rigged truck crane the slewing gear must be switched off sle...

Page 886: ...tion that is indi cated in the following table for the specified counterweight rigged Tie down the hook block so that it cannot swing around Axle load table The axle loads apply to all permissible tyres à p 1 16 a reeved 3 sheave hook block à p 1 11 S Risk of damage to the axle lines Only bring the superstructure and the main boom into the specified posi tions This prevents excessive strain on the...

Page 887: ...5 7 12 566 0 0 0 0 0 0 5 60 front 13 5 29 8 17 0 37 5 0 0 0 0 0 0 40 82 rear 15 5 34 2 16 5 36 4 6 7 14 770 0 0 0 0 0 0 5 55 front 13 0 28 7 17 0 37 5 0 0 0 0 0 0 35 82 rear 16 0 35 3 17 0 37 5 8 5 18 739 0 0 0 0 0 0 5 50 front 12 5 27 6 17 5 38 6 0 0 0 0 0 0 30 82 rear 16 5 38 6 17 5 38 6 9 7 21 385 0 0 0 0 0 0 5 45 front 12 0 26 5 18 0 39 7 0 0 0 0 0 0 25 82 rear 17 5 38 6 18 0 39 7 11 6 25 573 ...

Page 888: ... 30 9 21 5 47 4 0 0 0 0 0 0 5 75 rear 21 5 47 4 19 0 41 9 24 0 52 911 50 0 0 0 0 0 5 25 front 13 0 28 9 22 5 49 6 0 0 0 0 0 0 5 75 rear 23 0 57 3 19 0 41 9 26 2 57 761 50 0 0 0 0 0 5 20 front 12 5 27 6 23 5 51 8 0 0 0 0 0 0 50 70 rear 23 0 50 7 19 0 41 9 Counter weight in t lbs Telescope status I II III IV V VI Main boom angle in Superstruc ture position1 Maximum Axle load 2 in t x 1 000 lbs front...

Page 889: ... current Free on wheels 0 to the rear working position Tie down the load so that it cannot swing back and forth Before driving with a load observe the specifications in the relevant section à Driving from the driver s cab p 13 13 à Driving from the crane cab p 13 17 G Risk of accidents when driving with a lifted load When driving with a lifted load you must be able to operate the crane at any time...

Page 890: ... and axle loads 13 6 3 302 690 en Operating manual GMK4100L 1 23 11 2017 13 2 3 Axle loads The axle loads do not exceed 25 0 t 55 116 lbs if the main boom is within the permissible working range in a permissible Lifting capacity table Free on wheels working position ...

Page 891: ...ust be green s S Risk of damage to the tyres Only drive the rigged truck crane if the tyres are at the prescribed pressure level Never reduce the tyre pressure in order to increase the bearing surface of the tyres G Risk of accidents due to excessively high wind speeds You may not drive the rigged truck crane if the wind speed exceeds the maximum permissible values specified in Lifting capacity ta...

Page 892: ... are just above the ground Lowering wheels Use the Raise axle function to lower all wheels to the ground à Operating the axle raising system p 12 64 G Danger of overturning by unevenly retracting the outrigger cylinders Retract the outrigger cylinders evenly This prevents the truck crane from overturning while retracting individual outrigger cylinders S Risk of damage to the axle lines Retract the...

Page 893: ... inclination display the marking 1 must be in the middle of the 1 measuring range The displays 2 must show an even axle load à Operating the axle raising system p 12 64 To secure the truck crane Retract the outrigger cylinders until the outrigger pads are about 5 to 10 cm 2 to 4 in above the ground Leave the outrigger beams extended G Danger of overturning if outriggers are retracted Always leave ...

Page 894: ...off p 5 16 Now lower all wheels to the ground G Danger of overturning by unevenly retracting the outrigger cylinders Retract the outrigger cylinders evenly This prevents the truck crane from overturning while retracting individual outrigger cylinders S Risk of damage to the axle lines Retract the outrigger cylinders evenly This prevents excessive strain on the axle lines G Danger of overturning wh...

Page 895: ...gers until the lamp 1 is the only one illuminated in the measuring range 1 Switching off the suspension Switch off the suspension the symbol must be red à Switching the suspension on off p 5 16 To secure the truck crane Retract the outrigger cylinders until the outrigger pads are about 5 to 10 cm 2 to 4 in above the ground Leave the outrigger beams extended G Danger of overturning if outriggers ar...

Page 896: ...Driving with a rigged truck crane 13 3 Before driving the rigged truck crane 13 12 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 897: ...ifferential locks à p 5 51 switch on the transverse differential locks à p 5 51 G Risk of accidents when driving the truck crane from the driver s cab with a lifted load With a lifted load drive the truck crane only from the crane cab You must be able to carry out crane movements in an emergency at all times S Risk of damage to the steering linkage Always switch on separate steering before driving...

Page 898: ...realign the truck crane using Raise axle as described in the section Putting the truck crane on the wheels with Raise axle function à p 13 8 S Risk of damage to the steering linkage The steering linkage can be damaged if the steering wheel is moved while the vehicle is stationary S Risk of damage to the axle lines The suspension struts could be damaged if the maximum permissible operation pressure...

Page 899: ...itch separate steering off after driving à p 5 63 Engage the parking brake Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise until none of the wheels touches the ground Enabled outrigger spans For the Standard slewing range type à p 12 30 For the MAXbase slewing range type à p 12 34 ...

Page 900: ...Driving with a rigged truck crane 13 4 Driving from the driver s cab 13 16 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 901: ... so that the hook block load does not swing G Risk of accidents due to partially obstructed view of the truck crane When driving the truck crane always stay in visual or radio contact with a banksman who can observe the parts you are unable to see e g the raised main boom in 0 to the rear G Risk of overturning by slewing superstructure When driving the rigged truck crane the slewing gear must be s...

Page 902: ... s cab must be locked with the second ignition key in order to secure it against unauthorised use e g braking The parking brake is engaged In the crane cab The ignition must be switched on The hand held control must be disconnected and bridging plugs plugged into all the sockets The superstructure must be locked The parking brake is engaged 13 5 2 Opening closing the Driving menu Opening The brake...

Page 903: ...ite The symbols 3 indicate the current switching state The symbols 4 are active Crane s hydraulic system on off Arrow 1 orange crane s hydraulic system on Selecting the transmission modes RM or DM automatically switches on the crane s hydraulic system You can now carry out crane movements Arrow 2 grey crane s hydraulic system off Selecting the neutral position N switches off the crane s hydraulic ...

Page 904: ...100L 1 23 11 2017 Closing Push the button below apply the parking brake Select and confirm the symbol 1 Press button 2 or 3 The carrier ignition is switched off The transmission shifts to neutral position The main menu opens The engine speed for crane operation is now regulated with the accelerator pedal 1 ...

Page 905: ...eering direction The steering direction is adjusted automatically to suit Turned to the front The buttons direction of movement corresponds to the steering direction of the truck crane if the superstructure is in the 180 to the front position Turned to the rear The buttons direction of movement corresponds to the steering direction of the truck crane if the superstructure is in the 0 to the rear p...

Page 906: ...ate steering when driving a rigged truck crane There are two steering modes with separate steering Driving around corners When the separate steering is switched on the steering angle is larger than for normal steering mode the turning circle is smaller Crab travel mode When the separate steering is switched on the truck crane drives side ways if you turn the wheels of the front and rear axle lines...

Page 907: ... on The symbols 5 are red steering unlocked If the symbols 5 are yellow Steer using the buttons 1 or 2 until the symbols 5 turn red If the error symbol is displayed contact Manitowoc Crane Care à p 8 24 s 1 Manual mode the 3rd and 4th axle lines are manually steered for driving around corners crab travel mode 2 When driving around corners the 3rd and 4th axle lines are steered automat ically 3 In ...

Page 908: ...is reached The electronics will register the steering angle on the 1st and 2nd axle lines and steer the wheels of the 3rd and 4th axle lines correspondingly A When driving around corners The 3rd and 4th axle lines are steered in line with the turning radius contrary to the steer ing angle of the 1st and 2nd axle lines B For crab travel mode The 3rd and 4th axle lines are steered in the same direct...

Page 909: ...4th axle lines with the button 3 The axle lines are steered as long as you keep the button pressed or until an end position is reached A For driving around corners Steer the 3rd and 4th axle lines in the oppo site direction to the 1st and 2nd axle lines B For crab travel mode Steer the 3rd and 4th axle line in the same direction as the 1st and 2nd axle line s To turn to the left Press the button 2...

Page 910: ...igged truck crane always use the separate steering Switching to normal steering mode Turn the wheels to the Straight ahead position current wheel position is displayed Select and confirm the symbol 4 display symbol 2 After the switchover to normal steering mode the symbols 1 turn green steering locked If the symbols 1 are yellow Depending on the steering mode steer using the buttons 3 or 5 until t...

Page 911: ... the crane s hydraulic system is switched on or off Crane s hydraulic system on You can select only the transmission modes RM or DM The 1st gear forwards or reverse is always engaged In order to carry out crane movements after the truck crane is halted you must switch to neutral position or apply the parking brake Crane s hydraulic system off You can select all transmission modes In transmission m...

Page 912: ... speed is limited to a maximum of approx 20 km h 12 mph 6th gear maximum Use this transmission mode only when the main boom is completely retracted the main boom is resting in the boom rest and the outrigger beams cylinders are fully retracted Warning messages If a symbol is shown in area 1 à Warning messages on the CCS display p 14 3 à Error messages on the CCS display p 14 7 G Risk of accidents ...

Page 913: ...ng state Longitudinal transverse differ ential locks With an 8 x 8 x 8 drive the drive of the 2nd axle line is switched on and off together with the longitudinal differential locks Straighten the steering Stop the truck crane For switching on and off the current speed needs to be under about 5 km h 3 mph s S Risk of damage to the differential locks Leave the transverse differential locks switched ...

Page 914: ...differential locks B Start moving slowly display First symbol 2 yellow then symbol 3 red differential locks on Switching off Select and confirm the symbol 1 for the Longitudinal differential locks A or Transverse differential locks B Display first symbol 2 yellow followed by symbol 3 green differential off If symbol 3 is not green then drive back and forth slowly If the error symbol is displayed c...

Page 915: ...gitudinal differential lock off 3 Switch off transverse differential locks 2 Switch on normal steering mode 4 Press down button 7 once The lamp 6 lights up symbol 5 is red the parking brake is applied If necessary switch the engine off à Switch off the engine p 10 11 Remove the ignition key from the ignition lock in the driver s cab and lock the driver s cab to prevent unauthorised access Put the ...

Page 916: ...Driving with a rigged truck crane 13 5 Driving from the crane cab 13 32 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 917: ...ting the emergency stop switch p 4 19 H The battery master switch cannot be used as an emergency stop switch for the engine The engine continues to run after the battery master switch has been switched off G Risk of overloading if used improperly Press the emergency stop switch only if it is no longer possible to stop the crane movements with the normal operating elements The emergency stop switch...

Page 918: ... emergency operation with the hand pump p 14 51 Lock the truck crane to prevent unauthorised use Remove the ignition key and lock away the hand held control Inform your supervisor Try to eliminate the malfunction Inform Manitowoc Crane Care if you cannot correct the malfunction Load cannot be set down Secure the danger area using cordons and warning signs Notify Manitowoc Crane Care G Risk of acci...

Page 919: ...he serial number after a malfunction occurs before notifying Manitowoc Crane Care Open the Program version menu 1 14 3 1 Warning messages on the CCS display If the CCS detects a malfunction then a symbol is shown in the display area for example the symbol 1 If several warning messages exist all of the corresponding symbols are displayed one after the other in consecutive order s 1 Serial number di...

Page 920: ... off the ignition and wait about 15 seconds then switch it on again If the malfunction is still present contact Manitowoc Crane Care Engine oil pressure Switch off the engine as quickly as possible Check the engine oil level and top up with oil if necessary à Maintenance manual If the oil level is correct then start the engine from the driver s cab and check the warning messages that are present S...

Page 921: ...ible à Maintenance manual Slewing gear brake too hot Stop crane operation as soon as possible and let the slewing gear brake cool down Anemometer not connected Connect the anemometer to the electrical power supply à p 12 126 Voltage monitoring The voltage in the electrical system is too high or too low Display of the current voltage à p 10 8 Air intake inhibitor triggered It is only possible to st...

Page 922: ...nterweight à p 12 88 Reduction of slewing speed switched off Blue information The slewing speed is not reduced automatically Red warning The maximum permissible slewing speed stated in the lifting capacity table for the current loading case has been exceeded There is a risk of accidents slowly reduce the slewing speed to a permis sible value and where possible engage the reduction of slewing speed...

Page 923: ...enu 3 For the subsequent procedure à p 8 17 2 Crane operation error The buzzer tone sounds once Open the Crane operation error menu 4 Display of error total errors Display 3 shows the error total and display 2 shows which error is displayed 3 5 for example means Error 3 is shown There is a total of 5 errors Displaying errors The rotating symbol 1 indicates that further unacknowledged errors are pr...

Page 924: ...ged consult Manitowoc Crane Care Error message display For each error the display shows the error code 5 the symbols for Exiting the menu You can exit the error menu at any time via button 1 or 2 If not all errors have been acknowledged then the symbol 1 will be displayed continuously When all errors are acknowledged the symbol 1 goes out The buzzer tone sounds once and the symbol 1 flashes when a...

Page 925: ...ear p 9 120 Main boom angle too large Lower the main boom à Derricking gear p 9 120 s S Risk of damage if warning messages are disregarded Observe the following information in good time and take the appropriate remedial measures if a warning message appears This prevents these malfunctions causing defects in the truck crane G Risk of accidents due to overridden or faulty RCL Only override the RCL ...

Page 926: ...nsion operating manual Lattice extension angle too large Lower the lattice extension à Lattice extension operating manual Boom extension angle not measured different sensor values Main boom load capacity chart not present Lattice extension load capacity chart not present RCL override switch 1 not actuated RCL override switch 1 actuated RCL override switch 2 not actuated RCL override switch 2 actua...

Page 927: ...override switch 3 actuated RCL override all switches actuated Learn in phase Displayed only during maintenance by service personnel Data acquisition Displayed only during maintenance by service personnel Lattice extension maximum permissible load exceeded Load too low RCL error status display Active working range limiter maximum permissible overall height reached s ...

Page 928: ...slewing angle reached Active working range limiter maximum permissible working radius reached Hoist rope travel limitation upper or lower limit reached Hoist rope travel limitation working radius or telescope status changed If the described measures do not solve the problem try to remedy the error by switching off the ignition and switching it on again after about 15 seconds ...

Page 929: ...d Engine malfunction à Malfunctions on the engine p 8 19 Malfunction Cause Solution Main hoist not working or malfunctioning Main hoist off lamp in button lights up dimly à Switching on the main hoist p 11 76 à Switching on the auxiliary hoist p 11 79 Dead man s switch not actuated Press dead man s switch Emergency stop switch on à Resetting the emergency stop switch p 4 19 Control unit fuse blown...

Page 930: ...ot working Function disabled by CCS If required acknowledge error message once and briefly turn off the ignition it if occurs again notify Manitowoc Crane Care No lift function Control unit fuse blown Replace the blown fuse à p 14 73 Lifting or lowering is either not possible at all or only at a low speed Speed limited Increase limit à p 11 125 Lifting or lowering func tion cannot be switched off ...

Page 931: ...ween camera and monitor is disconnected Check cable connection and notify Manitowoc Crane Care if necessary Extendable tripod not working Fuse F7 5 blown Replace blown fuse à p 14 73 Malfunction Cause Solution No image appears on the monitor after it is switched on Fuse F6 8 blown Replace blown fuse à p 14 73 Fuse blown in camera or monitor Check fuses and replace as necessary à Manufacturer opera...

Page 932: ...notify Manitowoc Crane Care Lowering function not working Lifting limit switch approached lamp lights up Leave the shutdown range and lower the auxil iary hoist RCL shutdown lamp lights up Leave the shutdown range à p 11 58 Control unit fuse blown Replace the blown fuse à p 14 73 Derricking function not working Function disabled by CCS If required acknowledge error message once and briefly turn of...

Page 933: ...itowoc Crane Care Extending function not working Control unit fuse blown Replace the blown fuse à p 14 73 RCL shutdown lamp lights up Leave the shutdown range à p 11 58 Lifting limit switch approached lamp lights up Leave the shutdown range retract boom Retracting function not working Insufficient lubrication Lubricate main boom à Maintenance manual Main boom is not steep enough Leave the shutdown...

Page 934: ...tion Cause Solution Malfunction Cause Solution Slewing gear not func tioning Slewing gear off lamp in button lights up dimly Switch on the slewing gear à p 11 116 Superstructure locked Unlock superstructure à p 11 15 Dead man s switch not actuated Press dead man s switch Emergency stop switch on à Resetting the emergency stop switch p 4 19 Control unit fuse blown Replace the blown fuse à p 14 73 C...

Page 935: ...f 360 Standard or reduce the working radius MAXbase or slew in the opposite direction to leave the shutdown angle Slewing not possible or only at low speed Speed limited Increase limit à p 11 125 Slewing gear no longer responds to the control lever movement CCS malfunction Emergency stop switch à p 14 1 No response to control lever movements CCS malfunction for operat ing elements in the crane cab...

Page 936: ... electrical or logical error Extend lifting cylinder not working Superstructure unlocked à Lock the superstructure p 11 16 Malfunction Cause Solution Hydraulic oil temperature above 80 C 176 F fan in the hydraulic oil cooler running Hydraulic system is heavily loaded Stop the crane operation and keep the engine run ning until the oil has cooled down Hydraulic oil temperature above 80 C 176 F fan i...

Page 937: ...blown fuse à p 14 73 Pre selected function cannot be performed Another function has been pre selected Pre select the desired function Operation not possible Malfunction in the control system Inform Manitowoc Crane Care Malfunction Cause Solution Crane cab inclination function not working Control unit fuse blown Replace the blown fuse à p 14 73 Malfunction Cause Solution The menu cannot be opened S...

Page 938: ...bridging plug not inserted Parking brake not applied Slewing gear switched on Disconnect hand held control or insert bridging plug à p 12 25 Lock the parking brake à p 5 46 Switching the slewing gear off à p 11 120 When operating from the control units Display fields switched off Switch on display fields à p 12 43 Hand held control connected to the superstructure or a bridging plug not inserted Di...

Page 939: ...ellow Ambient temperature too high Cool the crane cab Display weak Ambient temperature too high brightness is reduced automatically The set brightness is restored after cooling Malfunction Cause Solution The transmission the dif ferential locks and the separate steering do not respond to the operating elements symbols grey Parking brake applied Releasing the parking brake à p 13 18 Ignition key in...

Page 940: ...the bolts 2 and remove the cover 1 Check the associated fuse on the plate 3 and replace it if necessary à Fuses in the crane cab p 14 73 Loosen the screws 4 and fold down the plate 3 to the front S Risk of damage if procedure is incorrect Observe the following notes to avoid malfunctions and damage Always switch the ignition off before changing a fuse and before check ing the antenna plugs Replace...

Page 941: ... 3 302 690 en 14 25 GMK4100L 1 23 11 2017 Check the fuses 1 and replace them if necessary Check whether the plugs 2 are plugged in After checking Fold the plate 3 up and secure it with the screws 4 Fasten the cover 1 using the bolts 2 Designation Amperage F3401 5 A F3402 5 A ...

Page 942: ...Malfunctions during crane operation 14 4 Troubleshooting 14 26 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 943: ...operations and programs This section contains all the information about possible emergency opera tions and emergency programs The following are available Mechanical emergency activation for retracting The Telescoping emergency program menu Entering the telescoping after an emergency operation Operation of the power units with the hand held control ...

Page 944: ...nd confirm the current rigging mode of the truck crane The current rigging mode must be shown on the RCL display Lower the main boom If the RCL allows the boom to be lowered into a horizontal position You can reach the locking points with a ladder and need only one auxiliary crane to telescope the unlocked telescopic sections If the RCL is deactivated prior to reaching the horizontal position In o...

Page 945: ...lescopic section cannot be locked or unlocked manually There are two M8 bolts for every telescopic section You will need a suitable hexagon L wrench 3 at least 250 mm 9 8 in long In order to unlock the telescopic section screw the bolts 4 into the bores 1 in the locking pins Pins located further inside are reached through the bores 2 s G Risk of accidents due to sudden retraction of a telescopic s...

Page 946: ...ec tion as well Locking the telescopic section A Retract the telescoping until the locking pin 2 is in the middle of the opening Remove the bolt from the bore hole 1 until the locking pin 2 is extended completely Remove the bolt from the bore 1 B Retract the telescoping further until the telescopic section is set down S Risk of damage due to a mechanically released lock Under no circumstances may ...

Page 947: ...e of the position of the swing away lattice A Before telescoping with the emergency program check that the swing away lattice is swung outwards so the telescoping parts 1 can move past the swing away lattice B If the swing away lattice is swung towards the main boom you must swing the swing away lattice outwards using emergency operation Swinging in emergency operation is described in the lattice ...

Page 948: ...r 7 buttons Once the correct entry has been made the Telescoping emergency programme is started The emergency program has a time limit The display 1 counts down a time span of about 360 seconds Within this time you can operate the telescop ing mechanism using the emergency program If the time is not sufficient you must restart the emergency program H In the emergency program all functions for retr...

Page 949: ...wn in 2 only This section provides a brief explanation of the displays shown in 2 The meaning of the symbols in displays 1 and 2 is identical s 1 Time remaining until the emergency program closes automatically 2 Extended length of the telescoping cylinder value from the length indicator of the CCS crane control 3 Extended length of the telescoping cylinder value from the length indicator of the RC...

Page 950: ... locking point of a telescopic section In this case consult Manitowoc Crane Care 1 Display for the position of the telescoping cylinder in the foot section There are four different displays A Shortly before the locking point the locking point is reached by extending B Shortly after the locking point the locking point is reached by retracting C At the locking point D Telescopic cylinder not in a fo...

Page 951: ...ithout telescopic section à p 14 36 Status 1 Telescoping cylinder at locking point Carry out the check for the current locking status and observe the result Telescoping cylinder and telescopic section locked Select and confirm one of the symbols for unlocking e g the symbol 2 for the telescopic cylinder Check that the symbol 1 is displayed Telescoping cylinder or telescopic section unlocked Select...

Page 952: ...n run without telescopic section In this status you should first check the functioning of the display for Shortly after the locking point and then check the functioning of the emergency program For the next telescopic section to be retracted note down the value for the locking point of the telescoping cylinder à p 14 41 Checking display for Shortly after the locking point In the next step start by...

Page 953: ...n the emergency program if the telescoping cylinder is moved too far In such cases you must stop the movement in time when the locking point is reached during every return run Checking functioning of emergency program Move the telescoping cylinder to the locking point check on the length indicator 1 or 2 or on the display 4 Select and confirm the symbol 3 for locking Check that the symbol 5 is dis...

Page 954: ... 39 4 Extend and lock the telescoping cylinder à p 14 39 1 Unlock the telescopic section Select and confirm the symbol 1 The telescopic section is unlocked display symbol 2 2 Retract and lock the telescopic section For the current telescopic section note down the value for the locking point at 0 à p 14 41 While telescoping never select and confirm the symbol 3 for locking Slowly retract the telesc...

Page 955: ...copic section to be retracted note down the value for the locking point of the telescoping cylinder à p 14 40 While telescoping never select and confirm the symbol 3 for locking Slowly extend the telescoping cylinder to the locking point at 0 check on the length indicator 1 or 2 Select and confirm the symbol 3 The telescoping cylinder is locked display symbol 4 You can now unlock this telescopic s...

Page 956: ...locking the telescoping cylinder Table for locking the telescoping cylinder Telescopic section Locking point at fixed length Extended length of telescoping cylinder in in mm in ft Telescopic section I 0 50 92 100 5 4 115 7 567 8 224 0 02 13 50 24 83 26 98 Telescopic section II 0 50 92 100 274 4 420 7 903 8 565 0 90 14 50 25 93 28 10 Telescopic section III 0 50 92 100 536 4 674 8 149 8 811 1 76 15 ...

Page 957: ...ength for locking and unlocking the telescopic sections Table for locking unlocking the telescopic sections Telescopic section Locking point at fixed length Extended length of telescoping cylinder in in mm in ft Telescopic section I 0 50 92 100 5 4 140 7 592 8 249 0 02 13 58 24 91 27 06 Telescopic section II 0 50 92 100 274 4 445 7 928 8 590 0 90 14 58 26 01 28 18 Telescopic section III 0 50 92 10...

Page 958: ...Malfunctions during crane operation 14 5 Emergency operations and programs 14 42 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 959: ...om the RCL display Select and confirm the symbol 1 the Unknown telescoping menu is opened Select and confirm the symbols 1 to 4 Confirm the entry with the symbol 5 You can cancel the entry at any time using the 6 or 7 buttons Once the entry has been made correctly the Unknown telescoping menu is opened Entering target values Select and confirm the symbols for tele scopic sections 1 to 6 one after ...

Page 960: ...11 2017 You can cancel the entry at any time using the 1 or 2 buttons S Risk of damage due to incorrect input Before working with the crane check whether CCS indicates the current telescoping and correct if this is not the case Entering incorrect values causes malfunctions and may result in damage to the telescoping mechanism ...

Page 961: ...e into a safe state or to shut it down Prerequisites The ignition in the crane cab must be switched off The ignition is switched off in the driver s cab Connect the hand held control Connect the hand held control to the connector 1 All power units can be operated from this connection Information on connecting à p 12 25 Starting the engine Press the button 1 once the engine will start à p 10 10 s G...

Page 962: ...in hoist press button 1 first and then also button 2 The further you press button 2 the quicker the movement The maximum speed is limited to about 50 for all power units The table shows all the button combinations Engaged buttons are shown in black G Danger of overturning when moving into the shutdown ranges Avoid lowering the boom If you cannot avoid lowering try to set down the load beforehand a...

Page 963: ...vement continues until you release the button or the end position is reached s Pre selected power unit Button combination Telescoping mechanism Derricking gear Slewing gear Hoist Lattice extension c e f a d None Lower Lock turntable Lowering Lower Retract Raise Unlock turntable Lifting Raise None None Slew to right None None None None Slew to left None None ...

Page 964: ... 4 19 Switch off the engine You can switch off the engine only by using the hand held control Stop all crane movements Press the button 1 the engine will switch off 14 5 5 Notes on slewing in emergency operation For the Standard slewing range type If the MAXbase slewing range type is activated à p 14 50 Slewing is not monitored by the RCL in emergency operation G Risk of overturning when slewing i...

Page 965: ...t 1 764 lbs 1 4 5 t 9 920 lbs 5 7 t 12 566 lbs 6 7 t 14 770 lbs 8 5 t 18 739 lbs 9 7 t 21 385 lbs 11 6 t 25 573 lbs Slewing Slewing 13 1 t 28 880 lbs Slewing Permissible not 14 9 t 32 848 lbs not permissible2 17 4 t 38 360 lbs Permissi ble 19 9 t 43 872 lbs 21 4 t 47 179 lbs 24 0 t 52 911 lbs 26 2 t 57 761 lbs 1 Slewing permissible only if the working radius permissible in the working range is obs...

Page 966: ...city table are correctly shown on the RCL display Slew slowly towards a safe range and check that the current position 1 changes accordingly Derrick slowly towards a safe range and check that the current position 1 changes accordingly If the RCL display still displays correctly You can use the RCL display for orientation while slewing and correct the working radius before reaching the slewing rang...

Page 967: ...ate the derricking gear and the main hoist e g to raise the main boom in the case of a defective engine The hand pump 1 which is activated by switching over a valve is used as the energy source for the crane s hydraulic system The hydraulic circuits are switched via the valves 2 The crane movements are performed by operating the hand pump 14 6 2 Switching over the crane s hydraulic system for cran...

Page 968: ...er Releasing securing valves Releasing securing is described for a valve The procedure is identical for valves 1 to 3 Release for the emergency operation Unscrew the handle 1 Move the disc 2 to position A Fasten the handle 1 Rigging for crane operation Unscrew the handle 1 Move the disc 2 to position B Fasten the handle 1 S Danger due to operating error Following emergency operation secure the val...

Page 969: ...gency operation Unlock the valves 1 2 and 3 à p 14 52 Switch the valves 1 to 3 to the positions for the desired crane movement as shown in the following table For lowering the boom for example you must switch valve 2 upwards Valves 1 and 3 must be switched downwards s Emergency operation for crane movement Valves upwards Valves downward Additional switching operations Lowering 3 1 2 Valve Y1104 on...

Page 970: ...valve Y1104 Lowering 1 Remove the plug 4 Screw the cap with pin 3 on to the valve continuous operation is now switched on Switching off continuous operation Unscrew the cap 2 from the valve 1 Screw the cap on so that the pin 3 can be seen Insert the plug 4 S Danger due to falling loads Switch off continuous operation immediately after emergency activation Check that the pin can be seen on the cap ...

Page 971: ...ke the corresponding crane movement using the hand pump 1 Insert the pump lever 2 provided into the holder at the hand pump lever Pump with the lever the corresponding crane movement is performed 14 6 5 After emergency activation You must restore the truck crane to its original state after finishing emergency activation After each emergency activation Switch valves 1 to 3 to crane operation à p 14...

Page 972: ...4 6 Hydraulic emergency operation with the hand pump 14 56 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Remove the lever from the hand pump Additionally after the lowering Switch off continuous operation on the valve Y1104 à p 14 54 ...

Page 973: ...y supply of another truck crane Emergency operation In emergency operation you can drive the main hoist derricking gear and slewing gear The energy source for the crane hydraulics is a transformer 1 which is driven by the car rier s hydraulic system in case of self suffi ciency or is driven by a hydraulic external energy source in case of an external power supply The hydraulic circuits are switche...

Page 974: ...ing manual GMK4100L 1 23 11 2017 Emergency supply You can supply another crane that also has an hydraulic emergency operation BGR159 In the event of emergency supply the connec tions 1 feed a transformer 2 which is con nected to the hydraulic system of the other crane à Emergency supply of another crane p 14 71 ...

Page 975: ...ve the warnings and safety instructions specified here 1 For emergency operation with self sufficiency Attach and connect the transformer to the superstructure à p 14 61 Switching on emergency operation à p 14 63 2 For emergency operation with external energy source Attach and connect the transformer to the superstructure à p 14 64 3 Establishing the required hydraulic circuits à p 14 65 Carrying ...

Page 976: ...fety instructions specified here 1 Switching off emergency operation After emergency operation with self sufficiency à p 14 63 After emergency operation with external energy source àOperating manual of energy source 2 Establish hydraulic energy circuit for the crane operation Switch valves 1 to 5 into position for crane operation à p 14 65 Switching off continuous operation à p 14 67 Open valve 6 ...

Page 977: ...off Connecting The hoses are assigned according to the various diameters On the carrier Attach the transformer 3 to the super structure Connect the hoses 2 to the connections 1 Superstructure Connect the hoses 2 to the connections 1 s S Risk of damage to the hoses Lay the hoses in such a manner that they can be moved freely so as to pre vent them being crushed or torn or becoming caught during sub...

Page 978: ...2017 Removing After the emergency operation you must disconnect the hoses and the transformer On the superstructure Remove the hoses 2 from the connec tions 1 Close off the hoses and connections with the caps On the carrier Remove the hoses 2 from the connec tions 1 Close off the hoses and connections with the caps Remove the transformer 3 ...

Page 979: ... 14 63 GMK4100L 1 23 11 2017 14 7 5 Switching emergency operation on off Switching on Start the engine Select and confirm the symbol 1 Symbol 2 is displayed Emergency operation is switched on Switching off Select and confirm the symbol 2 Symbol 1 is displayed Emergency operation is switched off Switch the engine off ...

Page 980: ...re assigned according to the various diameters Switch off the hydraulic energy source Attach the transformer 3 to the super structure Connect the hoses 2 to the connections 1 Connect the hoses 4 to the supplying energy source Switch on the hydraulic energy source Removing Switch off the hydraulic energy source Remove the hoses 2 from the connec tions 1 Remove the hoses 4 from the supplying energy ...

Page 981: ...rcuits You must switch over the necessary valves to establish a hydraulic circuit Switching over valves The valves 1 to 5 are labelled with their respective numbers For crane operation Switch the valves 1 to 5 downward s G Danger from mutual interference of the power units For crane operation always switch all the valves 1 to 5 down This prevents the power units suddenly starting to move ...

Page 982: ...4 and 5 must point down G Danger from mutual interference of the power units For one crane movement always switch valves upward This prevents wrong crane movements being performed and several movements being performed unintentionally at the same time Emergency operation for crane movement Valves upwards Valves downward Additional switching operations Lifting 1 2 3 4 5 Valve Y1105 on continuous ope...

Page 983: ... cap 3 e g off valve 1 Remove the plug 5 Screw the cap with pin 4 on to the valve continuous operation is now switched on Switching off continuous operation Remove the cap 3 from the actuated valve 1 2 Screw the cap on so that the pin 4 can be seen Insert the plug 5 s 1 Valve Y1104 Lowering or 2 Valve Y1105 Lifting S Danger due to falling loads Switch off continuous operation immediately after eme...

Page 984: ...2 690 en Operating manual GMK4100L 1 23 11 2017 For slewing After switching over the valves behind the crane cab you must also close a valve A Emergency operation position Close the valve 6 lever 1 at right angles to the line B Crane operation position Open the valve 6 lever 1 parallel to the pipe ...

Page 985: ...the control lever in the crane cab Slowly move the control lever 1 in the required direction s G Risk of overturning when slewing in emergency operation Crane operations are not monitored by the RCL whilst the hand held control is connected Various checks are therefore necessary depending on the active slewing range type before slewing in emergency operation à p 14 48 G Risk of accidents during sl...

Page 986: ...ry Move the control lever 1 in the required direction Lifting lowering Move the control lever 1 in the required direction G Danger of overturning if the working radius is too large when lowering the boom In emergency operation operations are not shut down by the RCL This also applies if the RCL displays are still active after switching on the igni tion The truck crane will overturn if you exceed t...

Page 987: ...ed Attach the transformer 3 Attach the hoses 4 à Operating manual of the other crane On the GMK4100L 1 Switch the engine off Connect the hoses 2 to the connec tions 1 Switch on the hydraulic emergency opera tion à p 14 63 After emergency supply On the GMK4100L 1 Switch off the hydraulic emergency opera tion à p 14 63 Remove the hoses 2 from the connec tions 1 On the crane that was supplied Disconn...

Page 988: ...Malfunctions during crane operation 14 7 Hydraulic emergency operation as per BGR 159 14 72 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 989: ... a fuse has to be replaced s S Risk of damage if the ignition is switched on Switch off the ignition whenever a fuse has to be replaced This prevents the new fuse being blown immediately by the increased starting current after being installed S Risk of damage by overloading Replace blown fuses only with new fuses of the same amperage This pre vents parts being overloaded and damaged or the fuse be...

Page 990: ...uding their amperage and functions Observe the instructions for fuse changes à p 14 73 The designations 1 to 8 in the tables correspond to their order from left to right fuse 1 is always the left fuse Designation Amperage A Function F1 1 15 Control unit UB 1 CCM 10 F1 2 15 Control unit UB 2 CCM 10 F1 3 15 Control unit UB SCM F1 4 15 Control unit UB IOS 20 F1 5 5 Control unit UB UE IOS 21 F1 6 15 C...

Page 991: ...L 30 F2 3 15 Control unit UB 2 IOL 30 F2 4 15 Control unit UB 1 IOL 34 F2 5 15 Control unit UB 2 IOL 34 F2 6 15 Control unit UB 2 IOL 34 F2 7 15 Control unit UB 2 IOL 34 F2 8 Unassigned Designation Amperage A Function F3 1 Unassigned F3 2 Unassigned F3 3 Unassigned F3 4 3 Contact switch for cab lighting F3 5 5 CCS display F3 6 5 Hand held control F3 7 7 5 Comfort seat1 F3 8 5 Cigarette lighter 1 A...

Page 992: ...4 2 3 Reserve F4 3 3 CraneSTAR system F4 4 10 Radio 1 F4 5 Unassigned F4 6 Unassigned F4 7 Unassigned F4 8 Unassigned Designation Amperage A Function F5 1 5 Control unit 15 SCM CCM 10 Control unit UE IOL 30 IOS 22 F5 2 5 Control unit 15 UE IOS 20 and 21 F5 3 3 CCS display F5 4 3 CAN bus system F5 5 5 Control lever supply F5 6 Unassigned F5 7 Unassigned F5 8 5 Switch lighting 1 Additional equipment...

Page 993: ...6 7 3 Radio control F6 8 5 Camera system Designation Amperage A Function F7 1 3 Rotating beacons F7 2 5 Diagnostic connection F7 3 3 Heating system F7 4 3 Extendable step for crane cab F7 5 5 Hoist camera tripod F7 6 Unassigned F7 7 Unassigned F7 8 Unassigned Designation Amperage A Function F8 1 5 Crane control power supply F8 2 3 Crane control power supply F8 3 3 Crane control power supply F8 4 3...

Page 994: ...Malfunctions during crane operation 14 8 Fuses in the crane cab 14 78 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 995: ...unclear we have not included every single element from the instrument panel Those elements such as switches and buttons lamps and displays are described and named in detail in the overviews of Chapter 3 and Chapter 9 Truck Crane Description From there you are as usual referred to more detailed descriptions of these elements ...

Page 996: ...Index 15 2 3 302 690 en Operating manual GMK4100L 1 23 11 2017 Blank page ...

Page 997: ...9 electrical connection 8 22 8 23 hydraulic connection 8 21 Making breaking the connection between the auxiliary hoist and the turntable 8 20 transportation 8 24 lifting and lowering 13 80 short description of the operating elements 11 116 switch off 13 81 switch on 13 79 Axle loads required speed limit 8 7 weighing the truck crane 8 9 Axle loads when driving the rigged truck crane 15 6 B Batterie...

Page 998: ...2 6 brightness of the display 6 11 Operating elements in the crane cab Menu group Setting Units 5 31 operating elements in the crane cab general information menu independent displays 11 18 overview of the menu groups 11 22 start menu 11 19 in menu for outriggers outrigger beams 11 30 outrigger cylinders 11 32 in the driving menu 11 34 in the Settings menu operating hours 13 133 Menu groups RCL tel...

Page 999: ...ating the crane 13 1 extending the outriggers 14 39 installing auxiliary hoist 8 18 outrigger beams mounting 8 32 removing the outrigger beams 8 30 retracting the outriggers 14 41 rigging counterweight 14 76 rigging for crane operation with main boom 14 1 unrigging counterweight 14 78 unrigging for crane operation with main boom 14 7 Checks before driving 7 7 counterweight secured 14 69 safety equ...

Page 1000: ...air heater 13 155 CraneSTAR system 13 158 ventilating 13 152 Crane control CCS in the driver s cab overview of the menu groups 5 24 short description of the operating elements 11 95 Crane operation CHECKLIST checks before operating the crane 13 1 permissible slewing ranges 13 21 preheating hydraulic oil 13 14 slewing range type MAXbase 13 23 enabled slewing ranges 13 25 note on outrigger spans wit...

Page 1001: ...ing elements auxiliary air heater 5 19 auxiliary water heating system 5 18 on the CCS display 5 23 On the instrument panel 5 11 on the steering column 5 10 standard heating system 5 17 Steering column steering wheel 5 10 Transmission 5 14 overview 5 6 radio 7 80 tilting and lowering 10 43 10 44 prerequisites 10 43 window 5 74 Driving at low temperatures CHECKLIST 6 4 brakes additional brakes 7 43 ...

Page 1002: ... the driver s cab preparations 15 13 whilst driving 15 14 rigging modes driving with load 15 5 driving without a load 15 5 route 15 1 E Earthing load 13 13 of the truck crane 14 15 Earthing the load 13 13 Electrical system checks in the crane cab 13 7 checks in the driver s cab 7 7 display and operating elements in the crane cab 11 145 operating elements in the driver s cab 5 46 Emergency operatio...

Page 1003: ...switch for crane operation 16 1 for driving 10 1 Engine malfunctions 10 19 16 13 operation in the crane cab AdBlue Check the filling level 12 3 checking after starting 12 8 checking the fuel level 12 3 checks before starting 12 4 resetting the emergency stop switch 12 12 setting the idling speed 12 9 starting 12 7 switch the ignition on 12 5 switching off 12 11 switching state alignment 12 6 when ...

Page 1004: ... the superstructure in the crane cab 16 73 H Hand held control connect the hand held control 14 25 disconnecting the hand held control 14 25 functionality and positions of the sockets 14 24 malfunctions 16 21 Heating system crane cab auxiliary heater 13 155 standard heating system 13 151 driver s cab auxiliary air heater 7 76 standard heating system 7 65 heating system driver s cab auxiliary water...

Page 1005: ...the valves on the hydraulic tank 6 8 checking the valves on the hydraulic tank 12 4 I Identification of the counterweight sections 14 73 Inclination indicator short description of the operating elements 11 108 Inclination indicators 14 58 Information conversion table for US measuring units 3 31 for operations planning 3 30 notes on the operating manual 3 23 Installing removing the air traffic cont...

Page 1006: ... while towing 10 31 Longitudinal differential locks operation from the crane cab 15 29 operation from the driver s cab 7 51 M Main hoist 13 75 folding the hoist mirror out in 14 130 lifting and lowering 13 76 short description of the operating elements 11 114 switch off 13 78 switch on 13 76 Malfunctions carbamide system 10 21 CCS control unit 16 21 16 23 counterweight hoist unit 16 20 derricking ...

Page 1007: ...nel 10 5 operating elements in the driver s cab overriding torque reduction 7 45 Operating manual example of how to use cross references 3 28 finding information 3 27 structure of the chapters and pages 3 25 symbols used 3 23 Outrigger removing installing outrigger beams 8 29 centre of gravity data 8 34 CHECKLIST installation 8 32 removal 8 30 disconnecting establishing the connection to the outri...

Page 1008: ...ing position 14 51 outrigger pressure display 14 66 overview MAXbase slewing range type 14 31 overview standard slewing range type 14 29 representation in the lifting capacity tables 14 29 permissible outrigger spans 14 30 preparing the truck crane for rigging 14 42 setting the outrigger spans 14 44 short description of the operating elements crane cab 11 100 Overview operating elements crane oper...

Page 1009: ...riving for driving with a dolly 8 13 switching on boom pre tensioning 8 16 switching on the boom floating position 8 15 switching on the slewing gear freewheel 8 14 removing installing outrigger beams 8 29 rigging the auxiliary hoist 8 17 Rigging work counterweight 14 69 main boom attaching the hook block to the bumper 14 100 picking up the hook block from a separate vehicle 14 101 picking up the ...

Page 1010: ...lining the crane cab 13 123 setting switching economy mode on off 13 126 setting the characteristic curves for the control levers 13 129 setting the constant idling speed 13 124 slewable spotlights 13 130 switching units of measure 7 64 13 128 Slewing gear short description of the operating elements 11 118 slewing 13 117 slewing gear brake applying 13 116 checking for correct functioning 13 115 de...

Page 1011: ...ating speeds 3 20 superstructure 3 19 Telescoping mechanism 13 89 assignment for display 13 94 checks before starting work 13 97 function of the control lever 13 98 main boom fixed length 13 95 main boom intermediate length 13 95 main boom telescoping length 13 95 Manual telescoping Checking the initial position 13 101 manual telescoping 13 101 locking the telescopic section 13 109 locking the tel...

Page 1012: ...elements in the driver s cab 5 49 operation from the driver s cab changing gears while driving 7 31 changing the driving direction 7 33 changing the operating mode 7 29 on the roller type dynamometer 7 34 selecting the direction of travel and starting gear 7 27 starting 7 30 starting at extremely low temperatures 7 34 stopping 7 33 switching on 7 25 switching to neutral position 7 26 procedure dur...

Page 1013: ...ions 4 4 Wheels and tyres inflating the tyres yourself 10 37 wheel change 10 33 Windscreen wiper 5 65 crane cab 11 148 Driver s cab 5 65 Windscreen wiper washing system 11 146 Work break 13 149 in case of short work breaks 13 149 in case of work breaks of more than 8 hours 13 150 Working range limiter 13 135 Entering limit values by approaching them for slewing angles 13 141 entering limit values ...

Page 1014: ...Index Operating manual 3 302 690 en 15 20 GMK4100L 1 23 11 2017 Blank page ...

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