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Manitowoc GROVE GMK 6400, Operating Manual

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Manitowoc GROVE GMK 6400 Operating Manual Download Page 392

Index
 

8 - 8

3 112 993 en

Operating manual GMK 6400

1

2

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7.

201

3

Emergency stop devices

Engine for crane operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 18
for the engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26

Emergency stop switch

for crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 1
for driving  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

Engine

Operation in the crane cab

When starting the engine for the first time of the day   . . . . . . . . . . . . . . . . 10 - 1

Short description of the operating elements  . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 59

Engine for crane operation

After starting the engine

Lamp test/switching state equalisation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 5

Checks after starting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 10
Checks before starting the engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 3
Malfunctions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   14 - 12,  14 - 20
Overriding torque reduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 14
Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 134
Refuelling   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 2
Setting idling speed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Starting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 8
Switching on the ignition   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
Turning off

During normal operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 17
in emergencies  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 18

Engine for crane operation,

Switching off Economy mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 13

Engine for driving

Air intake inhibitor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
Diagnostics  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61
Malfunctions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
Operation in the driver's cab

Resetting the emergency stop switch   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 26

Operation in the driver’s cab

Checking after starting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
Inspections before starting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11
Lamp test/equalisation of the switching states  . . . . . . . . . . . . . . . . . . . . . . 4 - 13
Monitoring elements  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
Setting the idling speed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
Starting  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Starting – CHECKLIST   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Switch on the ignition   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 12
Turning off   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25

Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 75
Procedure during malfunctions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 40
Starting from the crane cab – for rigging work  . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25
Starting with the hand-held control – for rigging work   . . . . . . . . . . . . . . . . . 12 - 23
Starting/turning off from the outrigger control units – for rigging work . . . . 12 - 27

Summary of Contents for GROVE GMK 6400

Page 1: ...3 112 993 en 12 07 2013 Operating manual Part 1 Driving ...

Page 2: ...anitowoc Crane Group Germany GmbH Industriegelände West D 26389 Wilhelmshaven Germany Phone 49 0 44 21 294 0 Fax 49 0 44 21 294 301 Distributing or reproducing this document as well as using or disclosing its contents is prohibited without express authorisation Any infringement shall be punishable by compensation for damages All patent and utility model registration rights reserved The original la...

Page 3: ...r the GMK6400 truck crane Only reeve the hoist rope as described illustrated in this correction sheet It is important that you still observe all notes and safety instructions regarding rigging work on the main boom in the operating manual supplied With 7 head sheaves 7 sheave hook block s Correction sheet Possible reeving methods on the main boom Reeving A 14x B 13x C 12x ...

Page 4: ...27 08 2018 2 3 302 804 en Correction sheet GMK6400 5 sheave hook block 3 sheave hook block Reeving A 11x B 10x C 9x D 8x Reeving A 7x B 6x C 5x D 4x ...

Page 5: ...Correction sheet GMK6400 3 302 804 en 3 27 08 2018 1 sheave hook block Hook tackle s Reeving A 3x B 2x C 1x Reeving A 1x ...

Page 6: ...27 08 2018 4 3 302 804 en Correction sheet GMK6400 With 10 head sheaves 11 sheave hook block 9 sheave hook block Reeving A 20x Reeving A 19x B 18x C 17x D 16x ...

Page 7: ...Correction sheet GMK6400 3 302 804 en 5 27 08 2018 7 sheave hook block 5 sheave hook block s Reeving A 15x B 14x C 13x D 12x Reeving A 11x B 10x C 9x D 8x ...

Page 8: ...27 08 2018 6 3 302 804 en Correction sheet GMK6400 3 sheave hook block 1 sheave hook block Reeving A 7x B 6x C 5x D 4x Reeving A 3x B 2x C 1x ...

Page 9: ...Correction sheet GMK6400 3 302 804 en 7 27 08 2018 Hook tackle Reeving A 1x ...

Page 10: ...27 08 2018 8 3 302 804 en Correction sheet GMK6400 Blank page ...

Page 11: ...pm without load Main hoist Rope speed when lifting and lowering Normal speed maximum 50 m min 164 ft min High speed mode maximum 120 m min 394 ft min Auxiliary hoist Rope speed when lifting and lowering Normal speed maximum 42 m min 138 ft min High speed mode maximum 104 m min 341 ft min Telescoping mechanism Extending from 15 4 to 60 0 m 50 5 to 196 9 ft approx 420 s In automatic mode during unin...

Page 12: ...06 06 2014 2 3 113 115 en Correction sheet GMK6400 Blank page ...

Page 13: ...through the procedure in this section before stepping between the main boom and the stand surface or between the stand surface and the main boom G Risk of accidents due to unsuitable fall prevention safety system Always secure yourself with a fall prevention safety system that is permis sible in the country in which you are working and includes a shoulder waist and seat belt with a two point catch...

Page 14: ...e applicable standards and regulations in the country in which you are working If you are unsure find out which standards and regulations apply for the country in which you are working The fall prevention safety system must consist of a combined shoulder waist and seat belt a catch belt with two lines for fastening at feet height H Only one person at a time is allowed to be secured by the safety h...

Page 15: ... on the truck crane to climb up à Operating manual Make sure you always attach one line of the fall prevention safety system with the safety harness before entering the main boom Attach the second line of the fall prevention safety system with the safety harness once you are located on the main boom s G Risk of accidents due to incomplete safety system Make sure you always attach one line of the f...

Page 16: ...ou may only detach the second line of the catch belt once you have reached a secure position Use the available ladders and access lad ders on the truck crane to climb down à Operating manual G Risk of accidents due to incomplete safety system Only detach the second line of the catch belt once you have reached a secure position on a ladder or access ladder This will prevent falling due to an incomp...

Page 17: ...mage wear mobility and deformations Replacement Make sure damaged worn or deformed fastening or connecting parts are immediately replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew H The safety harness must always be replaced completely following stress caused by a fall even if no damage can be detected G Risk of accidents if inspections are not carried out Make sure...

Page 18: ...22 01 2014 6 3 113 060 en Additional page GMK6400 Blank page ...

Page 19: ...transport and the anemometer 3 and air traffic control lights are transported in the crane cab s Anemometer and air traffic control light Transport S Risk of damage during on road driving Always store the anemometer and the air traffic control lights in the crane cab before on road driving and fasten the rod to the transport retainer This prevents the specified overall height from being exceeded a...

Page 20: ...from the rod 3 Fasten the linchpin 2 to the rod 3 B Place the rod 3 in the clamp 5 Secure the rod with the retaining pins 4 For operation Remove the pin 3 from the clamps 5 You will need the retaining pins 4 later for assembly Fit the anemometer 1 and the air traf fic control lights onto the rod 3 Secure the anemometer with the linchpin 2 Assemble the anemometer à Operating manual ...

Page 21: ...tional head sheave 3 The additional head sheave 3 is only designed for operation via the second head sheave 2 For operation via the head sheave 4 only reeve the hoist rope in the way described in the accompanying operat ing manual s Use of additional head sheaves G Risk of accidents if the procedure is not carried out correctly Observe the information on the permissible usage of the auxiliary hois...

Page 22: ... the second head sheave 2 together with the additional head sheave 3 Use the outer rope attachment point 1 for 2 fall reeving G Risk of accident due to a damaged hoist rope Always use the second head sheave together with the additional head sheave located underneath it or with the auxiliary single sheave boom top This prevents the hoist rope from becoming overloaded snapping during operation and l...

Page 23: ...ifting by the lash ing eyelets 1 The weight of the main boom must not be supported by the lashing eye lets 1 Always lock the trailer on both sides by the locking points 3 s Instructions for operation with a trailer S Risk of damage if procedure is incorrect Only use trailers where it is guaranteed that all support points and locking points can be used on the main boom as intended and ensure that t...

Page 24: ...ndi cated Support points The maximum force permitted for the support points 2 is F3 in the angle range between the horizontal 3 and vertical 4 axes F3 max 258 kN 58 000 lbf Locking points The maximum forces permitted for the locking points 3 are F4 F5 and F6 in the direction indicated Horizontally F1 max 45 kN 10 115 lbf Vertically F2 max 45 kN 10 115 lbf In the direction of travel F4 max 65 kN 14...

Page 25: ...Crane operation Contents overview of part 1 You will find chapter 9 to chapter 15 in part 2 Crane Operation 1 Overview 2 Basic safety instructions 3 Operating elements for driving 4 Starting turning off the engine for driving 5 Driving 6 Driving modes and rigging for on road driving 7 Malfunctions in driving mode 8 Index ...

Page 26: ...3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 27: ...nd weights of removable parts 1 10 1 5 4 Carrier 1 13 1 5 5 Superstructure 1 17 1 6 Documentation supplied 1 19 1 6 1 Questions on documentation 1 20 1 7 Notes on the operating instructions 1 21 1 7 1 What do the symbols used mean 1 21 1 7 2 How are the operating instructions structured 1 23 1 7 3 How do I find the information I need 1 25 1 7 4 What information is available for operations planning...

Page 28: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 29: ...ce 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 30: ...uck crane you can contact our branches at the following addresses Manitowoc Crane Care http www manitowoccranes com MCG_CARE Contact_Us EN ContactUs asp 1 2 2 Dealer list Visit the following address for a global list of dealers http www manitowoccranegroup com DealerLocator locator asp 1 3 Warranty specifications Please see the separately enclosed warranty certificate for information ...

Page 31: ...Overview 1 3 Warranty specifications Operating manual GMK 6400 3 112 993 en 1 3 12 07 2013 Blank page ...

Page 32: ...Overview 1 4 Terms used 1 4 3 112 993 en Operating manual GMK 6400 12 07 2013 1 4 Terms used ...

Page 33: ... 4 Axle lines 5 Outrigger beams 6 Supporting 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 Main hoist 17 Auxiliary hoist1 18 Counterweight 1 Additional equipment ...

Page 34: ...Overview 1 4 Terms used 1 6 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 35: ... Federal Law 1 5 1 Maximum lifting capacity Permissible temperature range 25 C to 40 C 13 F to 104 F Crane designation Truck crane in accordance with DIN 15 001 part 1 Crane application Service crane in accordance with DIN 15 001 part 2 Crane classification Hoist class H1 in accordance with DIN 15 018 part 1 Crane class A1 in accordance with ISO 4301 part 2 Max load bearing capacity 235 t 514 000 ...

Page 36: ...Overview 1 5 Technical data 1 8 3 112 993 en Operating manual GMK 6400 12 07 2013 1 5 2 Dimensions and weights of the truck crane axle loads All dimensions in the illustration are in mm ...

Page 37: ...58 m 57 7 ft A Height 385 95 R25 445 95 R25 525 80 R25 Max level change At on road level 3 95 m 13 ft 4 00 m 13 1 ft 130 170 mm 5 1 6 7 in B Width 385 95 R25 445 95 R25 525 80 R25 3 00 m 9 8 ft 3 00 m 9 8 ft 3 10 m 10 2 ft Angle of negotiable banks Front Rear At on road level 385 95 R25 approx 14 approx 8 Total weight depending on driving mode 72 t 158 730 lbs Axle loads depending on driving mode ...

Page 38: ...445 95 R 25 1 50 x 1 50 x 0 45 4 95 x 4 95 x 1 50 310 685 Spare wheel 525 80 R 25 1 50 x 1 50 x 0 53 4 92 x 4 92 x 1 74 355 785 Designation Length x width x height in m ft Weight in kg lbs Plastic outrigger pad diameter 0 70 x 0 14 2 30 x 0 46 43 95 Front outrigger1 complete per packet 2 98 x 0 37 x 1 20 9 78 x 1 21 x 3 94 1 252 2760 Rear outriggers1 complete per packet 2 98 x 0 37 x 1 10 9 78 x 1...

Page 39: ... 2 46 3 500 7 720 Double hook 9 sheaves 2 30 x 0 95 x 0 75 7 55 x 3 12 x 2 46 3 000 6 615 Double hook 7 sheaves 2 00 x 0 85 x 0 75 6 56 x 2 79 x 2 46 2 400 5 290 Double hook 5 sheaves 1 85 x 0 65 x 0 75 6 07 x 2 13 x 2 46 1 600 3 530 Single hook 3 sheaves 1 75 x 0 40 x 0 75 5 74 x 1 31 x 2 46 1 300 2 870 Double hook 3 sheaves 1 95 x 0 40 x 0 75 6 40 x 1 31 x 2 46 1 300 2 870 Single hook 1 sheave 1...

Page 40: ... x 2 50 x 1 71 17 98 x 8 20 x 5 61 15 000 33 070 each 10 t plate 1 95 x 2 45 x 0 38 6 40 x 8 04 x 1 25 10 000 22 050 each 10 t block 1 65 x 1 82 x 0 73 5 41 x 5 97 x 2 40 10 000 22 050 Designation Length x width x height in m ft Weight in kg1 lbs 15 t base plate 5 48 x 2 50 x 1 71 17 98 x 8 20 x 5 61 15 000 33 070 each 10 t plate 1 85 x 2 14 x 0 56 6 07 x 7 02 x 1 84 10 000 22 050 each 10 t block ...

Page 41: ... 3B1 EPA CARB off road Power 450 kW 612 HP at 1800 rpm 80 1269 89 491 EEC including all modifications 405 kW 550 HP at 1800 rpm 80 1269 89 491 EEC including all modifications Fuel tank 1 x approx 410 l 108 gal and 1 x approx 355 l 94 gal DEF tank1 approx 40 l 10 6 gal 1 Additional equipment Drive 12 x 8 x 12 1 axle line Steered and driven axle line 2 axle line Steered and driven axle line 3 axle l...

Page 42: ...riving speeds At an engine speed of 1800 rpm Climbing ability Transport weight 72 t 158 760 lbs 1 Additional equipment 385 95 R252 10 bar 145 psi 445 95 R25 9 bar 131 psi 525 80 R25 7 bar 102 psi 2 Michelin X Crane 9 bar 131 psi Alternator 28 V 100 A Batteries 2 each of 12 V 170 Ah Voltage 24 V Front towing coupling 100 kN 22 480 lbf permissible tension1 Rear towing lug 75 kN 16 860 lbf permissibl...

Page 43: ...98 x 8 50 1 00 m 26 1 x 27 9 3 3 ft Outrigger pads Diameter 700 mm 27 6 in Surface 3848 cm2 596 in2 Stroke of support cylinders 550 mm 21 7 in Maximum outrigger pressure Outrigger span 8 70 x 8 50 m 28 5 x 27 9 ft front 106 t 233 700 lbs rear 32 t 209 050 lbs Outrigger span 8 70 x 2 71 to 7 40 m 28 5 x 8 9 to 24 3 ft front 106 t 233 700 lbs rear 135 t 297 650 lbs Inclination indicator On the hand ...

Page 44: ...rview 1 5 Technical data 1 16 3 112 993 en Operating manual GMK 6400 12 07 2013 Turning radii All dimensions in the illustration are in mm R values for normal steering mode Ra values for all wheel steering ...

Page 45: ...unit group M 3 in accordance with ISO 4301 2 Load spectrum L 1 Factor of the load spectrum Km 0 125 Theoretical service life D 3 200 h Drum diameter 502 mm 19 76 in rope centre to rope centre Rope diameter 24 mm 0 95 in Rope length 690 m 2 263 8 ft Rope pull 104 kN line 23 380 lbf Power unit group M 3 in accordance with ISO 4301 2 Load spectrum L 1 Factor of the load spectrum Km 0 125 Theoretical ...

Page 46: ...ingle level telescoping cylinder with locking unlocking mechanism Power unit group Telescoping mechanism M 1 in accordance with ISO 4301 2 1 Additional equipment Main hoist Rope speed when lifting and lowering Normal speed maximum 63 m min 207 ft min High speed mode maximum 126 m min 413 ft min Auxiliary hoist Rope speed when lifting and lowering Normal speed maximum 63 m min 207 ft min High speed...

Page 47: ...he truck crane is supplied with additional equipment which is not described in the operating instructions 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...

Page 48: ...s For procurement of spare parts Information about the position and quan tity 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 2 You can also send questions in either German or English directly to E mail whv techpublications manitowoc com In case of re...

Page 49: ...tailed explanation 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 instruc tions 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 regardl...

Page 50: ... end of 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 indicates that you are working with substances which pose a risk to the envir...

Page 51: ... 10 to 14 describe procedures and are therefore struc tured relative to these operations For more extensive processes the description is given with checklists 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 deta...

Page 52: ...l 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 Des...

Page 53: ...n chapters 8 and 15 gives an alphabetic list of keywords and search terms with a reference to the relevant page in the operating instructions 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 systemati...

Page 54: ...he operating instructions 1 26 3 112 993 en Operating manual GMK 6400 12 07 2013 Cross references example The illustrations and texts in this section are only an example and may differ from the conditions on your truck crane ...

Page 55: ...contains a cross reference in the form 2 Parking brake à p 4 37 C Page 4 37 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 backwards The parking brake for the trailer...

Page 56: ...erations planning in order to guar antee safe smooth and efficient operation of the truck crane The operating instructions contain 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 permitted outrigger spans à p 12 32 the size of the outrigger pads à p...

Page 57: ...of measurement and vice versa Converting from in Multiply by mm in 0 03937 in mm 25 4 m ft 3 28084 ft m 0 30479 m2 ft2 10 76391 cm2 in2 0 155 cm3 in3 0 061 l gal US 0 264178 kg lbs 2 204622 lbs kg 0 45359 t lbs 2204 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 h or km ...

Page 58: ...Overview 1 8 Conversion table for US measuring units 1 30 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 59: ... designed for safe time saving operation of your 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 d...

Page 60: ...Overview 1 10 Identification 1 32 3 112 993 en Operating manual GMK 6400 12 07 2013 1 10 Identification ...

Page 61: ...rs on removable rigging parts e g counterweights lattice extension is described in the corresponding chap ters or in the relevant operating instructions provided 1 Serial number and crane type 2 The CE mark only with truck cranes that are delivered in member countries of the EU 3 The serial number of the driver s cab 4 The chassis number and crane type 5 The chassis number in front of the first ax...

Page 62: ...ode for completed state Only then does the truck crane receive a CE mark upon delivery If the truck crane is programmed otherwise on delivery no CE mark is given If this truck crane is later imported into an EC member state the importer is responsible for checking and confirming that the truck crane s rated capacity limiter programming and current rig ging mode correspond to guidelines specified i...

Page 63: ... instructions 2 1 Intended use 2 1 2 1 1 Improper use 2 2 2 2 Organisational measures 2 3 2 3 Qualifications of the staff 2 5 2 4 Safety instructions for driving the truck crane 2 6 2 5 Safety instructions for crane operation 2 6 2 6 Notes on transporting persons 2 8 ...

Page 64: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 65: ...he GMK 6400 truck crane may only be operated without the corresponding special equipment within the permitted temperature range à Technical data p 1 7 The GMK 6400 truck crane is designed solely for lifting loads which are within the permitted GMK 6400 lifting capacities The load must be slung as prescribed to a hook block which is positioned vertically over the load prior to lifting Intended use ...

Page 66: ...ut 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 overturning outrigger pressure higher than ...

Page 67: ...d All applicable requirements 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 hav...

Page 68: ...med 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 welding work You should therefore always consult Manitowoc Crane Care before any welding work Make sure that the prescribed intervals and the intervals specified in the operation and...

Page 69: ...e operating instructions You must be familiar with and have understood the accident prevention regulations You must fulfil all physical and mental requirements for truck crane oper ation e g perfect sight and hearing and the ability to react quickly Please also refer to the section in the Safety manual titled You as driver and crane operator Only experienced staff who are familiar with the valid a...

Page 70: ... all operating and control elements in the driver s cab before starting the engine After starting the engine take note of all the lights and control elements After driving secure the truck crane against unauthorized use 2 5 Safety instructions for crane operation Carefully select a safe site for the truck crane where you can work safely Walk around the truck crane and inspect it before beginning c...

Page 71: ... fall into the hoist rope diagonally 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 for the currently rigged counterweight before turning the superstructure Always level the truck crane before operating the crane Only use parts of equipment counterweight sections lattice extension that belong to yo...

Page 72: ...working Equipment for lifting persons To lift persons only use equipment for lifting persons that comply with the requirements specified in the standards and regulations applicable in the country in which you are working The equipment for lifting persons must be fastened and secured as pre scribed The prescribed personal protection equipment must be available and used safety harnesses etc Personne...

Page 73: ...ot exceed 50 during operation The number of reeved rope lines must be selected such that the load on the hoist rope does not exceed 50 of the rope pull At the same time the total weight of the lifted load must be considered consisting of the weights of the hook block the lifting gear and the equipment for lifting persons including the maximum payload When transporting persons the crane operator mu...

Page 74: ... can be set down and that persons transported can safely leave it even if there is a failure of the drive or crane control The hook that holds the lifting gear for the equipment for lifting persons must be fitted with a lockable latch that completely seals the hook opening The truck crane must be serviced as prescribed regularly inspected and repaired if required All safety stickers must be affixe...

Page 75: ...gger control units 3 29 3 1 14 Control unit of the rear outrigger box 3 30 3 2 Short description of the operating elements 3 31 3 2 1 Definition of direction information 3 31 3 2 2 General notes on the operating elements 3 32 3 2 3 General rules for buttons and symbols on the display 3 33 3 2 4 Engine 3 34 3 2 5 DEF system 3 37 3 2 6 Electrical system 3 39 3 2 8 Transmission 3 42 3 2 9 Reverse cam...

Page 76: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 77: ...ments 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 which are only available with additional equipment are designated accordingly These designations are made in this section only and are not repeated in the following sections Some figures show details from a different perspec...

Page 78: ...Operating elements for driving 3 1 Overview of the operating elements 3 2 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 1 On the outside of the truck crane ...

Page 79: ...11 Ladders à p 4 5 12 Outrigger control units1 Emergency stop switch Sockets for hand held control à p 3 29 à p 4 26 à p 3 28 13 Fuel tank Dual system fuel tank1 à p 4 8 à p 4 9 14 Connection for battery charger1 à p 7 11 15 Adjusting the mirrors à p 5 6 16 Battery master switch à p 4 12 17 Filler connection for the compressed air system Tyre inflator connection à p 7 6 à p 7 17 18 Warning plates ...

Page 80: ...Operating elements for driving 3 1 Overview of the operating elements 3 4 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 2 Driver s cab Overview ...

Page 81: ...3 11 Driver s seat à p 5 11 12 Behind driver s seat Warning triangle1 First aid kit1 Warning lamp1 13 To open lock door à p 3 63 14 Separate steering à p 3 52 15 Window winder à p 3 62 16 Adjusting the mirrors Mirror heating à p 5 6 à p 5 7 17 Adjusting the air vents à p 5 71 18 Tachograph or cover à p 3 15 19 Instrument panel à p 3 8 20 Radio cassette CD1 2 21 Heating Air conditioning system à p ...

Page 82: ... 1 Overview of the operating elements 3 6 3 112 993 en Operating manual GMK 6400 12 07 2013 Behind the cover In the rear of the driver s cab 1 Fuses à p 7 19 1 Spare key spare selector handle for battery master switch radio equipment ...

Page 83: ...ditioning system1 à p 3 26 3 Spotlights on the rear of the carrier1 à p 3 57 4 Outrigger lighting on off à p 3 57 5 Rotating beacon on off à p 3 57 6 Check dual tank à p 4 9 7 Switching the transmission retarder function on off à p 3 49 8 Overriding torque reduction1 à p 5 52 9 Battery heater on off1 2 à p 3 39 10 Hazard warning system on off à p 3 56 1 Additional equipment 2 à Separate operating ...

Page 84: ...Operating elements for driving 3 1 Overview of the operating elements 3 8 3 112 993 en Operating manual GMK 6400 12 07 2013 Middle ...

Page 85: ...icator lamp for trailer turn signal indicator1 à p 3 56 8 Parking light headlight indicator lamp à p 3 57 9 Indicator lamp for turn signal indicator à p 3 56 10 DEF level indicator lamp1 à p 3 37 11 Voltage monitoring warning à p 3 23 12 Additional brake indicator lamp à p 3 48 13 Hydraulic drive MegaDrive indicator lamp à p 3 44 14 Engine warning lamp à p 3 35 15 Engine malfunction à p 3 35 16 Fu...

Page 86: ...Operating elements for driving 3 1 Overview of the operating elements 3 10 3 112 993 en Operating manual GMK 6400 12 07 2013 Middle ...

Page 87: ...22 Steering malfunction à p 3 50 23 Steering warning lamp à p 3 51 24 Flame start system monitoring1 à p 3 35 25 Speedometer à p 3 60 26 Tachograph malfunction warning1 à p 5 16 27 Display driving mode à p 3 12 28 Tachometer à p 3 35 29 Coolant temperature display à p 4 22 30 Fuel level display à p 4 22 31 Keypad for driving display à p 3 12 32 Display supply pressure in brake circuits à p 3 48 1 ...

Page 88: ...mode display à p 5 27 5 Transmission error messages display à p 7 30 6 Torque reduction display override1 à p 5 52 7 Outside air temperature display à p 5 22 8 Day s kilometre counter à p 5 22 9 Date time display à p 5 22 10 Kilometre counter à p 5 22 11 Resetting the day s kilometre counter à p 5 22 12 Switching between km mi à p 5 22 13 Switching between degrees Celsius and Fahrenheit à p 5 22 1...

Page 89: ... steering wheel L 1 Horn headlight flasher headlight full beam Turn signal indicator wiper washing system à p 3 55 à p 3 55 2 Set idling speed Setting the Tempomat Setting the Temposet Engine retarder transmission retarder1 à p 3 34 à p 3 34 à p 3 34 à p 3 48 3 Ignition lock à p 3 34 4 Adjusting the steering column à p 5 13 1 Additional equipment ...

Page 90: ...erview of the operating elements 3 14 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 6 Transmission operating elements 1 Switch lever à p 3 45 2 Selecting the transmission mode Reverse camera on à p 3 42 à p 3 46 3 without function ...

Page 91: ...1 Display à p 5 19 2 Time correction à p 3 60 3 Time correction à p 3 60 4 Opening the drawer à p 5 17 5 Setting the time group driver 1 à p 5 18 6 Setting the time group driver 2 à p 5 18 7 Correction of time à p 3 60 8 Drawer à p 5 17 Setting the driving display time à p 5 22 9 Time correction à p 3 60 10 Time correction à p 3 60 1 Additional equipment ...

Page 92: ...Operating elements for driving 3 1 Overview of the operating elements 3 16 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 8 ECOS control unit p ...

Page 93: ...he buttons in the displayed menu correspond to the symbols next to or above the buttons à p 3 39 1 ECOS display Main menu overview Reverse camera display à p 3 41 à p 3 18 à p 3 46 2 Sensor for brightness1 à p 3 41 3 Error warning message à p 3 40 4 Buttons F1 to F14 à p 3 39 5 Sensor for brightness1 à p 3 41 6 Errors submenu Submenu overview à p 5 53 à p 3 25 7 Warning submenu Submenu overview à ...

Page 94: ...Operating elements for driving 3 1 Overview of the operating elements 3 18 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 9 ECOS display Main menu ...

Page 95: ... 47 7 Reverse camera on off à p 3 46 8 Hydraulic oil temperature display à p 3 23 9 Longitudinal differential locks display Longitudinal differential locks on off à p 3 47 à p 3 47 10 Hydraulic oil temperature display hydraulic drive à p 3 23 11 Settings submenu à p 3 22 12 DEF level display1 à p 3 23 13 Steering mode display à p 3 52 14 Separate steering crab travel mode on off à p 3 51 15 Separa...

Page 96: ...Operating elements for driving 3 1 Overview of the operating elements 3 20 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 10 ECOS display Submenus Level adjustment system submenu ...

Page 97: ...vel pre selection à p 3 58 4 Front level pre selection à p 3 58 5 Left level pre selection à p 3 58 6 Rear level pre selection à p 3 58 7 Right level pre selection à p 3 58 8 Setting the on road level à p 3 59 9 Vehicle level display à p 3 59 10 Suspension display Suspension on off à p 3 53 à p 3 53 11 Lowering raising the level à p 3 59 12 Lowering raising the level à p 3 59 13 Suspension operati...

Page 98: ...12 07 2013 Settings submenu 1 Setting the speed transmission mode DM and RM à p 5 34 2 Lamp test à p 4 13 3 Operating hours submenu à p 3 24 4 Display setting the brightness à p 4 15 5 Towing mode on off display à p 7 7 6 Switching towing mode on off à p 7 7 7 AMG diagnostics1 à p 3 61 1 For service personnel only ...

Page 99: ... Operating manual GMK 6400 3 112 993 en 3 23 12 07 2013 Submenu Checking s 1 Hydraulic oil temperature display à p 4 23 2 DEF supply display1 à p 4 23 3 Voltage monitoring display à p 4 23 4 Hydraulic drive temperature gauge axles 4 and 5 à p 4 23 1 Additional equipment ...

Page 100: ...xiliary hoist1 9 Slewing gear 10 Lattice extension1 2 11 ECOS carrier 12 Engine 1 Additional equipment 2 à Lattice extension operating instructions 1 Air intake inhibitor triggered 2 Voltage monitoring 3 Coolant level too low 4 Axle load or sideways tilt exceeded 5 Oil pressure too low 6 Hydraulic oil drive too hot 7 Replacing the hydraulic oil filter drive 1 8 Replacing the hydraulic oil filter d...

Page 101: ...ving 3 1 Overview of the operating elements Operating manual GMK 6400 3 112 993 en 3 25 12 07 2013 Error submenu 1 Displaying errors total errors à p 7 36 2 Next error à p 7 36 3 Previous error à p 7 36 4 Error display à p 7 37 ...

Page 102: ...3 26 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 11 Heating Air conditioning system Standard heating system 1 Setting the blower fresh air recirculated air à p 5 70 2 Air distribution à p 5 71 3 Setting the temperature à p 5 70 4 Air conditioning system à p 5 73 ...

Page 103: ... Auxiliary water heating system 1 Heating display à p 5 78 2 Setting the time and weekday à p 5 78 3 Saving the automatic heating start Switching the automatic heating start on and off à p 5 79 à p 5 80 4 Switching on the auxiliary heater Switching off the auxiliary heater à p 5 77 à p 5 78 5 Input à p 5 78 6 Input à p 5 78 ...

Page 104: ...carrier and sockets 1 to 3 on the superstruc ture for the hand held controls supplied The hand held controls contain the operating elements for the outrigger the inclination indicator for rigging work and for driving the power units in case of emergency Since these operating elements are required for crane operation they are described in Part 2 Crane operation à Hand held controls p 9 49 ...

Page 105: ...s for driving 3 1 Overview of the operating elements Operating manual GMK 6400 3 112 993 en 3 29 12 07 2013 3 1 13 Outrigger control units Contain operating elements for crane operation à Outrigger control units p 9 52 ...

Page 106: ...ts 3 30 3 112 993 en Operating manual GMK 6400 12 07 2013 3 1 14 Control unit of the rear outrigger box 1 Left auxiliary support control à p 3 54 2 Right auxiliary support control à p 3 54 3 Extending Retracting the pre selection à p 3 54 4 Locking pin control à p 3 54 ...

Page 107: ...ation always depends on whether the carrier or the super structure 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 to the front On the superstructure The main boom head is always at the front which means that s G Risk of accidents due to operati...

Page 108: ...gonal perpendicu lar or turned the following always applies 3 2 2 General notes on the operating elements Some switches have a lock button 1 The lock button is not mentioned again during operation The following applies to all switches with a lock but ton Down press 1 next to the symbol Up press 2 opposite the symbol Switching on First press the lock button then press the lower switch down To switc...

Page 109: ... 1 only indicates that the gear change has been completed Here you will also receive a report on the current gear change on an extra display 2 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 col ours If the i...

Page 110: ...t 15 km h 9 mph 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 daytime driving light on 3 Starting position à p 4 12 Lock unlock steering column à p 5 13 1 Up Increasing the idling speed 2 Down Reduces the idling speed 3 To the front Idling speed setting off à...

Page 111: ...function s Display engine speed in rpm à p 4 22 On Engine not ready to start is being warmed up Off Engine is ready to start à p 4 18 On Turn engine off as quickly as possible warning buzzer sounds warning message displayed à p 5 50 On Engine off ignition on or Engine on engine malfunction Off Engine on no malfunction à p 5 50 On Engine off ignition on or Engine on severe engine malfunction Off En...

Page 112: ...e operating elements 3 36 3 112 993 en Operating manual GMK 6400 12 07 2013 Superstructure ignition indicator lamp On Ignition in the crane cab on engine for driving cannot be started Off Ignition in the crane cab off engine for driving can be started à p 4 16 ...

Page 113: ... s cab Instrument panel DEF warning Torque reduction indicator lamp Torque reduction override button s Off Level sufficient On Reserve Flashing Empty à p 5 52 Off Torque reduction off On Torque reduction on Flashing Reduction in torque on the next time the engine is started à p 5 52 Press down 1 x Torque reduction overridden for 30 minutes after 30 minutes Press down again Torque reduction overrid...

Page 114: ...isplay driving mode Torque reduction display override The ignition is switched on or the engine is running ECOS display DEF supply monitoring submenu Off Torque reduction not overridden On Torque reduction overridden à p 5 52 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 ...

Page 115: ...System ECOS includes a control unit in the crane cab a control unit in the driver s cab and several control units ESX0 ESX1 ESX2 etc and I O circuit boards I O 0 I O 1 etc which are distributed on the superstructure and carrier Control unit This section contains the operating elements that are the same for all menus opened Buttons F1 to F14 The function of buttons F1 to F14 is shown on the symbol ...

Page 116: ...es The input mode is switched on Flashing New warning message or error has occurred On Error acknowledged but still present Off No warning message or error present à p 11 114 To open Press button 1 x submenu opens à p 11 114 To open Press button 1 x submenu opens à p 5 47 Press the button 1 x The opened submenu closes the menu from the next higher level is opened Input mode is deactivated Press th...

Page 117: ...menu appears after switching on the ignition Symbols which represent submenus are indi cated at the top left by a blue corner Submenus are opened by pressing the button next to or under the respective symbol Serial number program version display Warning display 1 Serial number 2 Current ECOS program version always state in the event of malfunc tions à p 7 35 1 Shows the symbol of a current warning...

Page 118: ...N Neutral position on No gear engaged Position D At a standstill Forward starting gear on For driving forwards Suitable gear on Clutch closes For driving in reverse Neutral position on Position DM At a standstill Hydraulic drive forwards on For driving forwards Transmission in neutral position clutch open For driving in reverse Neutral position on Position R At a standstill Reverse starting gear o...

Page 119: ... a standstill Hydraulic drive reverse on For driving in reverse Transmission in neutral posi tion clutch open For driving forwards Neutral position on 1 Neutral position switched on 2 Currently engaged gear forwards 1 to 6 e g 5 3 Currently engaged gear reverse 1st gear 4 Currently engaged gear reverse 2nd gear 5 Hydraulic drive forwards 6 Hydraulic drive reverse 1 Automatic operating mode 2 Manua...

Page 120: ...g manual GMK 6400 12 07 2013 Error messages display Hydraulic drive MegaDrive indicator lamp 1 Severe malfunction stop the truck crane 2 Other malfunction 3 Error messages entry Error messages à p 7 41 On Engine off ignition on or Engine on hydraulic drive malfunction Off Engine on no malfunction à p 5 51 ...

Page 121: ...tarting gear 1 gear Push to the rear 1 x Shift down starting gear 1 gear The truck crane is in motion Push forwards 1 x Shift up 1 gear Manual operating mode on Push to the rear 1 x Shift down 1 gear Manual operating mode on à p 5 31 The parking brake is engaged and neutral position is activated The brake pedal is activated To the front All current error codes are shown The brake pedal is not acti...

Page 122: ...e camera 1 or 2 The reverse camera displays the area behind the truck crane on the ECOS display in the driver s cab à Installing the reverse camera p 6 68 Switching on Automatically when reversing 1 Manually press button 2 The display 5 shows the area behind the truck crane Switching off Automatically when driving forwards or in neutral position 4 Manually press button 6 The display 3 shows the EC...

Page 123: ...pment the drive of the second axle line is switched on and off simultaneously The current status is shown using different symbols Switching on Press button 1 x dot 1 green maximum 20 km h 12 mph Switching off Press button 1 x dot 1 black Switching on Press button 1 x dot 1 green maximum 20 km h 12 mph Switching off Press button 1 x dot 1 black A Transverse differential locks display B Longitudinal...

Page 124: ...onal brake indicator lamp 1 Current supply pressure in brake circuit 1 2 Current supply pressure in brake circuit 2 3 Red supply pressure insufficient White supply pressure sufficient 4 On Supply pressure below approx 5 bar 73 psi Off Supply pressure above 5 5 bar 80 psi à p 5 9 0 To the front Engine retarder and transmission retarder off 1 To the rear Engine retarder 2 To the rear Engine retarder...

Page 125: ...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 Pull the lever down until it locks into place Press in ...

Page 126: ...alfunction à p 5 37 On Approx 10 km h 6 mph not reached or Steering malfunction stop and check for oil loss Off Emergency steering pump ready to function à p 5 37 On Engine off ignition on Display symbol 2 goes out after engine start Display symbol 3 ignition off on symbol goes out While driving Display symbol 1 5th and 6th axle still in straight run ning position forward drive possible Flashing A...

Page 127: ...7 Switching on Press button 1 x dot 1 green maximum 5 km h 3 mph Steering wheel steers 1st and 2nd axle lines 3rd to 6th axle line steer in the same direction Switching off Press button 1 x dot 1 black à p 5 66 Switching on Press button 1 x dot 1 green maximum 5 km h 3 mph Steering wheel steers 1st and 2nd axle lines 3rd to 6th axle lines steer for the smallest turning circle Switching off Press b...

Page 128: ... different symbols Driver s door Separate steering The separate steering is switched on Press button and hold 1 Separate steering driving around corners 2 Separate steering crab travel mode 3 Separate steering manual 4 Normal steering mode on road driving separate steering off à p 5 66 To the left 5th and 6th axle lines turn to the left To the right 5th and 7th axle lines turn to the right à p 5 6...

Page 129: ...ress button 1 x dot green Switching off Press button 1 x dot black à p 5 15 Green Suspension on enabled for on road driving Red Suspension off blocked for crane operation à p 5 15 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 Suspension pressure 3rd and 4th axle ...

Page 130: ...t auxiliary supports pre selection Extending retracting The movement stops after a button is released or when an end position is reached Press in to the left Locking pin pre selection à p 6 71 1 Press in at bottom Pre selection left auxiliary support 2 Press in at bottom Pre selection right auxiliary support à p 6 59 Press in to the left Extending the auxiliary support or locking pin Press in to t...

Page 131: ...ight flasher Upward The parking light headlight is switched on 3 Parking light headlight Middle position 4 Headlight full beam Down latches into place 5 Right turn signal indicator Forwards 6 Left turn signal indicator Backwards 7 Windscreen wiper washing system Press 7 Windscreen wiper Turn off 0 intermittent slow fast 7 Adjusting the wiper stroke interval Switch on intermittent Switch off after ...

Page 132: ...Flashing Turn signal indicator on Off Turn signal indicator off or turn signal indicator on and filament lamp defective Flashing Turn signal indicator on and trailer electrically con nected Flashes 1 x Turn signal indicator on and trailer not electrically con nected Off Turn signal indicator off Switching on Press downwards light in the switch flashes Switching off Press in above gone out 1 Light ...

Page 133: ... is switched on Rotating beacon on off Outrigger lighting on off Spotlights on rear of carrier on off s On Headlight on Off Headlight off 4 Fog light on 5 Fog tail light on 6 on Switching on Press down Switching off Press up Switching on Press down Switching off Press in at top position for driving on road Switching on Press down Switching off Press in at top position for driving on road ...

Page 134: ...ment system p 5 60 Level adjustment system submenu Overall level pre selection 7698 The following functions are operated in the same manner Front level pre selection Rear level pre selection Right level pre selection Left level pre selection 1 Permanently on 2 Permanently off 3 On off via door contact 1 On 2 Off To open Press button 1 x submenu opens Suspension struts pre selec tion Press button 1...

Page 135: ...vel display The current status is shown using different symbols Setting the on road level Display of current inclination s 1 To lower Press button suspension struts retract 2 To lift Press button suspension struts extend à p 5 62 1 Green on road level 2 White no on road driving level 3 Yellow level change 4 Violet error à p 5 60 To set the on road level Press the button until the symbol 1 is green...

Page 136: ...e the current measuring range 1 or 5 is shown à p 5 62 1 Open the time menu Press the button the time correction menu opens 2 Time correction Press the button the time 4 is increased 3 Time correction Press the button the time 4 is decreased 1 Indicates the speed in km h 2 Indicates the speed in mph 1 Press the button the time is increased 2 Press the button the time is decreased Setting the hours...

Page 137: ...may only be operated by service staff from the engine and transmission manufacturer or by Manitowoc Crane Care Displays submenu Settings submenu 1 AMG diagnostics OK STOP or the service symbol spanner is displayed depending on the severity of the error 2 Diagnostics submenu If there is a malfunction press button 2 1 x read the values in the submenu and report to Manitowoc Crane Care ...

Page 138: ...d 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 T...

Page 139: ...rom outside with the handle 2 pressed in 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 3 Unlocking Turn the key towards A or Pull the handle 3 Opening Pull the handle 1 or Pull the handle 2 Keys Different keys are supplied 1 Door locks ignition lock of driver s cab 2 Control unit outrigger1 3 Fuel tank1 2 4...

Page 140: ...00 12 07 2013 3 2 20 Front flap Opening Move the front flap 1 up as far as it will go holding it by the lower edge The front flap is held in the open position Closing Fold the front flap 1 down holding it by the upper edge Press the front flap against the driver s cab on both sides until you can hear it latch into place ...

Page 141: ... the engine 4 11 4 1 6 Switch on the ignition 4 12 4 1 7 Lamp test equalisation of the switching states 4 13 4 1 8 Display setting the brightness 4 15 4 1 9 Start the engine 4 16 4 1 10 Inspections after starting the engine 4 19 4 1 11 Monitoring elements 4 22 4 1 12 Monitoring submenu 4 23 4 1 13 Setting the idling speed 4 24 4 2 Turning off the engine 4 25 4 2 1 On the ignition lock with hand he...

Page 142: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 143: ...ne using the hand held control or from the crane cab à Starting the engine for driving for rigging work p 12 23 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 there 1 Check that the valves on the hydraulic tank are ope...

Page 144: ...bridging plugs are inserted in the sockets for hand held control à p 10 4 All emergency stop switches have been reset à p 4 26 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 12 9 If necessary set the brightness on the ECOS display à p 4 15 of the instrument lighting...

Page 145: ...bles level à Refuelling p 4 8 à DEF p 4 10 11 Shift the transmission to the neutral position à p 5 24 12 If the truck crane has a flame start system wait until the lamp goes out à p 4 18 13 Start the engine à p 4 16 14 Conduct the necessary checks after starting the engine à p 4 19 15 In the event of low outside temperatures à CHECKLIST At low tem peratures p 4 4 ...

Page 146: ... use in the outside tempera ture in question à Separate engine manufacturer s operating manual 2 The engine coolant must contain sufficient antifreeze à Separate engine manufacturer s operating manual 3 The windscreen washing system must contain sufficient antifreeze à Maintenance manual 4 1 3 Ladders and access ladders Access ladders The access ladders are firmly attached There are two access lad...

Page 147: ...adder 1 outwards and fold it down Secure this with the spring latch 2 If necessary you can pull out an additional stair 5 from the ladder Unlock the spring latch 4 and pull out the step 5 Folding in Unlock the spring latch 4 and slide in the step 5 Unlock the spring latch 2 and pivot the ladder 3 out of the carrier Secure this with the spring latch 1 s G Risk posed by ladders falling down Always s...

Page 148: ...the engine from the driver s cab 4 6 3 112 993 en Operating manual GMK 6400 12 07 2013 A folding ladder is also mounted on the carrier You can fold out the ladder 1 While driving Push the ladder 1 into the holders 3 and 4 and secure it with the spring latch 2 ...

Page 149: ...Starting turning off the engine for driving 4 1 Starting the engine from the driver s cab Operating manual GMK 6400 3 112 993 en 4 7 12 07 2013 Blank page ...

Page 150: ... suf ficient space for the fuel to be able to expand H Also fill the tank for the crane operator s cab heating system à Fuel tank auxiliary heater p 11 5 G Danger of fire due to inflammable gases Switch off the engine the heater and all additional heaters before refuel ling G Risk of accidents if the tank is not closed Close the tank each time you have refilled it In this way you can prevent other...

Page 151: ...tank 1 is filled with the fuel for driv ing The fuel tank 2 is filled with the fuel for crane operation Open the filler neck to refuel Refill the appropriate fuel in due time and close the tanks 1 and 2 with the cap Leave sufficient space for the fuel to be able to expand Switching over the fuel supply When fitted with the dual tank system the fuel supply is automatically switched over when you st...

Page 152: ...n override this torque reduction à Overriding torque reduction p 5 52 H In order to comply with exhaust emission regulations the truck crane may only be driven with DEF Driving with an empty DEF tank will invalidate the truck crane s licence for use on public roads 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 G Risk of injury from ammonia ...

Page 153: ... 1 5 Inspections before starting the engine On the hydraulic tank Before you start the engine all valves on the hydraulic tank must be open Check whether the valves are open lever 1 parallel to the line Open the closed valves s S Risk of damage to the hydraulic pumps You may only start the engine when all the valves on the hydraulic tank are open ...

Page 154: ...ff the selector handle 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 3 28 4 1 6 Switch on the ignition H The ignition can only be switched on if the bridging plugs have been inserted in all sockets for hand held control à Sockets for hand held control p 3 28 Insert the ignitio...

Page 155: ...ghts up continu ously Check that the lamps go on for about two seconds after switching on the ignition 1 Contact Manitowoc Crane Care if one or more lamps do not light up If you could not check all the lamps in the specified time you can conduct the lamp test again as follows s S Risk of accidents due to faulty lamps The lamps that are used to provide warnings and information during oper ation lig...

Page 156: ...ess of the display à p 4 15 Equalisation of the switching states When the ignition is switched on the switching states of the differential locks and the separate steering are compared The state last saved is retrieved In the main menu the corresponding symbols 1 are shown and the electronics system trig gers the switching operations The displays 2 and 3 show the current switching states If the dis...

Page 157: ...ns Press the button 3 once A red bar 2 appears below the display 1 Set the required minimum brightness with the switch 4 The brightness of the display changes during the setting procedure and you can view the set value 0 to 100 on the display 1 The degree of brightness which you set here is the minimum value for automatic regulation H There is no automatic regulation if you set 100 The displays al...

Page 158: ... instructions provided by the engine manu facturer for the operation of 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 3 28 The lamp 1 has gone out superstructure ignition off Check that the vehicle parking brake is locked If the brake is engaged the parking brake lever will point dow...

Page 159: ...o position 3 and hold it there until the engine starts Let go of the ignition key after the engine starts If the engine does not start abort the starting procedure after about 15 sec onds and wait one minute before trying again H If the engine does not start after several attempts à Malfunctions in the engine p 7 27 s S Danger of explosion when using starter fuel The engine may never be started wi...

Page 160: ...t 30 seconds otherwise you must switch on the ignition again and wait until the lamp goes out H If the lamp 1 does not go out there is a malfunction on the flame start sys tem à Malfunctions in the engine p 7 27 Wait until the lamp 1 goes out Do not press the accelerator Turn the ignition key to position 3 and hold it there until the engine starts Let go of the ignition key after the engine starts...

Page 161: ...main menu check the displays 1 and 2 Display 1 when the symbol is red à Right after starting p 5 37 Display 2 when a warning message is shown à Warning or malfunction mes sages on the instrument panel p 5 50 s S Risk of damage to the engine If symbol 1 lights up or the STOP lamp comes on and the warning buzzer sounds switch the engine off immediately The engine can be damaged by running it when th...

Page 162: ... main menu shows a symbol If the lamp 1 flashes The steering angle of the 5th and 6th axle line does not relate correctly to the 1st to 2nd axle line Steer using the steering wheel the steering angle is automatically off set and the lamp 1 goes out With the sym bol 2 The oil supply for the steering is still being built up If the symbol has not yet gone out contact Manitowoc Crane Care With the sym...

Page 163: ...ay not under any circumstances drive the truck crane Contact Manitowoc Crane Care and arrange for the error to be rectified S Risk of accidents due to the fact that the truck crane cannot be steered Under no circumstances should you drive the truck crane when the red lamp 1 is lit The truck crane can no longer be steered safely The 5th and 6th axle can steer in an uncontrolled manner which may lea...

Page 164: ...If the fuel tank is almost empty air can be sucked in and the fuel system must be bled à Maintenance manual DEF level display Coolant temperature display 1 Green Economic consumption 2 Yellow Engine brake active 3 Red Engine speed too high danger à Checks when driving downhill p 5 43 4 Lights up Engine speed is too high On DEF fuel almost empty Flashing DEF tank empty à p 4 10 1 White Coolant temp...

Page 165: ...ssary open the main menu ö and press the button 1 once The Monitoring submenu opens The following values are displayed The colour of the bar below the values indi cates in which area the value can be found 1 The hydraulic oil temperature in C F 2 DEF supply in per cent 3 Voltage in Volts 4 Oil temperature hydraulic drive axle line 4 and 5 in C F Green Value O K Yellow Limit value almost reached Re...

Page 166: ... the idling speed manually using the multipurpose switch H You can only set the idling speed when the truck crane is stationary Increasing reducing the idling speed Press the switch 2 up down until the required engine speed 1 has been reached or Press the switch 2 upwards downwards once The engine speed 1 is increased reduced by 20 rpm Switching off the idling speed change Push the switch forwards...

Page 167: ...on key to position 0 the engine will stop If the hand held control is connected Press the button 1 the engine goes off In this case it is not possible to switch off the engine with the ignition lock On the outrigger control units if the hand held control is not connected Press the button 1 the engine goes off After parking If you want to park the truck crane à p 5 53 G Risk of accidents due to the...

Page 168: ...bitor is present it is triggered H Do not operate the emergency stop switch to turn off the engine in normal operation Only operate the emergency stop switch in an emergency situa tion Resetting the emergency stop switch You can only restart the engine after you have reset the emergency stop switch Switch off the ignition Turn the actuated emergency stop switch until it disengages again If an air ...

Page 169: ... red at the Warning display and in the Warning submenu The symbol stays red until the ignition has been turned off The engine can only be restarted 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 is switched off The emergency stop switch is reset The indicator 2 show...

Page 170: ...Starting turning off the engine for driving 4 3 Air intake inhibitor 4 28 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 171: ...30 5 2 7 Changing the driving direction 5 32 5 2 8 Stopping 5 32 5 2 9 DM and RM transmission mode 5 33 5 2 10 On the roller type dynamometer 5 36 5 2 11 Preheating transmission 5 36 5 3 Driving and turning off the truck crane 5 37 5 3 1 Checks while driving 5 37 5 3 2 Cruise control 5 40 5 3 3 Cruise control 5 41 5 3 4 Driving downhill 5 42 5 3 5 Driving uphill 5 46 5 3 6 Warning submenu 5 47 5 3...

Page 172: ...3 112 993 en Operating manual GMK 6400 12 07 2013 5 6 1 Standard heating system 5 70 5 6 2 Air conditioning system 5 73 5 6 3 Auxiliary water heater 5 75 5 7 Towing a trailer 5 82 ...

Page 173: ...is on the boom rest All telescopic sections are interlocked the telescoping cylinder is locked with telescopic section I The slewing gear is switched off à p 11 103 The symbol 1 is displayed if present à p 5 8 2 When the main boom is resting on a trailer All telescopic sections are locked The slewing gear is switched off à p 11 103 The boom floating position is switched on à p 6 8 The slewing gear...

Page 174: ...d downwards if present à p 11 109 The lighting on the outrigger is switched off à p 3 57 5 Anemometer air traffic control light and camera on the main boom are dismantled à Anemometer and air traffic control light p 12 132 à Camera on main boom p 12 137 6 All ladders are secured à Ladders p 4 5 7 Check the tyres Tyre pressure when tyres are cold in on road mode à p 1 14 Other checks à Maintenance ...

Page 175: ... The detachable equipment parts are stripped down so that they fulfil the regulations of the country in which you are working as regards per missible 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 12 The fold up berth is folded up and secured à p 5 56 13 All additional parts which may be transported are secured ...

Page 176: ...witch on ignition à p 4 12 16 Adjust the driver s seat à p 5 11 17 Adjust the steering column à p 5 13 18 Adjust the mirrors à p 5 6 19 Set the tachograph insert the diagram sheet à p 5 16 20 Start the engine and carry out all inspections à Inspections after start ing the engine p 4 19 ...

Page 177: ...tching states for on road driving are set and that the corresponding symbols are shown Suspension switched on à p 5 15 Central and transverse differential locks switched off à p 5 58 Separate steering switched off the symbol for on road driving is shown à p 5 69 On road level is set à p 5 61 The retarder function should be switched on or off depending on the condition of the road à p 5 44 Establis...

Page 178: ...paired Parking light headlight rotating beacons fog tail light side marker lights Hazard warning system Brake lights Reversing lamp buzzer Full beam headlight Turn signal indicators 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 electricall...

Page 179: ...justment Turn the button to position Press the button 5 the mirror moves Mirror heating s A Neutral position B Mirror on the driver s side C Mirror on the passenger side 1 Up 2 Right 3 Down 4 Left 1 Switching on Press button once lamp 3 turns on 2 Switching off Press button once lamp 3 turns off ...

Page 180: ... with the spring latch 2 Displaying vehicle height The vehicle height given at on road driving level is only maintained when the main boom is resting in the boom rest à p 1 8 Open the main menu ö When the display 1 is present the position of the main boom in the boom rest is monitored Check that the 1 symbol is shown When the 2 symbol is shown derrick the main boom out until the 1 symbol appears S...

Page 181: ...brake is applied Allow the engine to keep running The supply pressure builds up and you can speed up this process by pressing the accelerator Light 1 turns off once the supply pressure reaches approx 5 5 bar 80 psi Build the supply pressure until Approx 8 bar 116 psi is reached A valve audibly releases pressure There is now sufficient supply pressure s G Risk of accident by truck crane moving unin...

Page 182: ... brake Release the parking brake The parking brake is released and the 1 light turns off when the supply pressure is sufficient G Risk of accident by truck crane moving unintentionally Always apply the service brake before releasing the parking brake This prevents the truck crane from rolling in an uncontrolled manner when the parking brake is released ...

Page 183: ...he driver s seat is off not pressed in Sufficient air pressure is available in the secondary consumer circuit You may have to build supply pressure à p 5 9 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 Seat heating on off1 2 Back rest angle 3 Seat longitudinal adjustment 4 Seat height 5 Adju...

Page 184: ...13 Settings for body shape Passenger s seat The passenger s seat is adjusted mechanically 1 Lumbar area support 2 Seat cushion longitudinal adjustment 3 Seat cushion angle 1 Back rest angle 2 Seat longitudinal adjustment 3 Seat cushion longitudinal adjustment 4 Seat cushion angle ...

Page 185: ...lding supply pressure p 5 9 Press the 1 button down once The steering column is unlocked for approx 6 seconds Bring the steering column into the desired position Press the 1 button up once Or wait until the steering column is locked automatically after about 6 seconds G Risk of accident by unlocked steering column Always stop the truck crane before you unlock the steering column You can no longer ...

Page 186: ...itch the suspension on and off you must open the Level Adjustment System submenu Opening the submenu You can only open the submenu when the truck crane is stationary or when the current speed is below approx 5 km h 3 mph If necessary open the main menu ö and press the 1 button once This opens the Level Adjustment System submenu The 1 dot indicates the selected switching state Symbol is green The s...

Page 187: ...inders are locked when the suspension is switched off This state is only intended for crane operation Press the 2 button once dot is black When the suspension is switched off the 1 symbol is red G Danger of overturning when switching on the suspension Only switch on the suspension when the truck crane has been rigged for on road driving and the main boom has been set down Were the rigged truck cra...

Page 188: ... detailed information marking the diagram sheets mal functions etc Requirements 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 If malfunction occurs Check that a malfunction has occurred If there is a malfunction in the tachograph 1 the lamp 2 on the tachometer lights up If a malfunction has occur...

Page 189: ... as it will go The diagram sheet mounting 2 and an isolating plate 1 are in the drawer Checking the time setting First check the time setting for the the dia gram 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 Correc...

Page 190: ...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 bracket 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 ele...

Page 191: ...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 time groups Set the time group for driver 1 using the but ton 1 The set time group is shown with the symbol 1 1 Set the time group for driver 2 using the but ton 2 The set time group is shown with the symbol 2 1 s ...

Page 192: ...and 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 rest times These times are prescribed by law and must be observed H If the drivers swap during two driver operation the diagram sheets in...

Page 193: ...sary open the main menu ö and press the 1 button once This opens the Settings submenu Press the 1 button once The Operating hours submenu opens When driving the ECOS operating hours 1 for the carrier and the engine 2 are recorded The value 3 indicates the hours e g 1680 hours The value 4 indicates the minutes e g 12 minutes The other displays relate to crane operation à Displaying the operating ho...

Page 194: ...ght or parking light is switched on Outside air temperature display Tempomat display 1 Daily kilometre counter position after the decimal point 1 100 m 33 ft 2 Overall route in kilometres 3 Reset daily kilometre counter 4 Switch between km mi 1 Time date 2 Select the day month year hours minutes 3 Increase the selected unit 4 Reduce the selected unit 1 Instrument lighting dimmer 2 Instrument light...

Page 195: ...sion is in neutral position N if the ignition is switched off Shift to position N If you switch on the ignition in positions D or R malfunctions may occur Switch the ignition on The electronic gear system is switched on and a warning buzzer sounds for several seconds The electronic gear system conducts a check CH entry When the check is completed the entry N appears If the electronic gear system d...

Page 196: ...If you switch 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 when trying to avoid an obstacle for example and the engine retarder will have no effect G Risk of accident from rolling truck crane Always apply the parking brake or the service brake before you switch to the neutral position This...

Page 197: ...cate AL airless If necessary wait until the supply pressure has built up and the AL entry goes out à Building supply pressure p 5 9 Release the accelerator In order to Drive forward shift to position D Drive backward shift to position R An acoustic signal sounds if addi tional equipment is present The operating mode Automatic is now selected An appropriate starting gear is selected and displayed F...

Page 198: ...ange the automatically engaged starting gear H Only change the starting gear if it is absolutely necessary to do so Starting gears which are too high cause premature clutch wear Press the switch lever forwards once The starting gear is upshifted by one gear Pull the switch lever backwards once The starting gear is shifted back by one gear The altered starting gear is shown on the display By changi...

Page 199: ...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 con ditions changing on short notice You can change over either with a gear change or without a gear change Changing without gear change Pr...

Page 200: ...led down and CL is no longer shown on the display Select a lower starting gear Start to move again H If you do not release the accelerator the gear is engaged automatically within a few seconds This can cause the engine to be throttled or the wheels to spin Exception Gears 1 and R are not engaged automatically Be careful not to allow the clutch to overheat G Danger by unexpected rolling Also apply...

Page 201: ...3 H In manoeuvring mode the truck crane responds more sensitively to the accelerator The gear positions DM and RM are provided for manoeuvring à DM and RM transmission mode p 5 33 If a transmission malfunction is detected the corresponding entries 1 2 or 3 are displayed à Error messages p 7 41 ...

Page 202: ...kick down the transmission first shifts to a lower gear After that it will shift to a higher gear once a higher engine speed has been reached in order to attain maximum accel eration If you execute a manual gear change using the transmission lever you simultaneously switch to Manual operating mode The transmission will only perform an automatic shift after you have switched to Automatic operating ...

Page 203: ...ever backwards briefly The newly selected gear will be shown in the display H If you initiate a gear change in which the maximum permitted speed would be exceeded the transmission does not shift In that case slow the truck crane down until a maximum permissible engine speed is reached and downshift again Upshifting one gear Push forwards once Upshifting two gears Briefly push forwards twice Upshif...

Page 204: ...e display H The transmission switches to neutral position if you switch between the positions D and R directly when the truck crane is moving or you are driving it 5 2 8 Stopping In order to stop remove your foot from the accelerator and press the brake pedal The transmission decouples shortly before the vehicle comes to a halt The current gear remains engaged Stopping for long periods If you stop...

Page 205: ...e transmission modes only the 4th and 5th axles are hydraulically driven You can restrict the maximum speed Switching on Stop the truck crane and release the accelerator Wait until the engine runs at idle speed Shift into DM or RM position for the required direction of travel The appropriate transmission mode is selected and appears on the display In the transmission modes DM and RM The transmissi...

Page 206: ...corresponding starting gear will be engaged If the truck crane is still moving a gear appropriate to the speed will be engaged The newly selected gear will be shown in the display The transmission mode DM or RM is switched off and The transmission shifts automatically Manual gear change is possible Limiting maximum speed For especially sensitive manoeuvring you can restrict the top speed in the DM...

Page 207: ...uired top speed with the switch 4 While making the setting you can read the value setting from the display 1 0 to 100 The speed setting is only reached when you press the accelerator down fully You can cancel the entry at any time using the 1 button The settings are then reset Apply the top speed entered press the button 2 once The red bar below the display disappears ...

Page 208: ...ture 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 unexpectedly 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 a...

Page 209: ...axle lines the turning radius increases accordingly Have the error resolved as soon as possible The lamp 1 lights up when a severe error is detected in the steering sys tem the symbol 2 is shown The 5th and 6th axle lines can longer be steered in a controlled manner Stop the vehicle as soon as possible Briefly turn off the ignition and then on again If the lamp is still lit contact Manitowoc Crane...

Page 210: ...e à Steering malfunctions p 7 32 The lamp 1 lights up when a severe malfunction is detected in the hydraulic drive MegaDrive If oil has leaked out Warn any vehicles on the road behind you Do not continue driving Refer to Manitowoc Crane Care à Malfunctions in the hydraulic drive MegaDrive p 7 30 S Risk of accident from unsteerable truck crane Stop as quickly as possible when the red lamp lights up...

Page 211: ...n the ECOS display shows a warning message 1 à Warning sub menu p 5 47 Also note the control elements for fuel supply and if necessary DEF supply engine speed coolant temperature transmission and hydraulic oil temperature à p 4 22 S Risk of damage if warning messages are not observed After a warning message appears on the ECOS display or combination instrument display always promptly observe all i...

Page 212: ...ed this speed with the accelerator After the accelerator is released cruise control goes back down to the set speed H On downhill slopes the speed set may be exceeded since cruise control does not brake the truck crane Switch cruise control off on downhill slopes Increasing reducing the speed Press the switch up down until the required speed has been reached or Push the switch upwards downwards on...

Page 213: ...n is switched on When the ignition is switched off 5 3 3 Cruise control You can use cruise control to limit the maximum speed Switching on You can only switch on cruise control at speeds of over 15 km h 9 mph Press the 1 button once Cruise control is switched on The current speed is regarded as the maxi mum speed You can exceed the speed by pressing the accelerator as far down as it will go kick d...

Page 214: ... you must do the following Shift into R position Apply the parking brake Press the accelerator Release the parking brake after coupling If the CL warning appears when starting Remove your foot from the accelerator immediately and actuate the service brake For the subsequent procedure à Warning when starting p 5 28 G Risk of accident when driving in neutral position Never switch into neutral positi...

Page 215: ... 5 44 Downshifting To increase the braking force of the engine you can select a lower gear Pull the switch lever backwards once The Manual operating mode is switched on and if possible one gear is shifted down If you initiate a gear change in which the maximum permitted speed would be exceeded the transmission does not shift In that case slow the truck crane down until a maximum permissible engine...

Page 216: ...e braking power Deactivate the retarder function e g in icy conditions Press switch 1 below down the light inside the switch lights up Re activate the retarder function when conditions improve again Press the switch 1 above the light in the switch goes out G Risk of accident from unexpected acceleration Maintain sufficient distance when the engine retarder is switched on The effectiveness of the e...

Page 217: ...ulate 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 forwards to level 5 0 The lamp 1 illuminates when the retarder is switched on 5 1 Only engine retarder Connection to the retarder power 5 2 50 power engine retarder 5 3 75 power engine retarder...

Page 218: ...moving backward you must do the following Shift into R position 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 The transmission can switch between two gears for certain gradients In that case either release the accelerator slightly or downshift by one gear G Danger of the truck crane s...

Page 219: ...l for the pending warning message For more information Press button 4 once the Warning sub menu opens The warning message has been acknow ledged the lamp 3 lights up no longer flashes Meaning of the symbols The colour of the symbols indicates whether a warning message is active in the corresponding area Symbol is grey no warning message Symbol is red warning message Perform the following checks a ...

Page 220: ...ed 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 27 Voltage monitoring The voltage in the carrier electrical system is too high or too low Current voltage display à p 4 22 S Danger of overheating There is a fault if the hydraulic oil temperature exceeds 80 C 176 F Stop the truck cran...

Page 221: ...uts and the lateral tilt à Warnings while driving p 13 9 Hydraulic oil drive for axles 4 and 5 too hot The hydraulic oil is hotter than 80 C 176 F Current temperature display à p 4 22 Possible cause and solution à p 7 33 Exiting the submenu You can exit the submenu at any time Press the 1 button once The same menu opens which was open before the Warning submenu opened If the same warning messages ...

Page 222: ...isplayed in red STOP warning When the STOP lamp lights up further messages are displayed on the instrument panel Switch off the engine as soon as possible à Malfunctions in the engine p 7 27 CAN BUS system interrupted If the lamp continues to light up switch off the ignition and switch it back on after 15 seconds notify Manitowoc Crane Care Battery charge indicator warning The voltage in the carri...

Page 223: ...oiled à Maintenance manual Replace the air filter The air filter is soiled à Maintenance manual Malfunction in steering circuit 1 or 2 The 5th and 6th axles were centred and can no longer be moved à Steering malfunctions p 7 32 Steering circuit 1 or 2 warning The 5th and 6th axles were not centred and can no longer be moved à Steering malfunctions p 7 32 Malfunction in the hydraulic drive MegaDriv...

Page 224: ...he DEF supply drops to the reserve level the lamp 1 lights up If the DEF supply is used up the lights 1 and 2 will light up If lamp 1 flashes the engine torque is reduced the next time the engine is started The engine torque is reduced Press button 1 down to override torque reduction You can override torque reduction up to 3 times The 1 symbol is displayed Refill with DEF immediately à DEF p 4 10 ...

Page 225: ...found on the Warning submenu à Malfunctions on the ECOS carrier p 7 35 5 3 10 Turning off the truck crane To turn off the truck crane you must Securing against rolling away The number of wheel chocks supplied varies according to country s 1 Stop the truck crane 2 Apply the parking brake 3 Switch to neutral position à p 5 24 4 Turn off the engine à p 4 25 G Risk of accident by truck crane moving un...

Page 226: ... folds out by spring force B Folding up Press the chock together until the locking bar 4 engages in the bore 5 Using additional equipment other chocks can be transported on the rear of the truck crane When stationary for more than 8 hours Switch off all current consumers e g auxiliary heaters Switch off the engine H In order to prevent malfunctions you should only switch off the battery master swi...

Page 227: ...d 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 unauthorised use Always stow away the hand held control in the crane cab or in the driver s cab before leaving the truck crane and lock the doors This prevents unauthorised persons from starting the engine with the hand held contro...

Page 228: ...the retainer 4 and fold it downwards Fasten both belts 3 in the retainers 2 Folding up Release the belts 3 from the retainers 2 and place them on the berth Fold up the berth 1 and fasten it in the retainer 4 Put up the back rests of the seats and fasten the neck rests Bring the seats and the steering column into the desired position à Driver s seat p 5 11 à Passenger s seat p 5 12 à Adjusting the ...

Page 229: ... à p 5 25 Select the Manual operating mode This way you will be able to drive care fully and promptly shift gears à Changing the operating mode p 5 27 Connections If the adjustments to the transmission are insufficient on their own you can additionally connect the following one after the other Then switch on the central differential locks à p 5 58 Then switch on the transverse differential locks à...

Page 230: ...pen the main menu if necessary 1 For switching on and off the current speed needs to be under about 5 km h 3 mph Switching on Press button 1 once for Central differential locks A Transverse differential locks B The dot turns green Start moving slowly Display The symbol 3 first turns yellow Then symbol 2 turns red differential locks on If the error symbol is displayed contact Manitowoc Crane Care S...

Page 231: ...07 2013 Switching off Press button 1 once for Central differential locks A Transverse differential locks B The dot turns black Display The symbol 3 first turns yellow Then symbol 2 turns green differential locks off If symbol 2 is not displayed then drive back and forth slowly ...

Page 232: ...bmenu when the current speed is below approx 5 km h 3 mph If necessary open the main menu ö and press the 1 button once This opens the Level adjustment system submenu Check that the symbol 1 is green suspension on If the symbol 1 is red press the button 2 once to switch on the suspen sion When the suspension has been switched on you can Set the on road driving level Pre select the suspension strut...

Page 233: ...lecting suspension struts You can pre select the suspension struts for five different level changes For a uniform level change For inclination Press the button next to the required symbol once the dot turns green e g for symbol 1 The corresponding suspension struts remain pre selected for approx 5 seconds During this time the symbols 1 and 2 are black and the corresponding buttons are active s 1 O...

Page 234: ... is reached During the entire procedure the symbol for the current state is shown e g after the truck crane is inclined the symbol 1 No on road level is shown Viewing the current inclination The inclination indicator shows the current alignment Switch between measuring ranges You can change the measuring range between 1 and 5 Press the 1 button once The current measuring range is displayed G Risk ...

Page 235: ...he assignment to the carrier is given by the directional indicator 2 B In this example the carrier would be standing higher to the rear on the right hand side Exiting the submenu You can exit the Level adjustment system submenu at any time Press the 1 button once Press the 1 button once The main menu opens The Level adjustment system submenu automatically closes as soon as the current speed rises ...

Page 236: ... position D or R Select a smaller starting gear with the switch lever Start driving as far as you can as high as possible Release the accelerator The gears disengage Let the truck crane roll in the opposite direction as far as it will go Start driving again as far as possible Repeat driving and letting the truck crane roll back until it has rocked itself free H It is not helpful to switch between ...

Page 237: ... the rear chassis wall using a shackle on a towing eye The towing eyes on the vehicle tail or the ROB are designed for a maximum tensile force of 75 kN approx 7 5 t 16 860 lbf approx 16 530 lbs when The direction of pull runs along the level of the longitudinal axis The direction of pull runs along the longitudinal axle towards the rear without diverting up or down S Risk of damage to the chassis ...

Page 238: ...ways if you turn the wheels of the front and rear axle lines in the same direction Open the main menu if necessary 5 5 1 Switching to separate steering Always switch to separate steering when Driving with the rigged truck crane Steering at low speed You can only change over to separate steering when the current speed is below approx 5 km h 3 mph G Risk of accident when driving on road with unlocke...

Page 239: ... 1st and 2nd axle lines with the steering wheel Steer the 6th axle line with the button 1 Axle lines 3 4 and 5 are steered automatically depending on the 1st and 6th axle lines and on the steering mode selected The axle lines are steered as long as you keep the button pressed or until an end position is reached s 1 Crab travel mode 6th axle line steered automatically 2 Driving around corners 6th a...

Page 240: ... 6th axle line in the same direction as the 1st and 2nd axle lines The other axle lines are always steered in the same direction Automatic Steer the 1st and 2nd axle lines with the steering wheel A for driving around corners The other axle lines are steered out in line with the turning radius and with or against the steering angle on the 1st and 2nd axle lines B for crab travel mode The other axle...

Page 241: ...ng mode which is switched on e g the button 1 for crab travel mode The dot in the symbol turns black When no steering mode is switched on the separate steering will be switched off The display 2 shows the symbol for on road driving Now Steer the 1st and 2nd axle lines with the steering wheel The 3rd and 4th axle lines remain facing forward Steer the 5th and 6th axle lines according to the turning ...

Page 242: ...erature Setting the blower fresh air recirculated air 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 A Recirculated air air is sucked in from the driver s cab ...

Page 243: ...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 Press in and position lengthwise To close Position crosswise To direct the air flow In intermediate position 2 To direct the air flow Rotate ...

Page 244: ... cold damp A Ventilating Turn the switch into the positions shown If necessary open the air vents for the side and centre B Defrosting the front windscreen Turn the switch into the positions shown Close the air vents for the side and centre Switching off Switching off the heater Turn the switch 1 as far as it will go in anti clockwise direction to Cold Switching off ventilation Turn the switch 2 t...

Page 245: ...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 air thoroughly The cooling down procedure can be accelerated by increasing the engin...

Page 246: ...en is fed in Set the air distribution with switch 2 open the air vents if necessary à p 5 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 recirculating air setting to the current conditions humidity and temperature of the out side air Set ...

Page 247: ... the engine switched off You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently You can use the auxiliary water heater to Preheat just the engine Preheat the engine and driver s cab simultaneously Preheating the engine If only the engine is to be preheated adjust the heating system as follows Switch 2 to Warm setting Switch 1 to Fan off setting Knob 3 press...

Page 248: ...t the heating system as follows if the driver s cab is to be preheated in addition to the engine Switch 2 to Warm setting Switch 1 on the Recirculated air symbol level 1 Open the air vents à p 5 71 Button 3 pulled If you heat the driver s cab at the same time the amount of time required to preheat the engine will increase significantly ...

Page 249: ...xiliary 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 switched off However the pump for the auxiliary heater continues to run until you switch the auxiliary heater off H Always switch off the auxiliary heater when you turn off the truck crane when the battery master switch is switched on In this way you p...

Page 250: ...period of time You can set this remaining time à Air conditioning system p 5 73 Setting the time and weekday 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 If the power supply is interrupted all symbols in the display will flash and you must set the time and day again Press the button 1 for longer ...

Page 251: ... the new value To retrieve a storage location press the button 1 once Flashing displays The retrieved storage location e g 2 The last saved heating start e g 6 00 s t Set the time for the desired heating start e g 8 00 Wait for approx 5 seconds until the day of the week for the heating start flashes e g MO for Monday s t Set the day of the week for the desired heating start Wait for approx 5 secon...

Page 252: ... 10 to 120 minutes Wait for approx 5 seconds until the current time is shown e g 14 00 hrs A new heating period has now been set Switching the automatic heating start on and off To switch on an automatic heating start you must retrieve the correspond ing storage location To retrieve a storage location press the button 1 once The display field flashes for 5 seconds and a storage location is shown e...

Page 253: ...ary heater continues to run for the remaining time Switch on the auxiliary heating using the 1 button Turn off the ignition The auxiliary heating continues to run and the residual run time set last flashes e g 48 minutes s t Set the desired remaining time on the flashing display You can set a remaining time of 1 to 120 minutes Wait for 5 seconds until the current time is shown The remaining time i...

Page 254: ...s For every 100 kg 220 lbs of drawbar load the axle loads on the 3rd to 6th axle lines are reduced by 43 kg 95 lbs G Risk of accident 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 from rolling away Ensure that it is still possible to swivel the front axle of the trailer G Risk of ac...

Page 255: ...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 s G Risk of injury when the automatic closing device is triggered Do not put your hand into the coupl...

Page 256: ...This socket 2 is designed for special equip ment Check the function of the trailer lighting Test the service brake and parking brake immediately after setting off G Risk of accident 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 accident if the hose...

Page 257: ...the trailer with the service brake and chocks as prescribed to prevent it from roll ing away Open the towbar coupling Push the lever 1 up until it latches into place Drive the truck crane carefully away from the trailer s G Risk of accident due to trailer moving unintentionally Always first remove the hose from the supply line so that the trailer is braked This prevents the trailer from moving whe...

Page 258: ...y closing the towbar coupling 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 close...

Page 259: ...is position the parking brake on the trailer is released the parking brake on the truck crane remains engaged 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 engaged S Risk of accident from truck crane mo...

Page 260: ...Driving 5 7 Towing a trailer 5 88 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 261: ... Securing releasing the derricking cylinder 6 31 6 3 10 Transporting the main boom 6 32 6 3 11 Inspections after main boom mounting 6 33 6 4 Installing removing outrigger beams 6 35 6 4 1 CHECKLIST Removing the outrigger beams 6 36 6 4 2 CHECKLIST Installing the outrigger beams 6 38 6 4 3 Preparing the truck crane 6 40 6 4 4 Removing attaching outrigger pads 6 41 6 4 5 Disconnecting establishing t...

Page 262: ...nstalling the reverse camera 6 68 6 5 9 Crane movements during installation and removal 6 69 6 5 10 Slinging points on the supporting box 6 70 6 5 11 Fixing releasing the outrigger pins 6 71 6 5 12 Transporting the supporting box on the separate vehicle 6 73 ...

Page 263: ...he braking deceleration required by the EU partial type approval cannot be ensured If country specific regulations allow the truck crane to be driven with axle loads greater that 12 t 26 500lbs 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 accident from increased brakin...

Page 264: ...The required rigging mode for this driving mode and the accessories you are allowed to transport are specified in the middle section next to Rigging mode Example of how to use the table Assuming your truck crane is equipped with 445 95 tyres aluminium rims and transmission retarder In this case the driving mode in the upper part next to equipment is 2 According to the specifications in the lower p...

Page 265: ...e truck crane in driving mode then the total weight decreases but can be distributed in such a way that the front or rear axle loads are over 12 t 26 500 lbs Without remova ble supporting box Also observe the effects on the axle loads when towing a trailer à p 5 82 s Driving mode 1 2 3 Equipment 385 95 R 25 tyres 445 95 R25 tyres 525 80 R 25 tyres Steel rims Aluminium rims Transmission retarder Ri...

Page 266: ...s 6 4 3 112 993 en Operating manual GMK 6400 12 07 2013 With removable supporting box Driving mode 1 Equipment 385 95 R 25 tyres or 445 95 R25 tyres or 525 80 R 25 tyres Steel rims or aluminium rims Rigging mode Front outrigger beam removed Supporting box removed ...

Page 267: ...m values Also note the information provided by the tyre manufacturer regarding the maximum permitted load duration G Risk of accident from overloading tyres Never exceed the maximum permitted speed which is given for the current axle load and tyre size This prevents the rope tyres from becoming overloaded and rupturing Tyre size tyre pressure in bar psi Current axle load in t lbs Maximum permissib...

Page 268: ...icable in the country in which you are working you can set the main boom onto a trailer dolly when driving For this purpose the truck crane must be fitted with a slewing gear free wheel boom floating position and if necessary with a boom pre tensioning device Before driving with the trailer you must Switch on the slewing gear freewheel à p 6 7 Switch on the boom floating position à p 6 8 Switch on...

Page 269: ...boom floating position p 6 8 Requirements The engine is running The slewing gear brake is released the lamp 1 has gone out à Releasing the slewing gear brake p 11 99 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 lock in the bore 1 and remove the key Fit and secure the pin 3 on the other slew ing gear in the same way Open the valve...

Page 270: ... padlock 2 Switch over valve I lever 1 upwards Secure the lever 1 with the padlock 2 Switch the valve IV lever 3 points down wards The boom floating position is now switched on H Switching off the boom floating position à p 12 17 G Risk of accident from the boom floating position being switched off Always switch on the boom floating position when the main boom is on a trailer This prevents the tra...

Page 271: ...tensioning Switch on the boom floating position à p 6 8 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 up The pressure accumulator is filled Fill up the pressure accumulator until the pressure stops rising on the pressure gauge 1 Close the valve I...

Page 272: ...ghts With additional equipment consisting of the switch 1 the lamps 2 and 3 can be switched on or off separately when the park ing light or headlights are switched on Switching off When the boom is set down on a trailer you can switch off the Superstructure driving lights when necessary e g in order to conform to country specific regulations for the colour of front and rear lights Push the switch ...

Page 273: ...A derricking cylinder support 1 A tightening belt 4 A lifting device 3 Lifting gear 2 as well as An auxiliary crane with sufficient lifting capacity A separate vehicle with sufficient load bear ing capacity and loading area Transport dimensions and weight à p 1 10 G Risk of accident when removing installing the main boom without pulling devices Only remove or install the main boom if the truck cra...

Page 274: ...Driving modes and rigging for on road driving 6 3 Removing installing main boom 6 12 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 275: ...en unrigged The counterweight is unrigged All lattice extensions have been removed The Mega Wing Lift is removed All telescopic sections are fully retracted and locked The hook block has been unreeved and the hoist rope has been reeled on the drum up to the main hoist The superstructure is slewed to the front The truck crane is supported by an outrigger span of at least 8 70 x 2 71 m 28 5 x 8 9 ft...

Page 276: ... the load off of the head pin Release the head pin Pull the head pins out à p 6 21 6 Connect the hand held control on the turntable à Connecting discon necting the hand held control p 12 21 7 On the boom pivot pin Switch the hydraulic circuit over Prepare the pulling device Retract the pivot pin à p 6 24 8 Raise the main boom from the turntable à p 6 29 9 Put the main boom on the separate vehicle ...

Page 277: ...ual There are accompanying operating instructions which are indicated by cross references Observe the warnings and safety instructions specified there Requirements The truck crane is supported by an outrigger span of at least 8 70 x 2 71 m 28 5 x 8 9 ft Checklist 1 Remove the tightening belt from the derricking cylinder à p 6 31 2 Connect the hand held control on the turntable à Connecting discon ...

Page 278: ...5 On the boom pivot pin Open the hydraulic circuit Extend the pivot pin Secure the pulling device Close the hydraulic circuit à p 6 24 6 Set down the main boom in the boom rest with the auxiliary crane and remove the sling gear 7 On the derricking cylinder head Level the derricking cylinder Fit the head pin Secure the head pin à p 6 21 8 Raise the main boom and connect the hydraulic electrical con...

Page 279: ...ving installing main boom Operating manual GMK 6400 3 112 993 en 6 17 12 07 2013 9 Remove the derricking cylinder support from the counterweight plat form 10 Place the main boom on the boom rest 11 Carry out the checks with the main boom set down à p 6 33 ...

Page 280: ...lifting gear to the slinging points intended for this purpose The mark ings are of following significance Installing the lifting gear If the installation is correct the load bearing equipment 2 of both brackets point to each other Lock both brackets in the wide position Secure the pins 1 using the retaining pins Install the front bracket first It hangs on longer ropes which makes installing the ba...

Page 281: ...etaining pin Pull the bracket to the centre the bracket must rest on the slinging point on both sides Install the bracket 5 in the same manner Before lifting make sure the brackets on both sides are resting on the slinging point 1 Removing the sling gear Remove the pin 2 and pull the bracket 3 out of the slinging point 4 Secure the bracket with the pin 2 and the retaining pin Pull the bracket out ...

Page 282: ...Driving modes and rigging for on road driving 6 3 Removing installing main boom 6 20 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 283: ...port must be erected Place the derricking cylinder support 1 between the holders 2 Set down the main boom on the boom rest Operating the lifting device A lifting device is needed in order to relieve and level the derricking cylinder Attach the lever in the holder 2 A Raising Close the drain plug 1 and pump the lever The piston rod 3 extends B Lowering Slowly open the drain screw 1 The piston rod 3...

Page 284: ... bracket 1 is resting firmly on the derricking cylinder Pulling out the head pin A Turn the switch 1 to the Pull ä position B Insert the lever into the clamp 2 Pump until the head pin 3 is completely drawn out Carry out the movement Lower until the derricking cylinder is in the derricking cylinder support C Fasten the disc with the bolt 4 Stow away the lever and the lifting device G Risk of accide...

Page 285: ... movement Raise until the head pin 4 is aligned with the bearing in the derricking cylinder 3 Fitting the head pin A Turn the switch 1 to the Pull â position B Insert the lever into the clamp 2 Pump until the head pin 3 is inserted as far as possible Securing the head pin C Fasten the disc with the bolt 4 Stow away the lever and the lifting device so that it is safe to drive on the road S Risk of ...

Page 286: ...xtending the boom pivot pin The boom pivot pin is retracted and extended with a hydraulic pulling device Before retracting Before retracting the boom pivot pin you must Open the hydraulic circuit unlock the pulling device Opening the hydraulic circuit Open valve 1 Position A Unlocking the pulling device Release the retaining pins and pull out the bolt 1 ...

Page 287: ...aulic circuit again secure the pulling device Closing the hydraulic circuit Switch the valve 1 Position B Securing the pulling device Insert the pins 1 and secure them with the retaining pins s G Risk of accidents from falling main boom Always secure the pulling device with the pins This prevents the boom pivot pin from retracting by itself and the main boom from falling and injuring people or bei...

Page 288: ...he lamp lights up Press the key combination 2 The pivot pin is retracted B Extending Press button 1 The lamp lights up Press the key combination 2 The pivot pin is extended Secure the pulling device à p 6 25 Switch off the engine S Risk of damage to the main boom Before retracting the main boom must be slung and all other sling gear must be tightened Before extending the bearing points on the turn...

Page 289: ...e hoses 3 from the ports Remove the plugs 2 from the sockets Insert the bridging plugs 1 Close all hoses connections plugs and sockets If necessary secure all the hoses cables so that they do not swing loose when the main boom is raised s S Risk of malfunction in the superstructure electronics Always turn off the ignition in the crane cab before you establish or separate the electrical connection ...

Page 290: ... to the sockets The assignment is given by the number of poles and the shape of the plug Connect all hoses 3 The assignment is given by the size and colour designations Lay the hoses cables so that they will not be damaged S Risk of malfunction in the superstructure electronics Always turn off the ignition in the crane cab before you establish or separate the electrical connection This prevents ma...

Page 291: ...n such a way that the main boom can be raised vertically without swinging Lift the main boom forwards and upwards from the turntable Make sure that The connection lines 2 do not hang loose The pivot point 1 is higher than the driver s cab s S Risk of damage to driver s cab Lift the main boom far enough to ensure that the pivot point of the derrick ing cylinder does not damage the driver s cab G Da...

Page 292: ...K 6400 12 07 2013 Lifting on to the turntable Lift the main boom backwards and down wards on to the turntable Make sure that The connection lines 3 do not hang loose The pivot point 1 is higher than the driver s cab The pivot point 1 is located forwards of the derricking cylinder 2 The connecting points are not tilted ...

Page 293: ...om in this position until the pivot pin is pushed in 6 3 9 Securing releasing the derricking cylinder A Securing Place the tightening belt 1 over the derrick ing cylinder and fasten it onto the holders 2 Tighten the tightening belt so that the der ricking cylinder is secure within the support B Releasing Loosen the tightening belt 1 and remove it from the holders 2 Stow the tightening belt away S ...

Page 294: ... place the main boom onto a suitable packing Secure the main boom against slipping using the holding ropes Load the main boom in such a way that other road users are not put at risk Load the transport vehicle in such a way that the weight is evenly distrib uted Secure the connection lines so that they will not slip and be damaged dur ing transport Keep the connecting points free of contamination S...

Page 295: ...met for the subsequent inspection The truck crane is supported on outriggers The main boom is resting in the boom rest The current rigging mode is set on the RCL Telescope the telescopic section approx 1 m out and back in Retract the telescoping cylinder into another telescopic section and mechanically lock it there Check to see if the hydraulic connections in the turntable are sealed H Before ope...

Page 296: ...Driving modes and rigging for on road driving 6 3 Removing installing main boom 6 34 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 297: ...n nections 1 which can be separated During rigging each outrigger beam is removed and mounted as a com plete package consisting of inner and outer outrigger beams cylinders and add 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...

Page 298: ...ng operating instructions which are indicated by cross references Observe the warnings and safety instructions specified there 1 Prepare the truck crane label the outrigger beams retract release and bolt them to each other à p 6 40 2 If necessary remove outrigger pad à p 6 41 3 Unscrew the spacer à p 6 45 4 Remove the hydraulic connections à p 6 43 Separate the electrical connection if necessary à...

Page 299: ...until it reaches the centre of gravity à p 6 47 7 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 outrigger beam p 6 47 à Transporting the outrigger beams p 6 51 8 Remove all necessary outrigger beams in the same way in accordance with this ch...

Page 300: ...ified there 1 Prepare the truck crane for the installation of the outrigger beams à p 6 40 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 lift ing gear à Inserting the outrigger beam p 6 49 3 Sling the outrigger beams and pull into the outrigger boxes until the connection ...

Page 301: ... pads into position à p 6 41 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 ...

Page 302: ...responding covers have been removed 1 The suspension is switched off blocked and the symbol 1 is red à p 5 14 For removal Each outrigger beam is designed 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 Labelling the outrigger beams Before you remove all outrigger beams f...

Page 303: ...frame the outrigger beams can be set down on the outrigger pad Removing outrigger pads Handling is easier if you remove the outrigger pad before removing the out rigger beams A Move the outrigger pad into the oper ating position Remove the pins 1 Extend the outrigger cylinder until the out rigger pad just touches the ground but is not yet under strain B Pull the outrigger pad off the outrigger cyl...

Page 304: ...d A Remove the pin 1 Extend the outrigger cylinder far enough so that the bearing surface 3 is below the guide 2 Push the outrigger pad onto the outrigger cylinder Move the outrigger pad into required posi tion On site move it to the working position B If you need to drive to the site in driving position C Insert the pins 1 and secure them Securing the pin Plug the pin with the peg 1 through the c...

Page 305: ...r beam The position of the valve block may differ from the drawings depending on the outrigger beam Disconnecting Always disconnect all connections 4 Hold the hose firmly 1 Pull the lock 2 against the stop The hose is pushed out of the connection 3 Seal all connecting points Establishing Always establish all connections 4 The assignment is differentiated by colour desig nations Insert the hose 1 i...

Page 306: ... with an outrigger pressure indicator A Separating the connection Pull the plugs 1 apart Protect the plugs against dirt and moisture B Connecting Put the plugs 1 together Protect the separating points against dirt and moisture S Risk of malfunctions in the electronic system Always turn off the ignition before you disconnect or establish the electrical connection This prevents malfunctions and corr...

Page 307: ... beam on the opposite side The illustrations show as an example the spacers for the outrigger beams on the rear 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 com pletely At the outriggers Undo the lug nuts 2 Unscrew the bolts 1 unti...

Page 308: ... At the outrigger box 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 outriggers Screw in the screws 1 Until the spacers 3 lie on top on the out rigger box 4 Until the distance X to the outrigger box 4 is an even 4 mm over the entire widt...

Page 309: ...B Connecting Fasten the bolts 1 with the nuts 3 in the connecting points 2 just tight enough that the attachment plates 4 still have lateral play 6 4 9 Extending retracting the outrigger beam Extending outrigger beam Check that the outrigger beams are released and are secured between each other à Preparing the truck crane p 6 40 Fasten the lifting gear 1 and a chain hoist Pull the outrigger beam o...

Page 310: ... 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 51 Fasten the connecting elements to the connecting points 1 of the sup ports G Risk of being crushed by the swinging outrigger beam Secure the outrigger beam with the guide ropes as it is lif...

Page 311: ...m in the outrigger box Remove the guide rope 1 s 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 outrigger box and the outrigger beam S Risk of damage to hydraulic lines Ensure that the hydraulic lines on the outrigger ...

Page 312: ...ossible 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 the lifting gear 1 and a chain hoist Fasten the chain hoist with a suitable mounting device on the bore hole 2 Pull the outrigger beam in so far until the connecting points 1 align Remove the chain hoist and lifting gear ...

Page 313: ...gger beam so that it that does not endanger other traffic When the outrigger pads are mounted Place the outrigger beam onto a suitable device 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...

Page 314: ...Driving modes and rigging for on road driving 6 4 Installing removing outrigger beams 6 52 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 315: ...Appropriate lifting gear chain or rope suspension gear of sufficient lift ing capacity and guide ropes A separate vehicle of sufficient load bearing capacity with a sufficient loading area Dimensions and weights of removable parts à Dimensions and weights of removable parts p 1 10 G Risk of overturning when slewing the superstructure Support the truck crane with an outrigger span of 7 98 x 8 50 1 ...

Page 316: ...arnings and safety instructions specified there 1 Rig the outrigger span 7 98 x 8 50 1 00 m 26 1 x 27 9 3 3 ft and align the truck crane horizontally à p 6 59 2 Disconnect the pneumatic connections between the carrier and outrig ger box à p 6 62 3 Install the reverse camera to the carrier à p 6 68 4 With the RCL set accordingly raise the main boom and slew the super structure to the rear à Crane m...

Page 317: ...er box is to be transported Turn off and secure the supporting box with truck crane on the separate vehicle à Attaching raising the supporting box with the truck crane p 6 65 à Transporting the supporting box on the separate vehicle p 6 73 9 If the outrigger box is to be set down Turn off the supporting box with truck crane on the supports à p 6 66 10 If the main boom is to be set down on the boom...

Page 318: ...is to be set down on a trailer With the RCL set accordingly slew the superstructure to the rear and lower the main boom à Crane movements during installation and removal p 6 69 12 On the outriggers Retract the front outrigger cylinders and outrigger beams and secure à CHECKLIST Retracting the outriggers p 12 31 Retract auxiliary support à Auxiliary supports p 6 60 ...

Page 319: ...there 1 Rig the outrigger span 7 98 x 8 50 1 00 m 26 1 x 27 9 3 3 ft and align the truck crane horizontally à p 6 59 2 With the RCL set accordingly raise the main boom and slew the super structure into the position for raising the outrigger box à Crane movements during installation and removal p 6 69 3 Sling the supporting box to the truck crane and remove from the sepa rate vehicle à Slinging poi...

Page 320: ... p 6 62 9 If the truck crane is at the site Retract auxiliary support à p 6 60 Extend all outrigger beams to the necessary outrigger span secure them and stabilize the truck crane à CHECKLIST Extending the out riggers p 12 29 10 If the truck crane has to be driven to the site With the RCL set accordingly slew the superstructure to the front and set down the main boom à Crane movements during insta...

Page 321: ...re with the rear outrigger box removed Removing installing the supporting box Setting down the main boom on a separate trailer or raising the main boom from a trailer H Loads of up to 55 7 t 122 789 lbs can arise on the outrigger pads of the aux iliary supports when the truck crane only stands on the supports If the ground cannot support these loads you must determine the required sup port area an...

Page 322: ...rt cylinders until they make contact with the ground Auxiliary supports Extending A Left auxiliary support Press and hold down the button 1 below Press the button 3 left B Right auxiliary support Press and hold down the button 2 below Press the button 3 left Extend the auxiliary supports until the out rigger pads make contact with the ground Extend the auxiliary supports on both sides until the tr...

Page 323: ...nual GMK 6400 3 112 993 en 6 61 12 07 2013 Retracting A Left auxiliary support Press and hold down the button 1 below Press the button 3 on the right B Right auxiliary support Press and hold down the button 2 below Press the button 3 on the right Retract the auxiliary supports until they reach the stop ...

Page 324: ...stablishing disconnecting the pneumatic connection When additional equipment is in use there is a pneumatic connection between the carrier and the supporting box A Making a connection Open the connection 1 Connect the hoses 2 to the connection 1 B Disconnecting the connection Open the connection 1 and remove the hose 2 Suspend the hoses in the clamp 3 ...

Page 325: ... from the socket 5 and plug it into the socket 4 Seal sockets 3 and 5 with the protective caps Establishing Remove the plug 6 from the socket 4 and plug it into the socket 5 Pull connecting cable 2 and 7 from dummy sockets 1 and 8 Insert them into the sockets 3 and 4 Seal dummy sockets 1 and 8 with the pro tective caps S Risk of malfunctions in the carrier electronics Always turn off the ignition ...

Page 326: ...ction The hydraulic connection between the supporting box and carrier consists of two hoses with couplings Always close off hoses or connections you do not need with appropriate caps Disconnecting Remove the hoses 2 from the connec tions 1 Place the hoses in the clamp 3 Establishing Remove the hoses 2 from the holder 3 Connect the hoses to the connections 1 The assignment is defined by the size ...

Page 327: ...e outrigger box s S Risk of damage to the suspension struts and tyres Always extend the auxiliary support before you raise the supporting box with the truck crane This prevents the suspension struts and tyres from becoming overloaded and damaged G Risk of overturning with the raised outrigger box Always enter an RCL code for the outrigger span 7 98 x 8 50 1 00 m 26 1 x 27 9 3 3 ft with the working...

Page 328: ...placed on a separate vehicle Move the separate vehicle up to the truck crane so that you can set down the outrigger box without overriding the RCL à p 6 73 Do not override the RCL Lift the outrigger box vertically out of the carrier retainers 1 with the truck crane Hold the supports 1 and remove the retain ing pins 2 Extend the supports 1 Secure the supports 1 by inserting the lock ing bolts 2 int...

Page 329: ...box Pull the locking pins 2 Retract the supports 1 Secure the supports by inserting the lock ing pins into the lower hole Where necessary to do so bring all the out rigger pads into driving position à p 12 43 Do not override the RCL Hoist the outrigger box onto the carrier in such a way that the pins 2 on the outrigger box are vertically above the mountings 1 on the rear of the vehicle Hang the ou...

Page 330: ...anual GMK 6400 12 07 2013 6 5 8 Installing the reverse camera Depending on the driving mode you can install the reverse camera on the carrier or the outrigger box A On the supporting box B On the carrier Fasten the reverse camera with the bolt 1 Install and secure the connecting camera so that it safe for use on roads ...

Page 331: ...e for 0 position to the rear or 180 position to the front Raise the main boom Enter the RCL code for the outrigger span of 7 98 x 8 50 1 00 m 26 1 x 27 9 3 3 ft for the 360 slewing range Rotate the superstructure into the position for mounting the rear support Enter the RCL code for the outrigger span of 7 98 x 8 50 1 00 m 26 1 x 27 9 3 3 ft for the limited slewing range of 20 to the rear After re...

Page 332: ...he supporting box At the top of the outrigger box there are two slinging points 1 Use only these slinging points for fastening the lifting gear G Risk of accident if used improperly Attach the outrigger box only to the designated points and only use lifting gear of sufficient lifting capacity Weight of the outrigger box à Dimensions and weights of removable parts p 1 10 ...

Page 333: ...sh the retaining plugs in until the balls at the bottom of the plugs are pushed out s G Risk of crushing when extending retracting the pins The pins on both sides are always moved at the same time from the Sup porting box control unit Make sure that no one is in the vicinity of the carrier retainers on the other side of the vehicle when you extend or retract the pins G Risk of damage to the securi...

Page 334: ...manual GMK 6400 12 07 2013 Releasing the locking pin Sling the outrigger box before releasing the pins Pull the securing plugs 4 out of the two pins 3 Press the button 2 on the left and the but ton 1 on the right Fully insert the pins 3 The movement continues till you release the button or the end position is reached ...

Page 335: ...ent them from falling from the transport vehicle slipping or damag ing other parts Load the transport vehicle in such a way that the weight is evenly distrib uted Transport the outrigger box only on a separate vehicle of sufficient lifting capacity à Dimensions and weights of removable parts p 1 10 Lashing eyelets Fasten the supporting box for the transport to the lashing eyelets 1 with holding ro...

Page 336: ...Driving modes and rigging for on road driving 6 5 Installing removing the supporting box 6 74 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 337: ... battery box 7 25 7 7 Troubleshooting 7 27 7 7 1 Malfunctions in the engine 7 27 7 7 2 Malfunctions in the DEF system 7 29 7 7 3 Malfunctions in the transmission 7 30 7 7 4 Malfunctions in the hydraulic drive MegaDrive 7 30 7 7 5 Service brake malfunctions 7 31 7 7 6 Steering malfunctions 7 32 7 7 7 Differential lock malfunctions 7 33 7 7 8 Malfunctions in the hydraulic system hydraulic oil cooler...

Page 338: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 339: ... an emergency Press an emergency stop switch 1 2 or 3 The switch engages The engine shuts down After activating an emergency stop switch à Resetting the emergency stop switch p 4 26 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 3 In t...

Page 340: ...Malfunctions in driving mode 7 1 Emergency stop switch 7 2 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 341: ...raffic 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 7 5 G Risk of accident due to poor visibility If possible do not stop in a tunnel or directly after a curve G Risk of accident during ...

Page 342: ...Malfunctions in driving mode 7 2 What to do when a malfunction occurs in road traffic 7 4 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 343: ... tow rod If the engine steering and service brake still work you can tow the truck crane with a lorry The wheels of the fifth and sixth axle lines must be in the forward position If the wheels can no longer be steered into the forward position notify Manitowoc Crane Care prior to towing If the engine steering or service brake no longer function properly the truck crane must be towed with a special...

Page 344: ...e must be supplied with compressed air by the towing vehicle so that the brake system is still operable Connect the filler connection 1 with the supply coupling head of the towing vehicle A supply pressure of at least 6 bar 87 psi must be displayed and the lamps 2 must not light up in the driver s cab when towing S Risk of accident and damage when towing the truck crane long distances Tow the truc...

Page 345: ...ly Switch on the battery master switch Turn on the ignition On the trans mission Switch the transmission to neutral position N Switching on towing mode Press the 1 button once The symbol 2 shows green Towing mode is switched on Switching off towing mode Press the 1 button once The symbol 3 shows red Towing mode is switched off s ...

Page 346: ...ntinues to light up the supply pressure may be too low Let the engine of the truck crane or towing vehicle run on the compressed air supply until the supply pressure has been built up à Building supply pres sure p 5 9 If the lamp 1 fails to go out the parking brake has been damaged refer to Manitowoc Crane Care G Risk of accident by faulty brakes If the service brake system has been damaged you ma...

Page 347: ... at least 2 km h 1 2 mph Tow the truck crane at a maximum of 10 km h 6 mph Ensure that the towing distance is a maximum of 1 km 0 62 mi 7 3 2 Starting to tow It is not possible for the truck crane to start towing for transmission reasons S Risk of damage to the chassis Starting to tow too quickly or in jolts can damage the chassis G Risk of accident from sluggish steering The truck crane is barely...

Page 348: ...Malfunctions in driving mode 7 3 Towing the truck crane 7 10 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 349: ...to the auxiliary vehicle s power supply 24 V Insert the plug 2 in the socket 3 Start the engine of the carrier B Remove the plug 2 Close the socket 3 Remove the cable 1 from the auxiliary vehicle 7 4 2 Battery charger Connecting The battery charging unit is located in the bat tery box A Connect the cable 1 with the plug 2 to the socket 3 and to a power source The battery charger switches on and th...

Page 350: ...Malfunctions in driving mode 7 4 Other emergency operations 7 12 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 351: ...op the truck crane taking the follow ing traffic into account and secure the truck crane as outlined in the appli cable legal stipulations of the country in which you are working Select an even place if possible to change the wheels Engage the parking brake s G Risk of accident by falling wheel If you briefly lean a wheel against the truck crane while changing it secure it with a rope to prevent i...

Page 352: ...k crane then Support the truck crane Enter the current rigging mode on the RCL Lift the spare wheel using only lifting gear with sufficient load bearing capacity à Spare wheel p 1 10 G Risk of accident by falling wheel 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 overturning if th...

Page 353: ...he bearing surfaces of the wheel rim and hub are clean no paint grease or oil Lightly grease the wheel studs Put the wheel on 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 onto the wheel studs Make sure the threads of the wheel studs are not damaged s G Risk of accident Check the wheel rim ...

Page 354: ...lug nuts 1 and 2 to secure the wheel Tighten the remaining lug nuts Always tighten the lug nuts in the order 1 to 12 First all lug nuts to 200 Nm 150 lbf ft Then all lug nuts to 400 Nm 300 lbf ft Finally all lug nuts to 650 Nm 480 lbf ft Tighten all lug nuts after 50 km 30 mi and 150 km 90 mi once more to 650 Nm 480 lbf ft ...

Page 355: ...e depending on the tyres à Tyres p 1 14 Always drive directly to a service station or garage and adjust the tyre pres sure as soon as you have inflated the tyres yourself The filling hose has a tyre inflator connection 2 and a connection 1 Connecting the filling hose Remove the caps 3 and 4 Fasten the connection 1 to the filler con nection 2 You can now inflate the tyres s S Risk of accident due t...

Page 356: ...nd inflate the tyre Disconnect the tyre connection 1 from the tyre valve Removing the filling hose Before driving you must remove the filling hose from the filler connection Remove the connection 1 from the filler connection 2 Close the filler connection and the connec tion with the caps 3 and 4 Stow the filling hose away Drive to a service station or workshop and adjust the tyre pressure S Risk o...

Page 357: ...o be replaced S Risk of damage when the ignition is switched on Always switch off the ignition whenever a fuse has to be replaced This pre vents the new fuse from being damaged by the increased starting current immediately after being installed S Risk of damage by overloading Replace blown fuses only with new fuses of the same amperage This pre vent parts from being overloaded and damaged or the f...

Page 358: ...belled with the numbers Observe the instructions on changing fuses à p 7 19 2 Fuse groups F1 to F10 3 Reserve fuses Designation Amperage A Function F1 1 20 Automatic parking light1 F1 2 10 Diagnostics plug cab lighting Cigarette lighter F1 3 20 Oil cooler 24 V 12 V voltage transformer F1 4 10 Hazard warning system light switch power supply1 F1 5 5 Engine electronic system ECOS control unit F1 6 10...

Page 359: ...wer supply1 F2 6 10 Retarder1 air conditioning system1 F2 7 15 ABS trailer F2 8 3 Low beam headlight1 Designation Amperage A Function F3 1 15 Rotating beacon F3 2 10 Flame start system1 vehicle height monitoring1 F3 3 15 Warm water auxiliary heater1 ignition lock F3 4 20 Air drier mirror adjustment window winder F3 5 15 Outrigger lighting rear carrier spotlights1 F3 6 10 Turn signal indicators F3 ...

Page 360: ...ation F4 4 10 Power supply F4 5 10 Tachograph F4 6 10 Engine electronic system ECOS control unit F4 7 10 Diagnostics plug F4 8 10 TCM supply Designation Amperage A Function F5 1 5 Generator F5 2 5 Emergency stop system air intake inhibitor1 F5 3 5 Power supply CAN BUS F5 4 20 Power supply ESX3 control unit F5 5 5 Air intake inhibitor1 F5 6 10 Engine electronic system ADM SCR F5 7 2 Emergency opera...

Page 361: ... 4 5 Right hand marker light and tail lamps F6 5 5 Left full beam headlight F6 6 5 Right hand full beam headlight indicator lamp for full beam headlight F6 7 5 Headlight left F6 8 5 Headlight right Designation Amperage A Function F7 1 2 Control unit ESX 4 F7 2 5 ESX 4 sensors fuse monitoring F7 3 20 Control unit ESX 4 F7 4 2 Control unit ESX 5 F7 5 5 ESX 5 sensors fuse monitoring F7 6 20 Control u...

Page 362: ...gaDrive control F9 3 1 MegaDrive control F9 4 1 MegaDrive control F9 5 1 MegaDrive control F9 6 3 MegaDrive control F9 7 1 MegaDrive control F9 8 Unassigned Designation Amperage A Function F10 1 3 Radio F10 2 Unassigned F10 3 15 Outrigger lighting F10 4 Unassigned F10 5 Unassigned F10 6 Unassigned F10 7 7 5 Window winder F10 8 5 Auxiliary heater time switch1 1 Additional equipment ...

Page 363: ...box Observe the instructions on changing fuses à p 7 19 S Danger from lead and lead compounds on battery 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 1 Fuse F7 2 Fuse F8 3 Fuse F9 4 Fuse F10 Designation Amperage A Function F7 100 Carrier central fuse F8 50 Flame start system F9 20 Prel...

Page 364: ...Malfunctions in driving mode 7 6 Fuses 7 26 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 365: ... s operating manual Malfunction Cause Solution Engine does not start Starter does not turn Battery master switch is switched off Switch on the battery master switch à p 4 12 Ignition off à Switch on the ignition p 4 12 Transmission not in neutral position à Switching the transmission to neutral position p 5 24 Parking brake released Apply the parking brake à p 3 49 Fuse F1 5 on carrier blown Repla...

Page 366: ...ual Outer surface of heat exchanger dirty Clean the heat exchanger V belt of coolant pump at engine loose Tighten V belt à Separate engine manufac turer s operating manual The fan wheel on the engine does not turn Switch the fan wheel to emer gency operation à p 7 39 Engine cannot be turned off with ignition key Malfunction in the electronics Turn off the engine with theemergency stop device à p 7...

Page 367: ...ghts up Flashes DEF level in tank at reserve level DEF tank empty Refill DEF à p 4 10 Light up DEF reservoir sensor faulty Error in the DEF dosing unit DEF lines blocked Temperature sensor faulty Cable break in DEF system Exhaust gas sensor faulty Have the exhaust system checked by Manitowoc Crane Care an authorised GROVE retailer or an authorised specialised workshop ...

Page 368: ... Replace blown fuse à p 7 19 Symbol A is red Transmission cannot shift down since the maximum permissible engine speed would otherwise be exceeded Slow down the truck crane until the symbol goes out Driving display has a mal function The electronic gear system has detected a malfunction à Procedure during trans mission malfunctions p 7 41 Transmission diagnostics plug not working Fuses F1 2 F4 7 b...

Page 369: ...in both circuits has fallen below 5 5 bar 80 psi 1 Top up the compressed air supply on the filler con nection à p 7 6 2 Tow the truck crane with the towing bar à p 7 6 Parking brake una ble to be released Supply pressure is too low à Building supply pressure p 5 9 Does not go out Off Also lights up at over 6 km h 4 mph The trailer ABS has failed Drive vehicle to next garage braking without ABS sup...

Page 370: ... no oil has leaked out p 5 38 Steering circuit has failed e g pump faulty Symbol d and e are red Both steering circuits have failed The truck crane cannot be driven any further since it can no longer be steered Separate steering cannot be activated Current speed over approx 5 km h 3 mph Slow down or stop the truck crane Separate steering cannot be switched off Current speed over approx 5 km h 3 mp...

Page 371: ...wn or stop the truck crane Drive train under tension Slowly drive truck crane back back and forth à p 5 58 Error symbol is displayed ECOS malfunction Read out error messages à p 7 35 and notify Manitowoc Crane Care Malfunction Cause Remedy Hydraulic oil temperature above 80 C fan in the hydrau lic oil cooler is running Hydraulic system under extreme strain and ambient temperature very high Stop th...

Page 372: ...f ficiently filled à Building supply pressure p 5 9 Suspension cannot be switched on or off Fuses F1 5 F2 1 F4 6 F5 4 blown Replace blown fuse à p 7 20 Error symbol is displayed ECOS malfunction Read out error messages à p 7 35 and notify Manitowoc Crane Care Malfunction Cause Remedy Level adjustment system not working Suspension switched off à Switching on the suspension p 5 15 Fuses F1 5 F2 1 F4...

Page 373: ...gram version Always note the number of the programme version before referring to Manitowoc Crane Care for malfunctions If required open the main menu ö The display 1 shows the number of the current programme version General malfunctions The following table contains information on troubleshooting and possible solutions H If further malfunctions occur the appropriate error messages are shown in the ...

Page 374: ... 3 5 for example means Error 3 is shown There is a total of 5 errors If the error shown is not acknowledged the lamp next to the button 3 lights up Acknowledging errors Press the 3 button once If there are further errors the next error is dis played and can be acknowledged When all errors have been acknowledged you can retrieve any pending errors using the buttons next to the symbols 1 and 2 Every...

Page 375: ...tand for The error code 5 consists of four digits e g 2332 Always note the error code before contact ing Manitowoc Crane Care Exiting the submenu You can exit the Errors submenu at any time Press the 1 button once The same menu opens that was open before the Errors submenu opened H All errors remain saved until you switch off the ignition even errors that have since been remedied All existing erro...

Page 376: ...Malfunctions in driving mode 7 7 Troubleshooting 7 38 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 377: ... cab and the doors Emergency operation is switched on at the fan wheel s hub Remove the bolts 1 Turn the metal plate 2 and remove it Press in the pin under the metal plate Emergency operation is switched on and the fan wheel runs continuously as long as the engine is switched on With a blocked fan wheel you may only drive up to 1000 km 620 mi G Risk of accident by turning fan wheel Always switch o...

Page 378: ...sary note the error messages à p 7 36 and refer to Manitowoc Crane Care Severe engine malfunction The STOP warning lamp 3 lights up In addition the following lamps light up Lamps 1 and 2 Stop the truck crane immediately while taking into account the traffic sit uation Switch off the engine If necessary note the error messages à p 7 36 and refer to Manitowoc Crane Care In the event of engine malfun...

Page 379: ...ic system conducts a check Serious fault 1 The STOP and Service symbol are displayed Service symbol 2 It is possible to continue driving However depending on the type of error there may be restrictions in Automatic operating mode or you can only shift the transmission in Manual operating mode Entry error message 3 The entry displays the error messages entry Drive on until you have a chance to stop...

Page 380: ...age clutch wear If CW is shown approx 10 seconds after switching on the ignition then refer to Manitowoc Crane Care Repairs will be necessary in the near future AL entry The supply pressure is insufficient Top up the supply pressure à p 5 9 If AL is still displayed check the compressed air system on the truck crane CL entry Release the accelerator after 30 seconds at the latest in order to prevent...

Page 381: ...the error code before referring to Manitowoc Crane Care Engage the parking brake Shift to position N For current error codes pending Do not depress the brake pedal 1 For stored error codes currently not pending Depress the brake pedal 1 Push the Transmission switch lever forward As long as you push the switch lever forward the display shows the current or stored error codes in repeated succession ...

Page 382: ...Malfunctions in driving mode 7 8 Procedure during malfunctions 7 44 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 383: ...Operating manual GMK 6400 3 112 993 en 12 07 2013 8 8 Index ...

Page 384: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 385: ...ear 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 will as usual be referred to more detailed descriptions of these elements ...

Page 386: ...Index 8 2 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 387: ...12 107 Raise onto the 20 t base plate 12 98 Raising and setting down the catcher 12 99 Securing the upper hook block in the catcher 12 106 Short description of the operating elements 9 76 Slinging points 12 92 Switching off 11 61 Switching on 11 59 Transport 12 93 Axle loads Required speed limit 6 5 B Battery master switch 4 12 Boom pre tensioning Switching off 12 17 12 19 Switching on 6 8 6 9 Bra...

Page 388: ...wing crane operation 12 5 Checks Before driving 5 6 Safety equipment 11 9 Vehicle height 5 8 Choosing a site 12 9 Compressed air system Building supply pressure 5 9 Counterweight 12 59 Assembling counterweight combination 12 67 CHECKLIST Counterweight rigging 12 62 Counterweight unrigging 12 65 Counterweight sections 12 59 Establishing disconnecting the hydraulic connection 12 81 Identification 12...

Page 389: ... 9 4 Standard heating system 11 130 Ventilating 11 131 Windows 9 112 Crane operation CHECKLIST checks before operating the crane 11 1 Permissible slewing ranges 11 55 Rigging CHECKLIST 12 1 Unrigging CHECKLIST 12 5 What to do in the event of malfunctions 14 3 Cruise control 5 40 5 41 D DEF system Operating elements in the driver s cab 3 37 Derricking gear 11 64 Raising and lowering 11 65 Short des...

Page 390: ...ring wheel 3 13 Transmission 3 14 Overview 3 4 Standard heating system 5 70 Windows 3 62 Driving at low temperatures CHECKLIST 4 4 Brakes Additional brakes 5 44 Checks before driving 5 6 Checks before driving CHECKLIST 5 1 Checks while driving 5 37 Downhill 5 42 Off road 5 57 Uphill 5 46 What to do in the event of malfunctions 7 3 With cruise control 5 40 5 41 Driving modes Tables for maximum axle...

Page 391: ...e driver s cab in the errors submenu 5 53 in the Monitoring submenu 3 23 in the Settings submenu 3 22 Operating hours 5 21 in the warning submenu 5 47 Electrical system Checks in the crane cab 11 6 Checks in the driver s cab 5 6 Display and operating elements in the crane cab 9 105 Fuses in the superstructure 14 6 Operating elements in the driver s cab 3 39 RCL fuses 14 11 Emergency operation Emer...

Page 392: ...ing 10 8 Switching on the ignition 10 4 Turning off During normal operation 10 17 in emergencies 10 18 Engine for crane operation Switching off Economy mode 10 13 Engine for driving Air intake inhibitor 4 27 Diagnostics 3 61 Malfunctions 7 27 Operation in the driver s cab Resetting the emergency stop switch 4 26 Operation in the driver s cab Checking after starting 4 19 Inspections before starting...

Page 393: ... 12 21 Malfunctions 14 20 Heating system Crane cab Auxiliary air heater 11 141 Auxiliary water heater 11 134 Standard heating system 11 130 Driver s cab Auxiliary water heater 5 75 Standard heating system 5 70 High speed mode 11 96 Derricking gear telescoping mechanism high speed mode 11 96 High speed mode for hoists 11 97 Switch on function 11 96 Hoist rope Checking the position 11 6 Positioning ...

Page 394: ...ion Conversion table for US measuring units 1 29 for operations planning 1 28 Notes on the operating instructions 1 21 Installing removing the air traffic control light 12 132 Installing removing the anemometer 12 132 K Keys for the carrier 3 63 for the superstructure 9 113 L Ladders and access ladders 4 4 Level adjustment system Changing the vehicle level 5 62 Exiting the submenu 5 63 Opening the...

Page 395: ...ifting off on the turntable 6 29 Retracting fitting the derricking cylinder head pin 6 21 Securing releasing the derricking cylinder 6 31 Slinging points 6 18 Transporting the main boom 6 32 Main boom removing installing disconnecting connecting hydraulics electrical 6 27 extending retracting the boom pivot pin 6 24 Main hoist 11 56 Folding hoist mirror out in 12 136 Lifting and lowering 11 57 Sho...

Page 396: ...gging for driving with a trailer 6 6 Switching on boom floating position 6 8 Switching on the slewing gear freewheel 6 7 Switching the superstructure driving lights on off 6 10 Main boom removing installing 6 11 Rear outrigger 6 53 Removing installing outrigger beams 6 35 Reverse camera installing 6 68 Supporting box CHECKLIST Assembly 6 57 Removal 6 54 Crane movements during installation and remo...

Page 397: ...ng the truck crane on outriggers Automatic 12 53 Inclination indicators 12 50 Manual 12 52 Outrigger pads Moving into driving position 12 43 Moving into working position 12 43 Outrigger pressure display 12 57 Permissible outrigger spans 12 32 Preparing the truck crane for rigging 12 33 Removing installing outrigger beams 6 35 CHECKLIST Assembly 6 38 Removal 6 36 Disconnecting establishing the conn...

Page 398: ...it 9 38 Overriding the RCL 11 40 RCL early warning 11 37 RCL shutdown 11 37 Due to error message 14 24 Due to overload 11 37 Switching on 11 20 Troubleshooting 14 22 Error messages 14 23 Errors submenu 14 25 General malfunctions 14 22 Rear outrigger Assembly 6 57 Removal 6 54 Slinging points 6 70 Rear outrigger box Control elements on the carrier 3 54 Reeving unreeving the hoist rope Rope end fitt...

Page 399: ... adjusting in the crane cab 11 7 in the driver s cab 5 11 Separate steering 5 66 Steering with separate steering 5 67 Switching to normal steering mode 5 69 Switching to separate steering 5 66 Settings before driving Adjusting the brightness of the display 4 15 Settings during crane operation Adjusting display brightness 10 7 Adjusting the power unit speeds 11 107 Adjusting the wiper stroke interv...

Page 400: ... lock houselock submenu Short description of the operating elements 9 89 Supporting box Establishing disconnecting the electrical connection 6 63 Establishing disconnecting the hydraulic connection 6 64 Establishing disconnecting the pneumatic connection 6 62 Hanging lifting on the truck crane 6 65 Transportation on a separate vehicle 6 73 Suspension Locking switching off 5 14 Operating elements i...

Page 401: ...tatus RCL display 11 74 Telescoping process 11 69 Telescoping sequence 11 74 Telescoping the main boom for maintenance 11 95 Telescoping the main boom when horizontal 11 95 Telescoping with teleautomation 11 91 Telescoping ECOS display 11 88 Towing 7 5 After engine transmission damage 7 6 Compressed air supply after engine failure 7 6 Electric power supply 7 7 Parking brake 7 8 Towing the truck cr...

Page 402: ... V Voltage monitoring Superstructure 9 105 W Warning plates for vehicle width 5 8 Welding work Safety instructions 2 4 Wheels and tyres Inflating the tyres yourself 7 17 Wheel change 7 13 Windscreen wiper 3 55 Crane cab 9 107 Driver s cab 3 55 Windscreen wiper washing system 9 105 Work break 11 128 in case of short work breaks 11 128 in case of work breaks of more than 8 hours 11 129 Working range...

Page 403: ...Index Operating manual GMK 6400 3 112 993 en 8 19 12 07 2013 Shutdown 11 127 Switching monitoring function on off 11 126 View current settings 11 116 ...

Page 404: ...Index 8 20 3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 405: ......

Page 406: ......

Page 407: ...3 112 993 en 12 07 2013 Operating manual Part 2 Crane operation ...

Page 408: ...anitowoc Crane Group Germany GmbH Industriegelände West D 26389 Wilhelmshaven Germany Phone 49 0 44 21 294 0 Fax 49 0 44 21 294 301 Distributing or reproducing this document as well as using or disclosing its contents is prohibited without express authorisation Any infringement shall be punishable by compensation for damages All patent and utility model registration rights reserved The original la...

Page 409: ...r the GMK6400 truck crane Only reeve the hoist rope as described illustrated in this correction sheet It is important that you still observe all notes and safety instructions regarding rigging work on the main boom in the operating manual supplied With 7 head sheaves 7 sheave hook block s Correction sheet Possible reeving methods on the main boom Reeving A 14x B 13x C 12x ...

Page 410: ...27 08 2018 2 3 302 804 en Correction sheet GMK6400 5 sheave hook block 3 sheave hook block Reeving A 11x B 10x C 9x D 8x Reeving A 7x B 6x C 5x D 4x ...

Page 411: ...Correction sheet GMK6400 3 302 804 en 3 27 08 2018 1 sheave hook block Hook tackle s Reeving A 3x B 2x C 1x Reeving A 1x ...

Page 412: ...27 08 2018 4 3 302 804 en Correction sheet GMK6400 With 10 head sheaves 11 sheave hook block 9 sheave hook block Reeving A 20x Reeving A 19x B 18x C 17x D 16x ...

Page 413: ...Correction sheet GMK6400 3 302 804 en 5 27 08 2018 7 sheave hook block 5 sheave hook block s Reeving A 15x B 14x C 13x D 12x Reeving A 11x B 10x C 9x D 8x ...

Page 414: ...27 08 2018 6 3 302 804 en Correction sheet GMK6400 3 sheave hook block 1 sheave hook block Reeving A 7x B 6x C 5x D 4x Reeving A 3x B 2x C 1x ...

Page 415: ...Correction sheet GMK6400 3 302 804 en 7 27 08 2018 Hook tackle Reeving A 1x ...

Page 416: ...27 08 2018 8 3 302 804 en Correction sheet GMK6400 Blank page ...

Page 417: ...pm without load Main hoist Rope speed when lifting and lowering Normal speed maximum 50 m min 164 ft min High speed mode maximum 120 m min 394 ft min Auxiliary hoist Rope speed when lifting and lowering Normal speed maximum 42 m min 138 ft min High speed mode maximum 104 m min 341 ft min Telescoping mechanism Extending from 15 4 to 60 0 m 50 5 to 196 9 ft approx 420 s In automatic mode during unin...

Page 418: ...06 06 2014 2 3 113 115 en Correction sheet GMK6400 Blank page ...

Page 419: ...through the procedure in this section before stepping between the main boom and the stand surface or between the stand surface and the main boom G Risk of accidents due to unsuitable fall prevention safety system Always secure yourself with a fall prevention safety system that is permis sible in the country in which you are working and includes a shoulder waist and seat belt with a two point catch...

Page 420: ...e applicable standards and regulations in the country in which you are working If you are unsure find out which standards and regulations apply for the country in which you are working The fall prevention safety system must consist of a combined shoulder waist and seat belt a catch belt with two lines for fastening at feet height H Only one person at a time is allowed to be secured by the safety h...

Page 421: ... on the truck crane to climb up à Operating manual Make sure you always attach one line of the fall prevention safety system with the safety harness before entering the main boom Attach the second line of the fall prevention safety system with the safety harness once you are located on the main boom s G Risk of accidents due to incomplete safety system Make sure you always attach one line of the f...

Page 422: ...ou may only detach the second line of the catch belt once you have reached a secure position Use the available ladders and access lad ders on the truck crane to climb down à Operating manual G Risk of accidents due to incomplete safety system Only detach the second line of the catch belt once you have reached a secure position on a ladder or access ladder This will prevent falling due to an incomp...

Page 423: ...mage wear mobility and deformations Replacement Make sure damaged worn or deformed fastening or connecting parts are immediately replaced by Manitowoc Crane Care or an authorised GROVE dealer or your repair crew H The safety harness must always be replaced completely following stress caused by a fall even if no damage can be detected G Risk of accidents if inspections are not carried out Make sure...

Page 424: ...22 01 2014 6 3 113 060 en Additional page GMK6400 Blank page ...

Page 425: ...transport and the anemometer 3 and air traffic control lights are transported in the crane cab s Anemometer and air traffic control light Transport S Risk of damage during on road driving Always store the anemometer and the air traffic control lights in the crane cab before on road driving and fasten the rod to the transport retainer This prevents the specified overall height from being exceeded a...

Page 426: ...from the rod 3 Fasten the linchpin 2 to the rod 3 B Place the rod 3 in the clamp 5 Secure the rod with the retaining pins 4 For operation Remove the pin 3 from the clamps 5 You will need the retaining pins 4 later for assembly Fit the anemometer 1 and the air traf fic control lights onto the rod 3 Secure the anemometer with the linchpin 2 Assemble the anemometer à Operating manual ...

Page 427: ...tional head sheave 3 The additional head sheave 3 is only designed for operation via the second head sheave 2 For operation via the head sheave 4 only reeve the hoist rope in the way described in the accompanying operat ing manual s Use of additional head sheaves G Risk of accidents if the procedure is not carried out correctly Observe the information on the permissible usage of the auxiliary hois...

Page 428: ... the second head sheave 2 together with the additional head sheave 3 Use the outer rope attachment point 1 for 2 fall reeving G Risk of accident due to a damaged hoist rope Always use the second head sheave together with the additional head sheave located underneath it or with the auxiliary single sheave boom top This prevents the hoist rope from becoming overloaded snapping during operation and l...

Page 429: ...ifting by the lash ing eyelets 1 The weight of the main boom must not be supported by the lashing eye lets 1 Always lock the trailer on both sides by the locking points 3 s Instructions for operation with a trailer S Risk of damage if procedure is incorrect Only use trailers where it is guaranteed that all support points and locking points can be used on the main boom as intended and ensure that t...

Page 430: ...ndi cated Support points The maximum force permitted for the support points 2 is F3 in the angle range between the horizontal 3 and vertical 4 axes F3 max 258 kN 58 000 lbf Locking points The maximum forces permitted for the locking points 3 are F4 F5 and F6 in the direction indicated Horizontally F1 max 45 kN 10 115 lbf Vertically F2 max 45 kN 10 115 lbf In the direction of travel F4 max 65 kN 14...

Page 431: ...e in Part 1 Driving 9 Operating elements for crane operation 10 Starting turning off the engine for crane operation 11 Crane operation 12 Rigging work 13 Driving with rigged truck crane 14 Malfunctions during crane operation 15 Index This section alone does not constitute the entire operating manual The basic safety instructions for crane operation can be found in Part 1 Chapter 2 ...

Page 432: ...3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 433: ...elements 9 57 9 2 1 Definition of direction references 9 57 9 2 2 General rules for buttons and symbols on the display 9 58 9 2 3 Engine 9 59 9 2 4 Seat contact switch and dead man s switch 9 61 9 2 5 ECOS crane control 9 62 9 2 6 Outriggers 9 65 9 2 7 Inclination indicators 9 70 9 2 8 Raise axle 9 71 9 2 9 Outrigger pressure displays 9 73 9 2 10 Anemometer display 9 73 9 2 11 Main hoist 9 74 9 2 ...

Page 434: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 435: ...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 only available with additional equipment are desig nated accordingly These designations are made in this section only and are not repeated in the following sections Some figures show details from a different perspective than t...

Page 436: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 2 3 112 993 en Operating manual GMK 6400 12 07 2013 9 1 1 Exterior of the truck crane ...

Page 437: ...41 11 Main hoist à p 9 76 12 Auxiliary hoist1 removed à p 9 77 13 Counterweight removed à p 12 59 14 Outriggers Outrigger lighting1 à p 12 29 à p 3 57 15 Shut off valves on the superstructure hydraulics à p 10 3 16 Drive unit2 17 Outrigger control units Control units for raising the axles Emergency stop switch à p 9 54 à p 9 54 à p 14 1 18 Storage compartment for anemometer and air traffic control...

Page 438: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 4 3 112 993 en Operating manual GMK 6400 12 07 2013 9 1 2 Crane cab ...

Page 439: ...age compartment 9 Windscreen washing system reservoir3 10 Cab lighting à p 9 105 11 Loudspeakers 12 Radio cassette1 2 Radio CD player1 13 Auxiliary water heater Auxiliary air heater à p 9 12 à p 9 13 14 Console rear à p 9 10 15 Fan with switch1 16 Crane cab seat Version 1 Crane cab seat Version 2 Seat contact switch à p 11 7 à p 11 7 à p 9 63 17 Cover with fuses behind it à p 14 9 18 Intake air ve...

Page 440: ...0 12 07 2013 9 1 3 Front panel 1 Emergency stop switch à p 9 66 2 RCL control unit Rated Capacity Limiter à p 9 38 3 Depending on the version Key operated RCL override switch symbol A or Key operated RCL override switch For RCL Lifting limit switch à p 11 45 à p 11 47 4 ECOS control unit à p 9 18 5 Front panel à p 11 8 ...

Page 441: ...s for crane operation 9 1 Overview of the operating elements Operating manual GMK 6400 3 112 993 en 9 7 12 07 2013 9 1 4 Side panel Below s 1 Ashtray 2 Standard heating system à p 9 11 3 Diagnostics behind lid à p 9 113 ...

Page 442: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 8 3 112 993 en Operating manual GMK 6400 12 07 2013 Above ...

Page 443: ...ng mechanism à p 9 80 7 Spotlight sockets on off à p 9 104 8 Slewable spotlight on off1 à p 9 104 9 Air traffic control light camera on off camera1 2 à p 9 104 10 Swinging the spotlight1 à p 9 105 11 Flame start system indicator lamp1 à p 9 61 12 Voltage monitoring warning à p 9 104 13 Carrier ignition indicator lamp à p 9 61 14 Rotating beacon on off1 à p 9 104 15 Houselock on off1 à p 9 90 16 Se...

Page 444: ...of the operating elements 9 10 3 112 993 en Operating manual GMK 6400 12 07 2013 Console rear 1 Configuration according to version1 2 Battery heater1 2 à p 9 62 3 Socket 12 V 1 4 Key operated switch1 2 1 Additional equipment 2 à Separate operating manual ...

Page 445: ... GMK 6400 3 112 993 en 9 11 12 07 2013 Standard heating system s 1 CraneSTAR systemAir conditioning system1 à p 11 133 2 Setting fresh air recirculated air mixed air à p 11 131 3 Setting the fan à p 11 131 4 Air distribution à p 11 132 5 Setting the temperature à p 11 131 1 Additional equipment ...

Page 446: ... Operating manual GMK 6400 12 07 2013 Auxiliary water heater 1 Heating display à p 11 137 2 Setting the day and time à p 11 138 3 Storing the heating start Switching heating start on off à p 11 139 à p 11 140 4 Switching on Switching off à p 11 137 à p 11 141 5 Input à p 11 138 6 Input à p 11 138 ...

Page 447: ... 112 993 en 9 13 12 07 2013 Auxiliary air heater 1 Heating display à p 11 142 2 Temperature à p 11 143 3 Setting the time day à p 11 143 4 Storing the heating start Switching heating start on off à p 11 143 à p 11 143 5 Switching on Switching off à p 11 142 à p 11 143 6 Input à p 11 143 7 Input à p 11 143 ...

Page 448: ...sion à p 9 16 2 Dead man s switch à p 9 63 3 Horn button or Slewing gear freewheel1 à p 9 78 4 Depending on which function is activated button for Derricking gear telescoping mechanism high speed mode on off à p 9 80 5 Auxiliary hoist slewing indicator à p 11 60 6 Slewing gear on off à p 9 78 7 Raise switch à p 9 81 8 Auxiliary hoist on off1 à p 9 77 9 Inclining the crane cab1 à p 9 88 1 Additiona...

Page 449: ...ration according to version à p 9 16 2 Dead man s switch à p 9 63 3 Horn button 4 Hoist high speed mode on off à p 9 76 5 Main hoist slewing indicator à p 11 57 6 Main hoist on off à p 9 76 7 Derricking gear on off à p 9 80 8 Telescoping mechanism on off à p 9 81 9 Derrick lattice extension on off1 2 1 Additional equipment 2 à Lattice extension operating instructions ...

Page 450: ...h two different 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 Slew to the left 5 Raise the boom 3 Slew to the right 7 Lower the boom 2 Extend 6 Lower the main hoist 4 Retract 8 Lift the main ho...

Page 451: ...control lever is configured with the Telescope function Left control lever Right control lever 1 Slew to the left 5 Raise retract2 3 Slew to the right 7 Lower extend2 2 Lower the auxiliary hoist1 6 Lower the main hoist 4 Raise the auxiliary hoist 1 8 Lift the main hoist 1 Additional equipment 2 Derrick the lattice extension à Lattice extension operating instructions ...

Page 452: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 18 3 112 993 en Operating manual GMK 6400 12 07 2013 9 1 7 ECOS control unit ...

Page 453: ...S display Main menu overview à p 9 66 à p 9 20 2 Brightness sensor1 à p 9 66 3 Error warning message à p 9 64 4 Buttons F1 to F14 à p 9 64 5 Brightness sensor1 à p 9 66 6 Opening Errors submenu Submenu overview à p 9 64 à p 9 36 7 Keycode entry à p 9 65 7 1 Open Warning submenu Submenu overview superstructure à p 9 64 à p 9 33 7 2 Open Warning submenu Submenu overview carrier à p 9 65 à p 9 34 8 E...

Page 454: ... crane operation 9 1 Overview of the operating elements 9 20 3 112 993 en Operating manual GMK 6400 12 07 2013 9 1 8 ECOS display main menu The main menu displays symbols for further submenus and symbols for current displays ...

Page 455: ...nu à p 9 28 8 Outriggers submenu à p 9 24 9 Remote control display1 3 10 Settings submenu à p 9 30 11 Power units display Slewing gear Auxiliary hoist Main hoist Derricking gear Telescoping mechanism à p 9 78 à p 9 77 à p 9 76 à p 9 80 à p 9 81 12 Superstructure lock submenu1 à p 9 23 13 Working range limiter submenu1 à p 9 36 14 Serial number and programme version displays à p 9 66 15 Derrick Lat...

Page 456: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 22 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 457: ...COS display submenus Superstructure lock submenu s 1 Superstructure locking status displays à p 9 89 2 Display slewing direction to 0 180 à p 9 90 3 Houselock locking status displays1 à p 9 90 4 Unlock turntable à p 9 89 5 Lock turntable à p 9 89 6 Slewing gear display à p 9 79 7 Current slewing angle display à p 9 79 1 Additional equipment ...

Page 458: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 24 3 112 993 en Operating manual GMK 6400 12 07 2013 Outriggers submenu ...

Page 459: ...er beam à p 9 69 6 Retract outrigger beam à p 9 69 7 Rear supporting cylinder à p 9 69 8 Front supporting cylinder à p 9 69 9 Extend supporting cylinders à p 9 69 10 Retract supporting cylinders à p 9 69 11 Rear left outriggers à p 9 69 11 1 Rear left hand outrigger pressure display1 à p 9 75 12 Left supporting cylinder à p 9 69 13 Front left outriggers à p 9 69 13 1 Front left hand outrigger pres...

Page 460: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 26 3 112 993 en Operating manual GMK 6400 12 07 2013 Telescoping submenu ...

Page 461: ...play à p 9 75 7 Locking point display à p 9 85 8 Enable telescoping display à p 9 85 9 Display for telescoping mechanism on off à p 9 82 10 Telescoping cylinder in the telescopic section display Teleautomation on display Manual telescoping on à p 9 82 à p 9 86 11 Telescoping cylinder length display à p 9 84 12 Current telescoping display à p 9 82 13 Telescope diagram display à p 9 83 14 Teleautoma...

Page 462: ...ewing gear speed à p 11 107 2 Enter telescoping mechanism speed à p 11 107 3 Enter main hoist speed à p 11 107 4 Enter derricking gear speed à p 11 107 5 Enter auxiliary hoist speed à p 11 107 6 Entered speed displays à p 11 107 7 Enter speed for lattice extension derricking gear1 8 Input mode display on 1 Additional equipment à Lattice extension operating instructions ...

Page 463: ...l GMK 6400 3 112 993 en 9 29 12 07 2013 Monitoring submenu s 1 Hydraulic oil temperature display à p 10 11 2 Fuel level display à p 10 11 3 Voltage monitoring display à p 10 11 4 Engine speed display à p 10 11 5 Coolant temperature display à p 10 11 6 DEF supply display1 1 Additional equipment ...

Page 464: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 30 3 112 993 en Operating manual GMK 6400 12 07 2013 Settings submenu ...

Page 465: ...off1 à p 9 69 5 Lamp test à p 10 5 6 Setting the characteristic curves for the control levers à p 11 108 7 Operating hours submenu à p 9 32 8 Adjusting display brightness à p 10 7 9 Main hoist pressure display 10 Auxiliary hoist pressure display 11 Switching Economy mode on off à p 10 13 12 Telescoping emergency programme access à p 9 86 13 Current telescoping mechanism status display à p 9 87 14 ...

Page 466: ...e displays à Displaying the operating hours p 11 110 1 ECOS superstructure 2 Auxiliary drive gears 3 Telescoping mechanism 4 Mega Wing Lift1 2 5 Derricking gear 6 Locking system 7 Main hoist 8 Auxiliary hoist1 9 Slewing gear 10 Lattice extension1 11 ECOS carrier 12 Engine 1 Additional equipment 2 Only active with additional equipment à Mega Wing Lift operating instructions ...

Page 467: ...ure s 1 Refuel 2 Air intake inhibitor triggered1 3 Voltage monitoring 4 Replace air filter 5 Coolant level too low 6 Top up DEF1 7 Engine malfunction 8 Torque reduction1 9 Torque reduction overridden1 10 Torque reduction override button1 à p 10 14 11 Correct main boom angle 12 Coolant too hot 13 Anemometer not connected 14 Oil pressure too low 15 Hydraulic oil too hot 16 Replace hydraulic oil filt...

Page 468: ...oring 4 Replace air filter 5 Coolant level too low 6 Top up DEF1 7 Engine malfunction 8 Torque reduction 9 Torque reduction override button à p 10 14 10 MegaDrive hydraulic oil too hot 11 Axle load or sideways tilt exceeded 12 Replace MegaDrive hydraulic oil filter 13 Hydraulic oil too hot 14 Replace the hydraulic oil filter 15 Replace hydraulic oil filter of steering circuit 1 or 2 1 Additional e...

Page 469: ...on 9 1 Overview of the operating elements Operating manual GMK 6400 3 112 993 en 9 35 12 07 2013 Errors submenu s 1 Current errors total errors display à p 14 32 2 Next error à p 14 32 3 Previous error à p 14 32 4 Error display à p 14 32 ...

Page 470: ...rall height display à p 11 118 3 Enter maximum working radius à p 11 118 3 1 Maximum current working radius display à p 11 118 4 Enter slewing angle submenu à p 11 119 4 1 Maximum current slewing angle display à p 11 119 5 Enter objects submenu à p 11 121 6 Manual input on off à p 11 124 7 Object monitoring on off à p 11 126 8 Slewing angle monitoring on off à p 11 126 9 Working radius monitoring ...

Page 471: ...1 121 s 1 Limited slewing angle display 2 Select slewing angle A 2 1 Maximum current slewing angle A dis play 3 Select slewing angle B 3 1 Maximum current slewing angle B dis play 4 Manual input on off 1 Limitation by object display 2 Point data display 3 Current point data display 4 Manual input on off 5 Select previous point 6 Select next point 7 Select angle working radius 8 Delete selected poi...

Page 472: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 38 3 112 993 en Operating manual GMK 6400 12 07 2013 9 1 10 RCL control unit ...

Page 473: ...p 9 93 à p 9 4 2 Brightness sensor1 à p 9 92 3 Error warning message à p 9 64 4 Buttons F1 to F14 à p 9 64 5 Brightness sensor1 à p 9 92 6 Opening Errors submenu Submenu overview à p 9 64 à p 9 47 7 Exiting submenu input mode à p 9 65 8 Acknowledging à p 9 92 9 RCL early warning à p 9 92 10 Entering values à p 9 65 11 RCL shutdown à p 9 92 12 Input confirmation à p 9 92 ...

Page 474: ...splay main menu The main menu shows symbols for further submenus and symbols for cur rent displays 1 Date time display à p 9 93 2 Enter rigging mode submenu à p 9 41 3 Errors submenu à p 9 47 4 Lifting capacity table submenu à p 9 45 5 Settings submenu à p 9 49 6 Monitoring submenu à p 9 42 7 Serial number and programme version displays à p 9 66 ...

Page 475: ...ring counterweight à p 9 95 2 Selection à p 9 94 3 Entering outrigger span à p 9 95 4 Maximum load display à p 9 96 5 Entering slewing range à p 9 96 6 Boom system display à p 9 97 7 Boom system entry for lattice extension1 à p 9 96 8 Entering reeving à p 9 94 9 RCL code entry à p 9 94 10 Determining RCL code display à p 9 94 11 Outrigger span monitoring display1 à p 9 95 1 Additional equipment ...

Page 476: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 42 3 112 993 en Operating manual GMK 6400 12 07 2013 Monitoring submenu ...

Page 477: ...CL code display à p 9 98 7 Current main boom length à p 9 101 8 Current overall height à p 9 101 9 Reeving display à p 9 98 10 Hoists display à p 9 98 11 Current main boom angle display à p 9 100 12 Maximum load display à p 9 100 13 Counterweight display à p 9 98 14 Turntable lock display 15 Current slewing angle display à p 9 101 16 Outrigger span display à p 9 98 17 Current working radius à p 9 ...

Page 478: ...ode monitoring submenu y 1 Query accept rigging mode 2 Permissible lattice extension working range1 3 RCL code 4 Length of lattice extension 5 Reeving 6 Permissible main boom working range 7 Hoists display 8 Counterweight 9 Permissible slewing range 10 Maximum load 11 Outrigger span à Accepting the rigging mode p 11 29 1 Additional equipment ...

Page 479: ... RCL code display à p 9 102 2 Reeving display à p 9 102 3 Selection 4 Maximum load display à p 9 102 5 Lifting capacity table display à p 9 102 6 Current degree of utilisation display à p 9 102 7 Current load display à p 9 102 8 Current working radius display à p 9 102 9 Telescope status display input à p 9 102 10 Working range submenu1 à p 9 46 1 Additional equipment ...

Page 480: ...2 07 2013 Working range submenu y 1 RCL code display à p 9 103 2 Reeving display à p 9 103 3 Maximum load display à p 9 103 4 Current load display à p 9 103 5 Current working radius display à p 9 103 6 Telescope status display input à p 9 103 7 Permissible working range display à p 9 102 8 Current position display à p 9 103 ...

Page 481: ... 1 Overview of the operating elements Operating manual GMK 6400 3 112 993 en 9 47 12 07 2013 Errors submenu 1 Selection à p 14 25 2 Display error location à p 14 25 3 Display of current errors total errors à p 14 25 4 Errors display à p 14 25 ...

Page 482: ... 3 112 993 en Operating manual GMK 6400 12 07 2013 Settings submenu y H Buttons displays 3 are only shown if a service device is connected For this reason these functions are not described in these operating instructions 1 Enter time date à p 11 51 2 Enter time date display à p 11 51 ...

Page 483: ...MK 6400 3 112 993 en 9 49 12 07 2013 9 1 13 Hand held controls H Required connections for the various movements à p 9 107 s 1 Engine control panel à p 9 108 2 Pre select emergency operation à p 9 109 3 Function buttons à p 9 109 4 Outriggers control panel à p 9 51 5 Rigging control panel à p 9 52 ...

Page 484: ...nation indicator à p 9 72 3 Front right outriggers à p 9 67 4 Rear left outriggers à p 9 67 5 Rear right outriggers à p 9 67 6 Switch measuring range à p 9 72 7 Pre selecting all supporting cylinders Pre select automatic alignment as additional function F1 à p 9 67 à p 9 67 8 Pre select high speed normal speed mode à p 9 67 9 Additional function F1 on 10 Horn à p 9 108 11 Additional function F1 on...

Page 485: ...anel 1 Rigging counterweight à p 12 84 2 Locking status 3 Rig auxiliary hoist à p 12 102 4 Boom pivot pin pulling device à p 6 26 5 Rigging winch1 6 no function 7 no function 8 Special function1 9 no function 10 no function 11 Special function1 12 no function 13 Special function1 14 Horn 15 Special function1 1 à Mega Wing Lift operating instructions ...

Page 486: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 52 3 112 993 en Operating manual GMK 6400 12 07 2013 9 1 14 Outrigger control units Button ...

Page 487: ...Outrigger pressure display à p 9 56 à p 9 57 à p 9 56 6 Additional function F1 on Position lights for indica tor lamps à p 9 71 7 Additional function F2 Select axle pairs à p 9 73 8 Additional function F3 Select axle pairs à p 9 73 9 Additional function F4 Menu selection Outriggers or Raise axle à p 9 73 10 In the Outrigger menu Retract all supporting cylinders In the Raise axle menu Raise axles à...

Page 488: ... GMK 6400 12 07 2013 Inclination and outriggerpressure display 1 Left hand outrigger pressure display opposite à p 9 75 2 Right hand outrigger pressure display opposite à p 9 75 3 Left hand outrigger pressure display à p 9 75 4 Right hand outrigger pressure display à p 9 75 5 Current inclination display à p 9 72 ...

Page 489: ...7 Axle load display for 1st and 2nd axle lines opposite à p 9 74 8 Axle load display for 1st and 2nd axle lines à p 9 74 9 Axle load display for 3rd and 4th axle lines opposite à p 9 74 10 Axle load display for 3rd and 4th axle lines à p 9 74 11 Axle load display for 5th and 6th axle lines opposite à p 9 74 12 Axle load display for 5th and 6th axle lines à p 9 74 13 Axle selection à p 9 73 14 Axle...

Page 490: ...Operating elements for crane operation 9 1 Overview of the operating elements 9 56 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 491: ... means that Forward always means the driver s cab is to the front of the direction of travel Backward always means the rear lights on the carrier are to the front of the direction of travel On the superstructure The main boom head is always at the front which means that Switches The terms down and up are used for switches and buttons Regardless of the fitting position vertical horizontal diagonal ...

Page 492: ...s the dot 1 only indicates that the switching operation has been completed Here you will also receive a report on the current gear change on an extra display 2 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 ...

Page 493: ...lamp s 0 Ignition off engine off key can be removed R 1 Ignition on and power supply on for instrument lighting ECOS engine control system RCL 2 Starting position à p 10 5 On Ignition in driver s cab on engine start not possible Off Ignition in driver s cab off engine start possible à p 10 8 Press down 1 x Engine starts idling speed standard Press down Increase idling speed Press up Decrease idlin...

Page 494: ...ting manual GMK 6400 12 07 2013 Console rear Battery heating system on off Further information on operation à Separate operating manual ECOS display There is no short description of the displays in the submenus à Monitoring submenu p 10 11 à Warning submenu p 11 111 Up Heating system on Down Heating system off ...

Page 495: ...own 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 rec...

Page 496: ...rol unit This section contains the operating elements that are the same for all menus opened Buttons F1 to F14 The function of buttons F1 to F14 is shown on the symbol next to or above the button After the button is pressed the function displayed is executed if it has been released Error warning message Opening Errors submenu The lamp 1 lights up or flashes Open Warning submenu The lamp 1 lights u...

Page 497: ...s the button 1 x This opens the Warning submenu for the carrier à p 11 111 Enter keycode Press buttons in the required sequence and con firm keycode à Telescoping emergency programme p 14 43 Press the button 1 x The opened submenu closes the menu from the next highest level is opened Input mode is deactivated Press the button 1 x A newly entered value is saved To the right Increases the value To t...

Page 498: ...Emergency stop switch May only be used in an emergency ECOS display Ignition on Main menu display Symbols with blue corner submenu Open submenu Press the button next to the symbol 1 x Serial number and programme version displays Press Engine off crane functions stop immediately Switch engages Turn switch while pressing Switch returns to initial position crane functions released à p 10 18 1 Serial ...

Page 499: ...e way Front left outriggers Front right outriggers Rear left outriggers Rear right outriggers As long as the lamp 1 is on you can pre select additional outriggers Pre select automatic alignment Pre select high speed normal speed mode Pre select Press button 1 x lamp 1 lights up pre selection on After 10 seconds lamp 1 goes out pre selection off Pre select Press button 1 x press button J 1 x Lamps ...

Page 500: ... beams Only supports on the same side are pre selected Supporting cylinders In the Outriggers submenu All directional information refers to the carrier à p 9 59 Outriggers submenu Slewing gear movements locked display 3 Extend 4 Retract à p 12 39 1 Extend Automatic alignment 2 Retract à p 12 47 To open Press button 1 x submenu opens Red Slewing gear switched off Green Slewing gear switched on outr...

Page 501: ...ng supporting cylinders Slewing gear is switched off outrigger pre selection on Movement stops after the button is released and when an end position is reached In the Settings submenu Outrigger control units on off s Pre select Press button 1 x dot 1 turns green pre selection on After 10 seconds dot 1 turns black pre selection off 1 To retract Press button outrigger beam retracts 2 To extend Press...

Page 502: ... pressed Movement stops after the button is released and when an end position is reached Operating the right hand outriggers next to control unit Operation is the same as on the button unit for Outriggers to the left of display field 1 Pre select Press button high speed mode pre selection on 2 Pre select Press button normal speed pre selection on 1 To retract Press button outrigger beam retracts1 ...

Page 503: ...ion display Raise axle menu Position lights for indicator lamps Light up when the ignition is on 1 To retract Press button all supporting cylinders retract 2 To extend Press button all support cylinders extend Movement stops after the button is released and when an end position is reached à p 12 46 Automatic levelling Press button 1 and button 2 Truck crane is levelled horizontally The process sto...

Page 504: ...ndicator Switch measuring range A On the hand held control B In the main menu In the Outriggers submenu C On the Outrigger control units 1 Measuring range display 2 Inclination indicator 3 Directional indicator A On the hand held control Press button 1 x lamp for current measuring range 1 or 5 lights up B In the Outriggers submenu C On the Outrigger control units Press button 1 x the current measu...

Page 505: ...raise or lower axle lines or axle pairs depending on the selection made Outrigger control units Raise axle display Switching on axle raising Press button 2 until display 1 appears Axle selection s 1 Selected axle pairs display 2 Directional indicator 3 Axle load display 4 Axle selection 5 Raise lower axles à p 13 7 Pre select Press button 1 the selected axle pairs 2 or axle lines turn black Pressi...

Page 506: ...the maximum permissible operation pressure 1 of 210 bar 3045 psi per axle pair has been exceeded then It is not possible to lower these axles any further Only the other axles can be moved H Operation of the axle raising on the opposite control unit is the same Raise Press button 1 the selected axles are raised and the truck crane is lowered Lower Press button 2 the selected axles are lowered and t...

Page 507: ...r display This function is the same in all the menus The anemometer is electrically connected Unit of measurement Displayed depending on setting t tons or klbs kilopounds 1 kilopound 1000 lbs Precision One decimal place à p 12 57 Unit of measurement Lights up depending on setting t tons or klbs kilopounds 1 kilopound 1 000 lbs Precision When in t one decimal place When in klbs no decimal point à p...

Page 508: ...Operating manual GMK 6400 12 07 2013 9 2 11 Main hoist à Main hoist p 11 56 Main hoist on off There is a lamp in the button Power units display Right control lever Press 1 x Lamp bright main hoist on Lamp dim main hoist off à p 11 57 Green Main hoist on Red Main hoist off Back Lift Forward Lower à p 11 57 ...

Page 509: ...or lamp for hoists Warning for lifting limit switch shutdown Left High speed mode on off when released 1 x to right High speed mode on continuous operation 1 x to right or 1 x to left High speed mode off à p 11 97 On High speed mode on Off High speed mode off à p 11 97 On Lifting limit switch triggered hoist stops Flashing Lifting limit switch triggered shutdown overridden Off Lifting limit switch...

Page 510: ...t on off There is a lamp in the button Power units display Left control lever Button and lamp for hoist high speed mode Short description with main hoist à p 9 76 Warning lamp for lifting limit switch shutdown Short description with main hoist Press 1 x Lamp bright auxiliary hoist on Lamp dim auxiliary hoist off à p 11 59 Green Auxiliary hoist on Red Auxiliary hoist off Back Lift Forward Lower à p...

Page 511: ...ar freewheel Press 1 x Lamp bright slewing gear on Slewing gear brake released Lamp dim slewing gear off Slewing gear brake engaged à p 11 99 Green Slewing gear on Red Slewing gear off On Slewing gear brake engaged Off Slewing gear brake released à p 11 99 To the left Slew to the left To the right Slew to the right à p 11 100 To switch on Move control lever to zero position and press button slewin...

Page 512: ...0 or 180 superstructure position Slewing gear display Current slewing angle display To open Press button 1 x submenu opens Both arrows 0 or 180 superstructure position reached One arrow Arrow direction slewing direction to reach 0 or 180 Green Slewing gear switched on Red Slewing gear switched off à p 11 99 0 Position 0 to the rear 180 Position 180 to the front 0 1 to 180 0 Turned to the right fro...

Page 513: ...is engaged High speed indicator lamp for derricking gear telescoping mechanism Press 1 x Lamp bright derricking gear on Power units with the same control lever configuration off Lamp dim derricking gear off à p 11 64 Green Derricking gear on Red Derricking gear off To the left Raise lift main boom To the right Lower lower main boom à p 11 65 Left High speed mode on off when released 1 x to the rig...

Page 514: ...ents for crane operation 9 2 Short description of the operating elements 9 80 3 112 993 en Operating manual GMK 6400 12 07 2013 Raise button shutdown bypassed On Shutdown bypassed Off Shutdown not bypassed à p 11 44 ...

Page 515: ...Control lever configuration version 1 Right control lever Control lever configuration version 2 Button and lamp for derricking gear telescoping mechanism high speed mode Short description with derricking gear à p 9 80 s Press 1 x Lamp bright telescoping mechanism on Power units with the same control lever configuration off Lamp dim telescoping mechanism off à p 11 76 Green Telescoping mechanism on...

Page 516: ...ress button 1 x submenu opens Green Telescoping mechanism on Red Telescoping mechanism off à p 11 79 1 Extended length of the telescopic sections in per cent 2 Telescopic section display is green On Telescoping cylinder is locked here Flashing Next possibility for locking telescoping cylinder à p 11 80 On Telescoping cylinder is locked here Flashing Next possibility for locking telescoping cylinde...

Page 517: ... Locked 2 On the telescoping cylinder None Unlocked or interme diate position à p 11 80 Locking pin Display 1 and 2 1 On the telescopic section Green Locked 2 On the telescoping cylinder Red Unlocked Yellow Intermediate position Violet Error symbol 3 à p 11 81 Display Yellow Telescoping cylinder unlocked Grey Telescoping cylinder locked Flashing yellow grey Unlock selected To select Press button 1...

Page 518: ...ess button 1 x Telescoping cylinder locked Unlock selected executed after moving the control lever Telescoping cylinder unlocked Unlock not selected symbol 1 flashes yellow grey as a prompt to Lock telescoping cylinder à p 11 86 Display Yellow Telescoping cylinder and telescopic section locked Grey Telescoping cylinder or telescopic section unlocked Flashing yellow grey Lock selected à p 11 85 à p...

Page 519: ...g display Entering target value for teleautomation s 1 Extend telescoping cylinder 2 Retract telescoping cylinder 3 Yellow approx 1 m 3 3 ft 4 Yellow less than 1 m 3 3 ft 5 Green At the locking point 1 Extend Red Blocked Green Enabled 2 Retract Red Blocked Green Enabled 1 Red Yellow Green Teleautomation off Enter target value Teleautomation on 2 Press button first time target value input on Press ...

Page 520: ...u à p 9 75 In the Settings submenu Telescoping emergency programme access The right dead man s switch is pressed 1 On Start teleautomation with Extending 2 On Start teleautomation with Retracting Flashing control lever movement incorrect à p 11 91 1 Teleautomation on à Telescoping with teleautomation p 11 91 2 Manual telescoping on à Manual telescoping p 11 79 Press the button 1 x After entering t...

Page 521: ...Operating manual GMK 6400 3 112 993 en 9 87 12 07 2013 Current telescoping mechanism status dis play The current status is shown using different symbols à p 14 17 1 Normal 2 Waiting 3 Emergency programme access 4 Keycode input 5 Emergency programme 6 Telescope status divergence 7 Inactive ...

Page 522: ...13 9 2 16 Hydraulic system Inclining the crane cab In the Settings submenu Current pressure in bar for movements of the Press down Incline back Press up Incline forward à p 11 105 1 Auxiliary drive gears Derricking gear Counterweight hoist unit Incline cab Locking units 2 Slewing gear 3 Telescoping mechanism 4 Main hoist 5 Auxiliary hoist ...

Page 523: ...atus of the locking pin is shown by different symbols Locking unlocking turntable The superstructure is in the 0 or 180 position Slewing gear display s To open Press button 1 x submenu opens 1 and 5 Green locked 2 and 5 Red unlocked 3 and 5 Yellow intermediate position 4 and 5 Violet error à p 11 14 1 To lock Press button locking pin extends 2 To unlock Press button locking pin retracts à p 11 14 ...

Page 524: ...ent symbols Houselock on off The slewing gear is switched off 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 11 101 Both arrows 0 or 180 superstructure position reached One arrow Arrow direction slewing direction to reach 0 or 180 à Locking unlocking the superstructure p 11 13 1 a...

Page 525: ...n of buttons F1 to F14 is shown on the symbol next to or above the button After the button is pressed the function displayed is executed provided it has been released Error Opening Errors submenu The lamp 1 lights up or flashes Exiting submenu input mode The lamp 1 lights up s On Error has occurred Off No errors à p 11 39 Press the button 1 x This opens the Errors submenu à p 14 25 Press the butto...

Page 526: ...is automatically adjusted à p 11 22 In the Rigging mode sub menu Press button 1 x Rigging mode monitoring submenu opens In the Rigging mode moni toring submenu Press button 1 x Rigging mode is accepted Monitoring submenu opens lamp 1 goes out Press the button 1 x Buzzer tone off error message acknowledged Flashing Degree of utilisation 90 100 buzzer tone on On Degree of utilisation about 100 buzze...

Page 527: ... à p 11 21 After a standstill of more than 48 hours Ignition on Enter rigging mode submenu opens à p 11 22 Main menu Date time display à Entering the time date p 11 51 Serial number and programme version displays s To the right Next greater value To the left Next smaller value Slowly turning changes the value gradually Quickly turning changes the value quickly à p 11 28 1 Time 2 Date 1 Truck crane...

Page 528: ...est value 2 Press button 1 x display next lowest value Input mode on Press button 1 1 x symbol turns green Input In input mode press button 8 9 1 x next RCL code on display 2 à p 11 28 Symbol 1 RCL code is determined after selecting Rigging mode No display New RCL code is displayed à p 11 25 Input mode on For main hoist Press button 4 until symbol 1 is green For auxiliary hoist Press button 4 unti...

Page 529: ...dentical for all outrigger beams 2 With displays 4 and 5 an error message is displayed after applying the rigging code à p 11 24 s Input mode on Press button 1 1 x symbol turns green Input In input mode press button 8 9 1 x next combina tion on display 2 à p 11 24 A 8 70 x 8 50 m 28 5 x 27 9 ft B 8 70 x 7 40 m 28 5 x 24 3 ft C 8 70 x 6 30 m 28 5 x 20 4 ft D 8 70 x 5 00 m 28 5 x 16 4 ft M 8 70 x 2 ...

Page 530: ...lewing range on display 4 à p 11 24 Maximum load display Short description with Monitoring submenu à p 9 100 Boom system entry 1 360 slewing range 2 Operating position 0 to the rear1 3 Operating position 180 to the front1 1 To accept switch off slewing gear Input mode on For boom system Press button 3 until symbol 2 is green For lattice extension length and angle Press button 3 until symbol 1 is g...

Page 531: ...anual GMK 6400 3 112 993 en 9 97 12 07 2013 Boom system display Boom system for displayed RCL code s 1 Main boom auxiliary single sheave boom top 2 Heavy load lattice extension 2 1 Angle 2 2 Length 3 Boom extension 3 1 Angle 3 2 Length 3 3 Angle 4 Luffing jib 4 1 Length 4 2 Angle 4 3 Main boom angle ...

Page 532: ... in tons t for displayed RCL code Outrigger span display Required outrigger span for displayed RCL code displayed in letters over view of outrigger spans à p 9 95 Hoists display 1 Required quantity of reeved ropes for displayed maximum load 2 I on Main hoist switched on first displayed reeving applies to main hoist II on Auxiliary hoist switched on first displayed reeving applies to auxiliary hois...

Page 533: ... display s Display Angle between lattice extension and main boom in degrees for displayed RCL code à p 11 35 Press the button 1 x The Lifting capacity table submenu opens à p 11 49 0 Position 0 to the rear 180 Position 180 to the front 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 35 Green Fixed length locked and set down Flashing Intermediate length locked ...

Page 534: ...opounds klbs for dis played RCL code Symbol 1 is red maximum load reduced by reeving Press button 3 1 x display 2 briefly shows maxi mum load for displayed RCL code à p 11 36 1 Display in percent 2 Colour display Blue 0 90 Yellow approx 90 100 early warning Red greater than 100 shutdown à p 11 36 Display Current angle between main boom and horizontal posi tion in degrees à p 11 35 Display Current ...

Page 535: ... 34 Service symbol display Symbol displayed service device connected s 0 Position 0 to the rear 180 Position 180 to the front 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 35 1 Error 2 Warning 3 Information 4 Corresponding number code press button 1 x next available number code à p 11 39 1 Current lattice extension length 2 Current main boom length 3 Current...

Page 536: ...enu To open Press the button 1 x submenu opens all crane movements are blocked the lights 1 light up 1 Lifting capacity in tons t or in kilopounds klbs 2 Working radius in metres m or feet ft 3 Show other values given in the table Display Telescope status 2 in percent Input Press button 1 New telescope status on display 2 Corresponding table on display 3 or all values 0 no table available RCL code...

Page 537: ...ope status Current position display Telescope status display input Other displays Function as in Lifting capacity table submenu s 1 Permissible working range surface under the curve 2 Maximum possible load 3 Maximum possible working radius 1 Current position defined by current load and current working radius Display Telescope status 2 in percent Input Press button 3 New telescope status on display...

Page 538: ... operated RCL override switch symbol B Turn to the right RCL shutdown overridden crane functions released no more monitoring à p 11 40 Turn to the left Lifting limit switch shutdown bypassed crane functions released no more monitoring à p 11 63 Turn to the right RCL shutdown overridden crane functions released up to 110 à p 11 40 Turn to the left Lifting limit switch shutdown bypassed crane functi...

Page 539: ...ating beacon on off s On Engine off ignition on or Engine on power failure switch off engine Off Engine on no malfunction à p 10 3 Switching on Press down voltage on both sockets Switching off Press up voltage off both sockets Switching on Press down voltage on socket switched on camera on Switching off Press up voltage on socket switched off camera off à Anemometer and air traffic control light p...

Page 540: ...6 3 112 993 en Operating manual GMK 6400 12 07 2013 Slewable spotlight on off Swinging the spotlight Cab lighting Reading lamp Switching on Press down Switching off Press up à p 11 109 Back Press down Forward Press up à p 11 109 1 Always on 2 Always off 3 On off if door open closed 1 On 2 Off ...

Page 541: ...en washing system Adjusting the wiper stroke interval In the Settings submenu Off Press up wiper goes to end position Interval Middle position Continuous operation Press down Off Press up wiper goes to end position Interval Middle position Continuous operation Press down Windscreen Press down Skylight Press up No additional wiping function is performed 1 Interval display 2 Press 1 x input mode on ...

Page 542: ...e when it is connected to the socket 4 The hand held control 5 is only active when it is connected to the socket 1 to 3 Pull plug Engine off ignition off Insert plug Ignition on à p 12 21 Released operations 1 Rigging Mega Wing Lift1 2 Emergency operation for crane movements except for telescoping mechanism Derrick lattice extension1 3 Emergency operation for crane movements Rigging counterweight ...

Page 543: ...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 engages Turn the engaged switch Switch returns to initial position crane func tions released 4 START engine Press 1 x Engine on 5 STOP engine Press 1 x Engine off Press...

Page 544: ...re four button combinations engaged buttons are 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 Luffing jib Pre select Press button 1 x...

Page 545: ... 111 12 07 2013 à Emergency operation with the hand held control p 14 55 Pre selected power unit Button combination Telescoping mechanism Derricking gear Slewing gear Hoists Lattice extension c e f a b d None Lower None Lower Lower Retract Raise None Lift Raise None None Slew to right None None None None Slew to left None None ...

Page 546: ... 1 inward Push the window forward Close window B Pull the window closed Turn both handles down pegs 2 located behind the holder 3 Crane cab door From outside Unlock Turn the key in direction A Lock Turn the key in direction B Open close Pull the handle 1 Slide the door S Risk of damage to the windscreen Do not open the windscreen if the Mega Wing Lift is in the rigging position This avoids a colli...

Page 547: ...or forwards by handle 1 engages Locking from inside not possible Opening Pull unlocking lever 2 push door back by handle 1 engages Keys Different keys are supplied 1 Crane cab door lock 2 Crane cab ignition lock 3 Key operated override switch 4 Distribution box 5 Windscreen washing system reservoir 6 Boom floating position lock 1 7 Slewing gear freewheel lock1 8 Covers 1 Additional equipment ...

Page 548: ...lements 9 114 3 112 993 en Operating manual GMK 6400 12 07 2013 9 2 23 Diagnostics The diagnostics connections may only be operated by the service staff The following connections are below the cover 4 1 ECOS diagnostics serial interface 2 ECOS diagnostics Can bus 3 RCL diagnostics ...

Page 549: ...sation 10 5 10 1 5 Adjusting display brightness 10 7 10 1 6 Start the engine 10 8 10 1 7 Checks after starting the engine 10 10 10 1 8 Monitoring submenu 10 11 10 1 9 Setting the idling speed 10 12 10 1 10 Switching off Economy mode 10 13 10 1 11 Overriding torque reduction 10 14 10 2 Starting the engine with the hand held control 10 15 10 3 Turning off the engine 10 17 10 3 1 During normal operat...

Page 550: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 551: ...ou start the engine from the crane cab The procedure depends on whether you Start the cold engine for the first time of the day Start the engine from the crane cab à p 10 8 Start the engine with the hand held control à p 10 15 10 1 When starting the engine for the first time of the day The first start of the day should always be made from the driver s cab as all the displays for monitoring the eng...

Page 552: ...l in percent 100 corresponds to about 765 l 202 gal The level indicator below the display changes colour depending on the level à Standard tank p 4 8 à Dual tank p 4 9 G Danger of fire from flammable gases Switch off the engine the heater and all additional heaters before refuel ling S Risk of damage to the engine and catalytic converter Unauthorised consumables can damage the engine and catalytic...

Page 553: ...3 en 10 3 12 07 2013 10 1 2 Checks before starting the engine On hydraulic tank The valve on the hydraulic tank must be open before starting the engine Check whether the valve is open 1 lever parallel to the cable Open the closed valve s S Risk of damage to hydraulic pumps You may only start the engine when the valve on the hydraulic tank is open ...

Page 554: ...ration from the crane cab Check whether bridging plugs 1 to 4 are inserted in all the sockets à p 12 22 You can start the engine from the crane cab but if the hand held control is connected the operating elements for crane operation are disabled 10 1 3 Switching on the ignition Insert the ignition key into the ignition lock and turn the key to position 1 After switching on the ignition a lamp test...

Page 555: ... on the ignition again Check whether lamps 1 and 2 light up briefly If one or more lamps do not light up refer to Manitowoc Crane Care If the specified time is insufficient you can perform the lamp test again as follows s S Risk of accident from faulty lamps The lamps that are used to provide warnings and information during oper ation light up for control purposes whenever the ignition is switched...

Page 556: ...3 112 993 en Operating manual GMK 6400 12 07 2013 Performing lamp test If necessary open the main menu ö and press button 1 once This opens the Settings submenu Press the button 1 The specified lamps light up until you release the button again You can adjust the minimum brightness of the display if necessary à p 10 7 ...

Page 557: ...opens the Settings submenu Press the 3 button once A red bar 2 appears below the display 1 Set the desired minimum brightness with the switch 4 The brightness of the display changes while setting and you can view the set value 0 to 100 on the display 1 The brightness set here is the minimum value for automatic regulation H There is no automatic regulation if you set the brightness to 100 The displ...

Page 558: ...t system This section pertains to starting a warm and cold engine Do not press the accelerator Turn the ignition key to position 2 and hold it there until the engine starts Let go of the ignition key after the engine starts If the engine does not start release the ignition key after about 15 seconds and wait one minute before trying again H If the engine does not start after multiple attempts à Ma...

Page 559: ... within the next 30 seconds otherwise you must switch on the ignition again and wait until the lamp goes out H If the lamp 1 does not go out there is a fault in the flame start system refer to Manitowoc Crane Care Wait until the lamp 1 goes out Do not press the accelerator Turn the ignition key to position 2 and hold it there until the engine starts Let go of the ignition key after the engine star...

Page 560: ...essage persists refer to Manitowoc Crane Care If other symbols in this menu are displayed in red à Warning submenu p 11 111 Also check the following lamps on the side panel If the lamp 2 does not go out or lights up while the engine is running switch the engine off and look for the cause If the lamp 1 does not go out or lights up while the engine is running there is a malfunction in the flame star...

Page 561: ...the main menu ö and press the button 1 once This opens the Monitoring submenu The following values are displayed The colour of the bar below the values indicates the area in which the value can be found 1 Hydraulic oil temperature in C F 2 Fuel supply in percent 3 Voltage in volts 4 Engine speed in min 1 rpm 5 Coolant temperature in C F 6 DEF supply in percent Green Value OK Yellow Limit value alm...

Page 562: ... view the settings below the current engine speed Increasing reducing idling speed Press the 1 button up down until the required engine speed has been reached When reducing After about 3 seconds idling speed standard value After about another 3 seconds engine off It is only possible to restart the engine when approx 7 seconds have elapsed or Press the button up down once The idling speed 2 increas...

Page 563: ...n The Economy mode is switched on when you start the engine for crane operation When the control lever is not moved for a period of four minutes then the engine speed is reduced first and the hydraulic drive is then switched off after this You can also switch off the Economy mode To do so open the main menu and press the button 1 once This opens the Settings submenu Press the 1 button once Economy...

Page 564: ... can be found on the Warning submenu à p 11 111 If the DEF supply falls to the reserve level then the 1 symbol is displayed in yellow If the DEF supply is empty the symbols 1 and 2 are displayed in yellow If the symbol 1 flashes the engine torque is reduced after the next engine start The engine torque is reduced Press the button 2 down to override torque reduction The symbol 1 is displayed You ca...

Page 565: ...is inserted in all unneeded sockets à p 10 4 The ignition in the driver s cab is switched off Starting the engine All checks required before starting the engine must be carried out à p 4 1 Wait until the lamps 1 and 2 light up If the lamp 2 does not go on or flash after about 20 seconds there is a mal function à p 14 20 Press the button 3 once the engine starts H If the hand held control is connec...

Page 566: ...Starting turning off the engine for crane operation 10 2 Starting the engine with the hand held control 10 16 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 567: ... will stop If the hand held control is connected Press the button 1 once the engine goes off It is not possible to switch off the engine with the ignition lock After turning off Observe the notes in the appropriate sections à In case of short work breaks p 11 128 à In case of work breaks of more than 8 hours p 11 129 G Risk of accident by suspended loads Never turn off the engine with a suspended ...

Page 568: ...cy stop switch You can only restart the engine after you have reset the emergency stop switch Turn off the ignition Turn the used emergency stop switch until it disengages again If an air intake inhibitor is present this must be loosened à Releasing the air intake inhibitor p 4 27 G Risk of overloading if used improperly Use the emergency stop switches only in an emergency i e if the crane functio...

Page 569: ...11 2 9 Displaying the lifting capacity tables 11 49 11 2 10 Entering the time date 11 51 11 3 Crane operation with main boom 11 53 11 3 1 Checks during crane operation 11 53 11 3 2 Permissible slewing ranges and working positions 11 55 11 3 3 Main hoist 11 56 11 3 4 Auxiliary hoist 11 59 11 3 5 Lifting limit switch and lowering limit switch 11 62 11 3 6 Derricking gear 11 64 11 3 7 Telescoping mec...

Page 570: ...Switching monitoring functions on off 11 126 11 5 6 Shutdown by working range limiter 11 127 11 6 Work break 11 128 11 6 1 In case of short work breaks 11 128 11 6 2 In case of work breaks of more than 8 hours 11 129 11 7 Heating and air conditioning system 11 130 11 7 1 Standard heating system 11 130 11 7 2 Air conditioning system 11 132 11 7 3 Auxiliary water heater 11 134 11 7 4 Auxiliary air h...

Page 571: ...ng 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 Ins...

Page 572: ...sary à p 11 109 4 Earth the load if necessary à p 11 12 5 Adjust crane cab seat and front panel à Adjusting the crane cab seat and front control panel p 11 7 6 Start the engine for crane operation à p 10 8 7 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 9 8 Check the position of the hoist ropes...

Page 573: ...ride switches à p 11 40 10 Compare current rigging mode to display on RCL enter current rig ging mode if necessary à p 11 23 11 Compare current reeving of hoist used against the display on the RCL enter current reeving if necessary à p 11 29 12 Check telescoping à Checks before starting work p 11 75 13 Perform lamp test on the RCL à p 11 20 s ...

Page 574: ...off houselock for other working positions symbol 2 is red à p 11 17 15 Check the electrical system for correct operation à p 11 6 16 Adjust the brightness on the ECOS display and the RCL display as required à p 10 7 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 ...

Page 575: ...nk 1 with the lid Visual inspection Walk around the truck crane and look out in particular for leaking oil fuel or coolant s S Danger of fire from 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 emer gency mode O Risk of environmental damage due to leaking consu...

Page 576: ...d The rope turns on the drum must be evenly spaced at a distance of 0 to 2 mm 0 to 0 08 in The cross over points must be at an angle of about 180 H The ropes of the top layer lie over the ropes of the bottom layer at the cross over points Checking the electrical system Check the following functions and have faulty parts repaired Spotlights air traffic control light rotating beacons Windscreen wipe...

Page 577: ... the seat contact switch à p 9 61 s 1 Control panel height 2 Back rest angle on both sides 3 Seat length adjustment without control panels 4 Seat height 5 Adjust suspension stiffness to body weight 6 Seat length adjustment with control panels 1 Control panel height 2 Back rest angle on both sides 3 Seat length adjustment without control panels 4 Seat length adjustment with control panels 5 Seat he...

Page 578: ...g manual GMK 6400 12 07 2013 Front panel You can adjust the height of the front control panel A Hold the front control panel by the han dle 2 Fold the pedal 1 upwards B Adjust the front control panel to the desired height Fold down the pedal 1 to lock the front con trol panel ...

Page 579: ...n boom until the 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 that 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 ...

Page 580: ...ops Turn the emergency stop switch until it dis engages Release the air intake inhibitor if required à Air intake inhibitor p 4 27 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 H Do not operate the emergency stop switch to turn off the engine in normal operation Only o...

Page 581: ... of the right dead man s switch and check whether the crane movement comes to a standstill within approx 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 standst...

Page 582: ...oss section of at least 16 mm2 0 025 in2 Clamp the other end of the cable 3 to a metal rod 2 with an insulated grip 1 Hold the metal rod by the insulated grip 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 thunde...

Page 583: ...ng points are at 0 and at 180 If necessary open the main menu ö and press the 1 button once The Superstructure lock submenu will open The display 1 shows the current superstructure position Slew to locking point at 0 or 180 The display 1 shows positive and negative values For an overview à p 11 101 At the locking point both arrows 1 are shown In the range of 20 around the locking point an arrow in...

Page 584: ... displayed contact Manitowoc Crane Care Unlocking the superstructure The RCL shutdown procedure will be triggered and slewing disabled if you unlock the turntable when an RCL code for 0 to the rear has been entered To acknowledge the shutdown procedure you must either lock the super structure or set down the load and enter an RCL code for a working range of 360 Press button 3 until symbol 1 turns ...

Page 585: ...it is to be locked and then stop the slewing movement If necessary open the main menu ö and press the button once The Superstructure lock submenu will open Switching off the slewing gear The slewing gear brake must be engaged when operating the houselock Press the 1 button once The slewing gear will be switched off and the slewing gear brake engaged Symbol 3 is red The lamp 2 lights up s S Risk of...

Page 586: ...eed to correct the position of the superstructure as fol lows Switch the houselock off press in the but ton 1 at the bottom until the symbol 4 turns red Switch on the slewing gear and slew the superstructure a little further minimally Switch off the slewing gear Press in button 1 at the top until symbol 2 turns green The slewing ring 5 will be displayed in the same colour as the displayed symbol 1...

Page 587: ...not à Switching off the slewing gear p 11 15 Press in button 1 at the bottom until sym bol 2 turns red The display will first show symbol 3 in yellow and when the houselock is switched off it will show symbol 2 in red 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 slewed during the locking proc...

Page 588: ...Crane operation 11 1 Before operating the crane 11 18 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 589: ... current rigging mode is cor rectly entered An incorrect entry will give you a false sense of security This may result in the truck crane overloading and causing an accident Registered based on measured values Registered based on manually entered values Main boom length Main boom angle Current load Lattice extension inclination1 Outrigger span3 Counterweight Length of lattice extension Lattice ext...

Page 590: ...ition A test programme runs after switching on the ignition A continuous buzzer tone sounds for about 2 seconds and a lamp test is performed Check whether you can hear a buzzer tone Lamp test Check that lamps 1 to 6 light up briefly after turning on the ignition If the specified time is insufficient switch on the ignition again If one or more lamps do not light up refer to Manitowoc Crane Care G R...

Page 591: ... displayed and symbols 1 and 2 will be green and flash You can accept the displayed values if they correspond to the current rigging mode Press button 3 once symbols 1 and 2 will stop flashing The lamps 1 and 2 go out The RCL code has been applied If no error message is displayed the RCL is set for crane operation and crane movements are enabled à Checks before operating the crane p 11 31 Any pend...

Page 592: ...g rigging mode will be displayed The display 1 shows the last reeving entered e g 1 Enter the current rigging mode à p 11 23 Brightness of the displays The brightness of the RCL display will adjust automatically to the ambient lighting after turning on the ignition Do not cover sensor 1 and keep it clean to avoid contamination that can affect the brightness adjustment You can also adjust the brigh...

Page 593: ... once The ö button is only active if all crane movements have been stopped The Enter rigging mode submenu will open There are two ways of entering the current rig ging mode Either enter the individual components 1 to 5 one after the other Or enter the RCL code 6 and the reeving 5 Then you must confirm and accept the newly entered rigging mode The following section describes the input procedure bas...

Page 594: ...monitoring In this order the values that can be selected for the current entry are always restricted by the previous entry As a result already entered values do not change When entering the components the corresponding RCL code 2 is dis played at the same time Then you must enter the current reeving 1 and accept the indicated rigging mode G Danger of overturning due to incorrectly set rigging mode...

Page 595: ... the Lifting capacity table The procedure for selecting is described based on the example of the counterweight symbol 1 green Press button 4 or 5 repeatedly until dis play 2 shows the rigged counterweight version The display 7 indicates the corresponding RCL code the symbol 6 is indicated while the RCL code is being determined The display 3 indicates the maximum load for the displayed rigging mode...

Page 596: ...on 4 repeatedly until the symbol for the required input is green Press button 3 repeatedly until The display 6 shows the rigged boom system e g the lattice extension or Until display 5 shows the rigged lattice extension length and in the case of an inclinable lattice extension the rigged lat tice extension angle Outrigger span without outrigger span monitoring Symbol 1 is green Press buttons 3 rep...

Page 597: ... required Otherwise an error message is displayed after applying the rigging code à p 14 27 H The error message can be supplemented by the shutdown as necessary s 3 Illuminated The required outrigger span is rigged 4 Flashes The required outrigger span is not rigged 5 No display The current outrigger span is not permitted S Risk of accident due to incorrectly supported truck crane A shutdown is no...

Page 598: ... 360 slewing range and slew the superstructure into the required position Entering the RCL code You must enter the RCL code for the rigging mode according to the Lifting capacity table Refer to the Lifting capacity table for the current rigging mode The corres ponding RCL code 1 is specified at the bottom of the table e g 1100 Press button 3 once symbol is green Press button 1 or 2 repeatedly unti...

Page 599: ...button 1 or 2 repeatedly until dis play 6 shows the number of currently reeved rope lines Accepting the rigging mode Prior to crane operation you must confirm and accept the newly entered rigging mode Confirming the rigging mode Press the 2 button once If the rigging mode is permissible lamp 1 will go out The Rigging mode monitoring submenu will open and you can accept the rigging mode If the rigg...

Page 600: ...g à p 11 31 G Risk of accident due to incorrectly set RCL If the current rigging mode varies from the displayed rigging mode the maximum load displayed by the RCL will not correspond to the actually permissible lifting capacity according to the Lifting capacity table Overloading and accidents will be the result 1 The rigged counterweight 2 The rigged outrigger span 3 The slewing range for the plan...

Page 601: ...ed when the Monitoring submenu is open After a standstill of less than 48 hours and after accepting a rigging mode the Monitoring submenu will open automatically You can also open the submenu manually If necessary open the main menu ö and press 1 button once The Monitoring submenu will open H You can only quit the RCL monitoring submenu when all crane movements have stopped control lever in zero p...

Page 602: ...th the crane if the current rigging mode of the truck crane is displayed G Risk of accident due to incorrectly set RCL If the current rigging mode varies from the displayed rigging mode the maximum load displayed by the RCL will not correspond to the actually permissible lifting capacity according to the Lifting capacity table Overloading and accidents will be the result 1 The angle of the rigged ...

Page 603: ...e lamp I for the main hoist is on The display 1 shows the reeving value entered last for the main hoist e g 9 If no reeving has been entered yet the RCL selects reeving 1 If necessary enter the current reeving à p 11 29 G Risk of accident due to incorrectly set RCL After switching over the hoists always check whether the displayed reev ing value corresponds to the current reeving value of the disp...

Page 604: ...Fixed and intermediate lengths differ in the locking pins 5 The current main boom length Shows the current main boom length in metres m or feet ft The current working radius Shows the current working radius horizontal distance between the turnta ble axis and the hook block axis The displayed value is calculated on the basis of the telescoping and the main boom or lattice extension angle The value ...

Page 605: ...n metres m or in feet ft depending on the setting The current lattice extension inclination Lattice extension luffable Shows the current lattice extension inclination in relation to the main boom in degrees Lattice extension inclinable Shows the angle of the lattice extension cor responding to the RCL code in degrees If the displayed RCL code does not apply to a lattice extension nothing will be d...

Page 606: ...load is reduced due to the reeving entered symbol 1 will be red In this case you can have the maximum possible load displayed briefly Press the 3 button once Display 2 shows the maximum possible load that can be lifted with suf ficient reeving according to the Lifting capacity table The degree of utilisation The degree of utilisation shows the weight of the current load as a percent age of the max...

Page 607: ...switch off the buzzer tone using button 1 The lamp 2 lights up Display 3 shows the current degree of utili sation e g 91 the bar is yellow H If the current crane continues to move in the same direction there will be an RCL shutdown 11 2 6 RCL shutdown There are different types of RCL shutdown Shutdown due to overload Shutdown due to an error à Error message with shutdown p 14 24 Shutdown due to ov...

Page 608: ... off the buzzer tone if necessary Leave the shutdown range by moving the crane according to the follow ing table H If you have left the shutdown range the lamp 1 goes out After pressing button Y the crane movements will be enabled Switched off crane movements Permitted crane movements Lift loads Lower loads Lower the main boom Raise the main boom1 Extend the main boom Retract the main boom1 Slew t...

Page 609: ...ng errors If an error occurs it will be displayed as fol lows Depending on the type of error the buzzer tone sounds once or as a continuous buzzer tone Lamps 1 and 2 light up Display 3 shows an error code and the associated symbol flashes Further indications depend on the type of error à Error messages in the Monitoring sub menu p 14 23 ...

Page 610: ...ed the status dis play 1 indicates this in the same way as the RCL display in the crane cab G Risk of accident 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 the RCL if it becomes absolutely necessary in the event of an emergency This is to put the tru...

Page 611: ...override the RCL Status display The status display informs people in the dan ger area of the truck crane About the current degree of utilisation In case of an RCL shutdown or early warn ing When the RCL has been overridden The warning will be visual and in part audi ble s 2 Key operated RCL override switch 3 Key operated rigging switch 4 Raise switch 1 Loudspeaker warning signal 2 Lamp green 3 Lam...

Page 612: ...he switches Switch pressed Degree of utilisation 0 90 approx 90 100 greater than 100 No switch normal operation Display 4 green Display 5 yellow Display 6 red Key operated rigging switch 1 Display 4 green Display 5 yellow Display 5 yellow flashing Button 2 Raise the boom Display 4 green Display 5 yellow Display 4 green flashing Key operated override switch 3 Display 6 red flashing Display 6 red fl...

Page 613: ...approx 100 of the maximum permissible load is exceeded Shutdown due to an error If the RCL has shut down the crane movements then Depending on the version lamp 1 lights up A continuous buzzer tone sounds The status display lights up red Now you can à Raising after RCL shutdown p 11 44 à Overriding RCL or lifting limit switch for rigging work p 11 45 à Overriding the RCL in an emergency p 11 47 s ...

Page 614: ...main boom Press the 1 button up once Raising is enabled The RCL will show an information code à p 11 48 The status display will flash green Raise the main boom with the control lever until the degree of utilisation is less than 100 The crane movements will then be enabled again 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 ...

Page 615: ...e the load moment is not reduced Requirement The engine for crane operation is running Overriding the lifting limit switch Turn the key operated switch 1 once anti clockwise Once the lifting limit switch has been acti vated the crane movement will only be stopped once and will then no longer be mon itored Overriding the RCL Turn the key operated switch 1 once clock wise Now a degree of utilisation...

Page 616: ...erride The override will be cancelled when you Press the key operated switch again Do not activate the control lever for 10 seconds Switch off the ignition S Risk of accident due to accidental override The key must not remain in the key operated switch while the crane is oper ating This prevents the RCL from overriding unintentionally ...

Page 617: ...he left or right once Now all crane movements will be enabled for 30 minutes The crane movements will no longer be monitored by the RCL The RCL will show an information code à p 11 48 The status display will flash red At a degree of utilisation over 110 the warning signal will sound à p 11 42 s G Risk of accident due to overridden or faulty RCL It is not permitted to work with an overridden or fau...

Page 618: ...operated switch while the crane is oper ating This prevents the RCL from overriding unintentionally Error code Cause Solution 8 04 4 Key operated rigging switch pressed no override effective Start the engine Reduce degree of utilisation to less than 110 Move the control lever within 10 seconds after operation 8 05 4 Raise switch pressed no override effective Start the engine Press switch again 8 0...

Page 619: ...rent status The lifting capacity table 2 applies to The entered RCL code The displayed telescoping 1 first the cur rent telescoping is displayed The maximum load 6 applies to working radius 5 For longer tables press buttons 4 to display more values You can have the lifting capacity tables dis played for all permissible telescoping sta tuses Enter the desired telescoping status 1 with the buttons 3...

Page 620: ...rent reeving 8 The cross 10 indicates the position in the working range for the current load 6 and the current working radius 5 The working range for all permissible tele scope statuses can be displayed Enter the desired telescoping status 4 with the buttons 5 The displays 1 2 and 3 show the respec tive permissible working range If the telescoping status is not within the work ing range The displa...

Page 621: ...utton 1 repeatedly until the desired value flashes Enter the new value with the buttons 7 and 8 or with the switch 9 Enter all the required values Press button 10 once the newly entered values will be accepted and displayed in the main menu Illogical values e g 77 seconds will not be accepted and the display will continue to flash You can cancel the input at any time Press the button 1 None of the...

Page 622: ...Crane operation 11 2 Operation of the rated capacity limiter 11 52 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 623: ... back to the 0 or 180 position you must immediately determine the cause and eliminate it and if necessary realign the crane Observe the posi tion of the superstructure when doing so à Levelling the truck crane on out riggers p 12 50 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 atten ...

Page 624: ...e value of the current wind speed The maximum permissible wind speed does not affect the colour of the bar If an anemometer is not available or in the event of a fault you can find out which speeds have been forecasted from the respective weather stations The Lifting capacity table contains an overview of the wind strengths wind speeds and their effects If the maximum permitted wind speed is excee...

Page 625: ... crane with the outrigger span required according to the Lifting capacity table Slew the superstructure to the rear into the 0 position For automatic stoppage at 0 à Braking the slewing movement p 11 102 Switch off the slewing gear à p 11 103 Enter an RCL code for the 0 to the rear according to Lifting capacity table à Entering the rigging mode p 11 23 The RCL will only accept this code if the sle...

Page 626: ...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 accident when raising loads at an angle Loads can bend the main boom 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 vertically I...

Page 627: ... lamp I flashes switch over the display à p 11 33 Check that the current reeving of the main hoist is displayed e g 10 Correct the reeving if necessary à p 11 29 Lifting and lowering 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 11 108 s G Risk of accident due to gaps in monitoring Operation of th...

Page 628: ...di cator 1 You can regulate the speed by moving the control lever and changing the engine speed with the accelerator You can set the desired engine speed idling speed with the button 1 à p 10 12 You can limit the maximum hoist speed à p 11 107 You can switch on the high speed mode for a higher speed à p 11 96 Switching off the main hoist If you no longer require the main hoist you should switch it...

Page 629: ...ould light up only dimly Symbol 2 must be red Press the 1 button 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 accident when operating the auxiliary hoist Read and observe all of the safety instructions in the section titled Main hoist p 11 56 before operating the auxiliary hoist All safety instructions for the operation of t...

Page 630: ...nd the control lever has been put in the initial position once When the hoist drum is turning you will notice a pulse on the slewing indi cator 1 You can regulate the speed by moving the control lever and changing the engine speed with the accelerator You can set the desired engine speed idling speed with the button 1 à p 10 12 G Risk of accident due to gaps in monitoring Operation of the hoist wi...

Page 631: ...st speed à p 11 107 You can switch on the high speed mode for a higher speed à p 11 96 Switching off the auxiliary hoist If the auxiliary hoist is not required it should be switched off to avoid unintentional use Press the 1 button once The lamp in the button 1 will light up dimly Symbol 2 is red when the auxiliary hoist is switched off ...

Page 632: ...r C the lifting limit switch weight is not attached The lifting limit switch will not trigger if it is locked The lamp 1 lights 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 perfo...

Page 633: ...nt due to gaps in monitoring If the lifting limit switch is overridden crane operation is no longer com pletely monitored When hoisting the lifting limit switch weight the crane movement will be stopped once After moving the control lever again the crane movement will again be enabled and will not be switched off again G Risk of accident due to incorrect setting or intended triggering Prior to ope...

Page 634: ...not intended for lifting loads If an overly heavy load is lifted by derricking the RCL will switch this process off You can have the operating hours of the derricking gear displayed à p 11 110 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 only light up dimly Press the 1 button once The ...

Page 635: ...working radius e g by retracting the telescoping the derricking speed will automatically be increased again You can set the desired engine speed idling speed with the button 1 à p 10 12 You can limit the maximum derricking speed à p 11 107 You can switch on the high speed mode for a higher speed à p 11 96 s G Risk of accident due to unexpected crane movements If assigned more than one function che...

Page 636: ...ing off the derricking gear If the derricking gear is not required it should be switched off to avoid unintentional use Press the 1 button once The lamp in the button 1 will light up dimly Symbol 2 will be red if the derricking gear is switched off If the control lever is assigned more than one function the derricking gear will also be switched off if you switch on another power unit which is assi...

Page 637: ...rocedure at about 10 15 if there are no rigging tables for the current rigging mode In this case you must bring the crane into a rigging mode for which a rigging table exists e g retracting setting down the load other superstructure position All rigging modes for which rigging tables exist can be found in the Lifting capacity tables G Danger of overturning with overridden RCL Do not under any circ...

Page 638: ...hen telescoping with teleautomation you enter a telescoping value and ECOS controls all the locking and unlocking processes automatically You may then need to manually telescope to an intermediate length With both ways control is possible on the ECOS control unit in addition to the control levers Here you initiate processes receive feedback and can monitor the telescoping process The ECOS display ...

Page 639: ...on 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 extended into the cutouts 6 the telescoping cylinder is locked The mechan...

Page 640: ...is unlocked 2 Moving and locking the telescoping cylin der The telescoping cylinder moves into the sec tion to be telescoped e g telescopic section III 3 The locking pins 5 extend the telescoping cylinder is locked 3 Unlock the telescopic section A The telescoping cylinder extends until the locking pins 7 are clear B The mechanism 10 retracts the locking pins 7 the telescopic section is unlocked ...

Page 641: ...ing pins 7 extend into the cutouts 4 The telescopic section is automatically set down The telescopic cylinder retracts until the locking pins 7 are positioned on the above telescopic section 1 The weight of the load is now on the telescopic sections and not on the telescoping cylinder Assignment for display The Telescoping submenu of the ECOS display shows two sectional views of the main boom The ...

Page 642: ...perating manual GMK 6400 12 07 2013 1 Telescopic section I 2 Telescopic section II 3 Telescopic section III 4 Cutouts 5 Locking pins on the telescoping cylinder 6 Cutouts 7 Locking pin on the telescopic section 8 Telescoping cylinder piston rod 9 Basic section 10 Mechanism ...

Page 643: ... 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 c...

Page 644: ...iate telescoping lengths in different ways Fixed lengths Possible fixed lengths 1 4 are 0 44 88 and 100 The locking pins 5 are green Intermediate lengths Telescoping sequence The telescopic sections can only be telescoped individually one after the other When Extending you must always extend the telescopic section with the highest numbering first then the telescopic section with the next lower num...

Page 645: ...elescoping mechanism error messages p 14 17 If a malfunction results in values being deleted ECOS can no longer calcu late the current telescoping and will not issue an error message Before telescoping the first boom compare the telescoping shown on the ECOS display with the current telescoping If the current telescope status is not correctly displayed enter the current telescope status à Entering...

Page 646: ...efore tele scoping a number of prerequisites need to be fulfilled as well Before manual telescoping à p 11 79 Before telescoping with teleautomation à p 11 91 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 11 108 G Risk of accident due to unexpected crane movements In the case of multiple configura...

Page 647: ...oping starts only if the arrow 1 for the selected telescoping direction is green If the arrow is red extension operations are disabled in the indicated direc tion This may have different causes e g the telescopic section being in final position a lifting limit switch shutdown a malfunction etc You can regulate the speed by moving the control lever and changing the engine speed with the accelerator...

Page 648: ...er speed à p 11 96 Switching off the telescoping mechanism If the telescoping mechanism is not required it should be switched off to avoid unintentional use Press the 1 button once The lamp in the button 1 will light up dimly The symbol 2 is 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 i...

Page 649: ...c section à p 11 86 Telescoping the telescopic section à p 11 88 Locking the telescopic section à p 11 89 H The operating order depends on the current initial position For an overview of a telescoping process example à p 11 69 H The lengths given in the following illustrations are purely sample values and may differ from the current display Checking the initial position Before telescoping you must...

Page 650: ... Position of the telescoping cylinder The display 4 shows how far the telescoping cylinder is extended e g 1200 mm 3 93 ft If the telescoping cylinder is near a locking point The display 3 shows the corresponding tel escopic section e g telescopic section III The display 2 shows the corresponding tel escopic section number is green The display 5 shows one or two arrows depending on the distance to...

Page 651: ...king 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 Requirements Telescoping mechanism on symbol 2 is green Telescoping cylinder locked symbol 1 is grey s 1 On the telescoping cylinder 2 On the telescopic section Red Unlocked Green Locked Yellow...

Page 652: ...ill flash the following is selected In the next step both selections are carried out one directly after the other Unlocking the telescoping cylinder Move the control lever for telescoping If required extend the locking pins 2 first The locking pins 3 retract In the Unlocked position symbol 1 will be yel low If the control lever is moved the telescoping cylinder will move immediately 1 Locking the ...

Page 653: ...ontrol lever The display 2 shows which movement you need to carry out to take the load off If removing the load does not cause the lock to be released you must lock the telescoping cylinder à p 11 85 and then restart unlocking s A Retracting B Extending S Risk of damage to the boom system If extending and retracting several times does not lead to the lock being released you must not telescope any ...

Page 654: ...een Telescopic section locked symbol 2 is grey Telescoping cylinder unlocked symbol 1 is yellow Extending retracting Move the control lever in the corresponding telescoping direction The telescoping cylinder 1 retracts extends The display 2 shows the currently extended length e g 1500 mm 4 92 ft Near a locking point the display 3 shows The distance to the locking point and The direction of travel ...

Page 655: ...is yellow To select lock Move the telescoping cylinder to the desired locking point e g to telescopic section III Wait until the display 2 A shows the desired telescopic section B shows no telescopic section and the desired locking point is reached next Press the 1 button once Symbol 1 will flash Lock telescoping cylin der is selected Locking the telescoping cylinder Move the control lever until l...

Page 656: ...n once If the telescoping cylinder is locked Symbol 1 will flash Unlock telescopic section is selected If the telescoping cylinder is unlocked Symbol 2 will flash the following is selected In the next step both selections are carried out one directly after the other Unlocking the telescopic section Move the control lever for telescoping If required extend the locking pins 3 first The locking pins ...

Page 657: ...pins are under load Release the control lever To relieve the load carefully retract and extend a little If removing the load does not cause unlocking you must lock the telescopic section à p 11 89 and restart unlocking s S Risk of damage to the boom system If extending and retracting several times does not lead to the lock being released you must not telescope any further against the stop ...

Page 658: ...locked Requirements Telescoping mechanism on symbol 3 is green Telescoping cylinder locked symbol 1 is grey Telescopic section unlocked symbol 2 is yellow Telescoping Move the control lever in the desired tele scoping direction The display 2 will show the currently extended length telescoping e g 55 for telescopic section III The current telescope diagram on the display 1 will change continually ...

Page 659: ... is grey To select lock Telescope to the desired fixed length e g telescopic section III to 100 If necessary wait until the telescopic section moves past a non desired fixed length by approx 5 e g at 50 display 2 Press the 1 button once Symbol 1 flashes Lock telescopic section is selected Locking the telescopic section Move the control lever until locking is com plete The locking pins 3 extend at ...

Page 660: ...ic section I was the last telescopic section to be retracted you can select locking directly If another telescopic section was retracted last you must do the following before selecting locking Unlock the telescoping cylinder à p 11 81 Move the telescoping cylinder into telescopic section I à p 11 84 Lock the telescoping cylinder à p 11 85 S Risk of damage to the telescoping cylinder Move the contr...

Page 661: ... further to the desired length manually Switch the telescoping mechanism on and open the Telescoping submenu à p 11 76 Display 1 to 4 desired telescope status objective of teleautomation Red values Teleautomation off No values Teleautomation disabled Telescope status input Press one of the buttons 1 to 4 Values are yellow input on To cancel input press button 5 once Enter the telescope status usin...

Page 662: ... Then the symbol for the new move ment will be displayed e g 2 for Retracting In the case of empty trips of the telescoping cylinder without telescopic section symbol 3 is displayed Ending teleautomation The teleautomation will stop when the entered telescope status is reached Move the control lever to its initial position Display 1 teleautomation off Cancelling teleautomation Press button 7 once ...

Page 663: ...ond to the opposite diagram once you have entered the desired tele scope status and confirmed it ECOS will calculate the following telescoping sequence Since the first step is retracting the arrow 1 points to the left Move the control lever to retract and hold it Telescopic section I is fully retracted The following processes are carried out automatically for this s Telescopic section I retract to...

Page 664: ...ontrol lever to its initial position Display 4 goes out Display 1 teleautomation off Values 5 are red Displays 2 and 3 current telescoping Teleautomation is switched off H To extend telescopic section I to 60 for example you can now further extend this telescopic section manually 1 Retract telescopic section I display 3 0 2 Lock telescopic section I pins 5 are green 3 Unlock telescoping cylinder p...

Page 665: ... à p 11 67 The RCL will automatically switch to the corresponding rigging table This table specifies the maximum permissible telescoping at which extending will be switched off shutdown values à Lifting capacity table Set down the load Extend the main boom only until the RCL switches off the extension pro cedure H If you continue to extend the main boom after an RCL shutdown you may enter ranges i...

Page 666: ... button 1 down on the right inwards High speed mode will be active until you release the button Continuous operation Press button 1 down on the left outwards High speed mode will be enabled until you press the button again The lamp 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 increa...

Page 667: ...d the control lever by more than 70 S Risk of accident 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 ...

Page 668: ...the initial position the slewing movement will be stopped At the same time the slewing gear brake will engage and lamp 1 will light up G Danger 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 rigg...

Page 669: ...osition 0 to the rear or Free on wheels an RCL shutdown will occur after switching on the slewing gear and slewing will be disabled To acknowledge the shutdown you must either switch off the slewing gear or set down the load and enter an RCL code for the 360 working range Releasing the slewing gear brake The slewing gear brake will be released as soon as you deflect the control lever 2 Lamp 1 will...

Page 670: ...s à Setting the characteristic curves for the control levers p 11 108 G Danger of overturning when slewing with an incorrectly set RCL Before slewing always check whether the RCL code valid for the current rigging mode is displayed This prevents slewing operations from being enabled within impermissible ranges which would cause the truck crane to overturn G Risk of crushing during slewing Before s...

Page 671: ...n if the control lever is brought into its initial position and the slewing gear is stationary You can set the desired engine speed idling speed with button 1 à p 10 12 You can limit the maximum slewing speed à p 11 107 Reading off the slewing angle In the Slewing gear houselock submenu display 1 shows the current posi tion 0 means that the superstructure is slewed to the rear Angles in the right ...

Page 672: ...e time the slewing gear brake will engage 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 e g when operating with two cranes Switch on the slewing gear Shift the control lever 2 to its initial position Press button 3 The slewing gear brake will be released lamp 1 will not light up S Risk of th...

Page 673: ...derricking gear can only be operated simultaneously when the control lever assignment is from Version 1 à p 9 16 The auxiliary power units tilt crane cab counterweight lifting unit can not be operated with the Extending movement Moving the auxiliary power units in combination with other power units can result in reductions of speed Lattice extension derricking gear The lattice extension derricking...

Page 674: ...to this you should ensure that the maximum permissible hydraulic oil temperature of 80 C 176 F is not exceeded The current hydraulic oil temperature is displayed in the Monitoring 8 sub menu If the maximum permissible temperature has been reached the bar below the display will turn red A warning message is issued additionally à Warning submenu p 11 111 If the hydraulic oil temperature reaches 80 C...

Page 675: ...at great heights For Mega Wing Lift additional equipment if this is in the rigging position then inclining the cab will be disabled in the rigging submenu the Mega Wing Lift symbol 1 will be red A To incline to the rear Close the crane cab door Press button 1 down B To incline to the front Close the crane cab door Press button 1 up The crane cab will tilt as long as you hold the button down or its...

Page 676: ...ue between 3 and 30 seconds for the front and roof window wiper stroke interval H The higher the selected value is the longer the pauses between the strokes of the wiper are If necessary open the main menu ö and press 1 button once This opens the Settings submenu The display 1 will show the current value Press the 3 button once Bar 2 is red input on To cancel the input press button 5 once Change t...

Page 677: ...om operation The values for the slewing gear and derricking gear only apply if they are lower than the auto matically limited values The automatically limited values are not displayed Button 4 will only be active if the auxiliary hoist is connected Changing values Repeatedly press for example button 3 for the slewing gear until the bar under the desired value is at 1 or 2 input on To cancel the in...

Page 678: ... characteristic curve will be shown on the display 2 Repeatedly press button 1 until the desired characteristic curve is displayed e g char acteristic curve 3 There are five characteristic curves Linear characteristic curve 1 The deflection of the control levers evenly increases the speed Even small movements of the control lever will produce a high speed Progressive characteristic curves 2 to 5 T...

Page 679: ...Switching off Press switch 1 up To direct the spotlights forwards Press button 2 up To direct the spotlights backwards Press button 2 down The direction of the spotlights will be adjusted until you let go of the button or they reach their end position G Risk of accident due to being dazzled during on road driving When driving on the road always direct the spotlight in such a way that the reflector...

Page 680: ...press 1 button once This opens the Settings submenu Press the 1 button once The Operating hours submenu opens The operating hours are displayed below the symbols e g 1680 hours and 12 minutes for the telescoping mechanism 2 or for the engine 4 Exception The value below the symbol 3 indicates how often the cycle Unlock telescopic section has been operated e g 13 750 times Auxiliary power units 1 in...

Page 681: ...ation Press button 4 or 5 next to the flashing lamp once the corresponding Warning submenu will be opened The warning message is acknowledged lamp 2 or 3 lights up will no longer flash Meaning of the symbols The colour of the symbols indicates whether a warning message is active in the corresponding area Symbol is grey no warning message Symbol is red warning message Perform the following checks a...

Page 682: ...nual Add oil if necessary If the error message persists refer to Manitowoc Crane Care Engine electronic system Malfunction in the engine electronics Immediately switch off the motor à Malfunctions in the engine p 7 27 S Risk of damage if warning messages are not observed Observe the following information in good time and take the appropriate remedial measures if a warning message appears This prev...

Page 683: ...eplace the corresponding hydraulic oil filter as quickly as possible à Maintenance manual Anemometer not connected Connect the anemometer to the electrical power supply à p 12 132 Voltage monitoring The voltage in the superstructure electrical system is too high or too low Current voltage display à p 10 11 Air intake inhibitor triggered The air intake inhibitor was triggered because the maximum pe...

Page 684: ...s the 1 button once The same menu opens which was open before the Warning submenu opened If the same warning messages are still present the lamps 1 and 2 light up If no warning message is present both lamps will have gone out Both lamps start flashing again as soon as a new warning message occurs 11 4 9 Errors submenu ECOS differentiates between error messages and warning messages warning messages...

Page 685: ...nt Do not deliberately 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 accident due to limits set too low When entering the limit values bear in mind that even after switching off the engine movements can still occur that would brin...

Page 686: ... displayed metres m or feet ft 11 5 2 Viewing current settings The Working range limiter submenu shows switched on monitoring func tions the limits entered and current values Monitoring on off The dots in the symbols 1 to 4 indicate the current status Dot is black Monitoring switched off Dot is green Monitoring switched on the monitored area is displayed à p 11 126 Dot is black Monitoring switched...

Page 687: ...put dis play 5 changes à p 11 124 The following applies to the slewing angle display 0 means that the superstructure is slewed to the rear Angles in the right semi circle are displayed as positive values 0 to 180 0 Angles in the left semi circle are displayed as negative values 0 to 179 9 H Viewing the limit values for object monitoring à Objects p 11 125 1 Overall height 2 Working radius 3 Slewin...

Page 688: ...ction 3 or 4 must be switched off dot is black à p 11 126 Press the button once Bar 5 is red input on Cancel input press button ö once A Move the main boom head to just before the shutdown point without a load e g at 17 5 m value 6 B Press button Ö once The current value 6 will be accepted as the limit value 7 The bar 5 goes out Switch on monitoring à p 11 126 G Risk of accident due to limits set ...

Page 689: ... entered in a submenu Before entering values monitoring 1 must be switched off dot is black à p 11 126 Press the 2 button once The Enter slewing angle submenu will open Display of the slewing angles The cross 1 shows the current position of the main boom The slewing angle A limits slewing to the left The slewing angle B limits slewing to the right The permissible slewing range is represented by th...

Page 690: ...isplayed The value 2 will be accepted as the limit 3 The bar 1 goes out Slewing angle B Press the 3 button once Bar 1 is red input on Cancel input press button ö once Slew the main boom 4 to the shutdown point from the left e g value 2 100 Press button Ö once The slewing angle B will be displayed The value 2 will be accepted as the limit 3 The bar 1 goes out G Risk of accident due to incorrectly s...

Page 691: ...presentation of points and objects Each point shown is numbered and defined by the point data slewing angle 9 1 and working radius 9 2 red An object is made up of points that are con nected by lines e g the points 1 to 3 and the points 5 and 6 The cross 10 and the point data 9 show the current position of the main boom blue H Only those points are displayed that are located within the entered maxi...

Page 692: ...ill be accepted for point 1 e g 2 and 20 m The first point has now been entered Enter the next point 2 in the same manner e g 90 and 20 m The point is connected with point 1 an object has been entered To enlarge the object you can enter subse quent points 3 to 8 e g point 3 You can also add objects Delete the subsequent point e g point 4 point data 0 0 à p 11 123 Enter the next point e g point 5 a...

Page 693: ...ou can delete selected individual points or delete all points at once A Selected points Press the 1 button once The selected point will be deleted e g point 4 point data 0 0 B All points Press button 2 once symbol 3 will appear You can cancel the process with the ö button Press button Ö once all points will be deleted ...

Page 694: ...once For slewing angles Open the Enter slewing angle submenu Press the button once Entering a limit value The bar 3 is red input on To cancel the input press button ö once Press button 2 once the dot will turn green manual input on A Enter the new limit value e g 17 5 with the switch 1 on display 4 B Press button Ö once Display 5 new limit value Display 4 current value e g 3 0 Bar 3 goes out Dot 2...

Page 695: ...t will turn green manual input on With button 13 select one of the following The slewing angle bar 10 is red The working radius bar 9 is red Input on Cancel input press button ö once Enter the new values e g 90 0 and 20 0 m with switch 14 Press button Ö once The new values for point 1 will be accepted You can enter additional points in the same way button 12 To end your input press the ö button on...

Page 696: ... monitored area will be displayed Working radius Circle 8 red Permissible slewing angle Circle sector clockwise from A to B Objects Points and lines e g 1 to 2 and 4 to 6 Overall height No display The current main boom position 7 is always displayed H It is impossible to move behind a defined object whenever a monitoring function is switched on 1 Overall height 2 Working radius 3 Slewing angle 4 O...

Page 697: ...d all movements enabled Shutdown point reached for Disabled movements Overall height Raising the boom Extending Lowering the hoist Derricking the lattice extension Working radius Lowering the boom Extending Lifting the hoist Derricking the lattice extension Slewing angle A Slewing to the left Slewing angle B Slewing to the right Objects Depending on the position of the object Slewing to the left o...

Page 698: ...light up slewing gear brake engaged 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 11 129 G Risk of accident by suspended loads Never turn off the engine with a load suspended You must have the control levers at hand in order to intervene at any time Always set down the load befor...

Page 699: ...urn the ignition key to position 0 and remove it Switch off all electrical loads 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 unauthorised use Always lock th...

Page 700: ...ing the fan Turn switch 2 to the required level 1 to 3 depending on the desired air quantity Setting fresh air recirculated air mixed air You can set the air to be sucked in by the fan Turn switch 1 to the position for Setting the temperature Turn switch 1 in the required direction A Recirculated air air is sucked out of the crane cab Change to fresh air often to ensure that oxygen is supplied B F...

Page 701: ...n adjust air vents 2 and 3 Adjusting the air vents Switching off Switching off the heater Turn the switch 1 as far as it will go in a counter clockwise direction to Cold Switching off ventilation Turn the switch 2 to the level 0 A Air vents 1 2 windscreen centre B Air vents 3 cab floor C Air vents 1 2 3 1 To open Press in and position lengthwise To close Position crosswise To direct the air flow I...

Page 702: ...me 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 air thoroughly The cooling down procedure can be accelerated by incre...

Page 703: ...air cooling will be quicker However no oxygen will be supplied Drying the air You can dry the air in the crane cab Here however no heating or only a small amount will be produced Press switch 1 down Turn the switch 5 as far as it will go to Warm Turn switch 3 to the required level Adjust the setting for fresh air recirculated air to the current conditions humidity and temperature of the outer air ...

Page 704: ...ary heater with the engine switched off You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently You can use the auxiliary water heater to Preheat just the engine Preheat the engine and crane cab simultaneously Preheating the engine If only the engine is to be preheated adjust the heating system as follows Switch 1 to Warm setting Switch 2 to position Fan off...

Page 705: ...ne cab is to be preheated in addition to the engine adjust the heat ing system as follows Switch 1 to Warm setting Switch 3 to the Recirculated air symbol Turn switch 2 to the required fan level Open the air vents à p 11 131 H The amount of time required to preheat the engine will be increased signif icantly by simultaneously heating the crane cab s ...

Page 706: ...ed 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 switched off However the pump for the auxiliary heater continues to run until you switch the auxiliary heater off H Always switch off the auxiliary heater when you turn off the truck crane when the battery master switch is switched on In th...

Page 707: ...rrupted all symbols in the display will flash and you must set the time and day again Press the button 1 for longer than 2 seconds The displayed time flashes e g 10 00 s t Set the current time on the flashing display e g 14 00 Wait five seconds The new time is saved and then the weekday flashes e g MO for Monday s t Set the current day of the week on the flashing display The display stops flashing...

Page 708: ...and is saved as the new value To retrieve a storage location press the button 1 once Flashing displays The retrieved storage location e g 2 The last saved heating start e g 6 00 s t Set the time for the desired heating start e g 8 00 Wait for approx 5 seconds until the day of the week for the heating start flashes e g MO for Monday s t Set the day of the week for the desired heating start Wait for...

Page 709: ...ing period of 10 to 120 minutes Wait for approx 5 seconds until the current time is shown e g 14 00 hrs A new heating period has now been set Switching heating start on off To switch on an automatic heating start you must retrieve the correspond ing storage location To retrieve a storage location press the button 1 once The display flashes for 5 seconds and a storage location is shown e g 2 The he...

Page 710: ...gnition while the auxiliary heater is in operation the auxiliary heater continues to run for a certain period of time You can set this remaining time à Setting the remaining time p 11 140 Setting the remaining time If the ignition is turned off while the auxiliary heater is running the heating system will continue to run for the remaining run time Switch on the heater using the 1 button Turn off t...

Page 711: ...2 Before switching on the heating system check whether it is allowed to be operated at the current site of the truck crane Find out whether there are any possible sources of danger that could result in an explosion Turn on the ignition à Switching on the ignition p 10 4 Press the 1 button once The auxiliary heater switches on automatically the control field lights up s G Risk of explosion when ope...

Page 712: ... counter clockwise The higher the selected temperature is the faster the fan of the auxiliary heater runs Switching off You can switch off the auxiliary heater manually at any time Press the 1 button once The auxiliary heater is switched off immediately Additional functions The auxiliary air heater has the same functions as the auxiliary water heater Setting the time day à p 11 137 Storing the hea...

Page 713: ...ws the position of the associated components and gives tips on troubleshooting The CraneStar system will only be activated at the request of the crane oper ator 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 of the information about activat ing the CraneStar system 11 8 2 Posi...

Page 714: ...Crane operation 11 8 CraneSTAR system 11 144 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 715: ... Starting turning off the engine from the outrigger control units 12 27 12 6 Outriggers 12 29 12 6 1 CHECKLIST Extending the outriggers 12 29 12 6 2 CHECKLIST Retracting the outriggers 12 31 12 6 3 Permissible outrigger spans 12 32 12 6 4 Preparing the truck crane 12 33 12 6 5 Setting the outrigger spans 12 34 12 6 6 Extending retracting outrigger beams 12 37 12 6 7 Moving the outrigger pads into ...

Page 716: ...00 12 8 8 Making breaking the electrical connection 12 101 12 8 9 Locking unlocking the auxiliary hoist 12 102 12 8 10 Checking the auxiliary hoist for correct functioning 12 105 12 8 11 Securing the upper hook block in the catcher 12 106 12 8 12 Railings on the auxiliary hoist 12 106 12 8 13 Permissible applications for the auxiliary hoist 12 107 12 9 Rigging work on the main boom 12 109 12 9 1 H...

Page 717: ...erences Observe the warnings and safety instructions specified there 12 1 1 CHECKLIST Rigging 1 Choose a suitable site à Choosing a suitable site p 12 9 2 Check that the parking brake is engaged if necessary engage the park ing brake 3 If the main boom is resting on a trailer Switching off the boom floating position à p 12 17 Switch off the slewing gear freewheel à p 12 18 If necessary switch off ...

Page 718: ...eels touches the ground à Outriggers p 12 29 8 Align the truck crane horizontally The lamp 1 lights up in the measuring range 1 à p 12 50 9 Turn off the engine and remove the hand held control à Starting turning off the engine with the hand held control p 12 23 à Disconnecting the hand held control p 12 22 G Danger of overturning if the truck crane is free standing When the truck crane is free on ...

Page 719: ...ane while looking out in particular for any leaking fluids oil fuel or water 13 Start the engine for crane operation à p 10 8 14 If necessary switch off the houselock and unlock the superstructure à Switching off the houselock p 11 17 à Unlocking the superstructure p 11 14 15 Pick up the hook block and reeve the hoist rope again if necessary à Hook block on a separate vehicle p 12 111 à Hook block...

Page 720: ...18 Perform all the required checks prior to crane operation à CHECKLIST Checks before operating the crane p 11 1 19 Enter the current rigging mode on the RCL à p 11 23 20 With the RCL adjusted accordingly rig the counterweight combination required for the operation according to the Lifting capacity table à CHECKLIST Counterweight rigging p 12 62 21 If required assemble the auxiliary hoist à CHECKL...

Page 721: ... 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 à Outriggers p 12 29 2 If required remove the auxiliary hoist à CHECKLIST Removing the auxiliary hoist p 12 96 3 With the RCL adjusted accordingly unrig the counterweight à CHECKLIST Counterweight unrigging p 12 65 4 Enter the current rigging mode with t...

Page 722: ...st rope p 12 118 7 For on road driving without trailer Turn superstructure to the 180 position to the front with the RCL adjusted accordingly Place the main boom on the boom rest 8 For on road driving with a trailer Set down the superstructure on a trailer with the RCL adjusted accord ingly and switch on the boom floating position à p 6 8 Switch on slewing gear freewheel à p 6 7 Switch on boom pre...

Page 723: ...12 137 Lower the slewable spotlights à p 11 109 12 Retract the outriggers à CHECKLIST Retracting the outriggers p 12 31 13 Activate unlock the suspension The symbol 1 must be green suspension on à p 5 15 14 Turn off the engine and if necessary remove the hand held control and stow it away in the driver s cab à Disconnecting the hand held control p 12 22 15 When the truck crane is no longer being u...

Page 724: ...Rigging work 12 1 Rigging work checklists for crane operation with the main boom 12 8 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 725: ...te 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 15 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 ground bearing area The stability of the truck crane primarily depend...

Page 726: ...APACITY OF THE GROUND Load bearing capacity t m2 lbs ft2 Backfilled not artificially compacted ground 0 to 10 0 to 2050 Natural apparently untouched 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 sound ...

Page 727: ...ulating the required ground bearing area If the outrigger pressure is 25 t and the ground has a bearing capacity of 40 t m2 then the required ground bearing area for this supporting cylinder is 0 625 m2 6250 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 44 G Danger of overturning if the ground bearing area...

Page 728: ...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 or undisturbed ground the safe distance a 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 pads 1 or s...

Page 729: ...l around the metal rod 3 for better conductivity Clamp an insulated cable 2 to the metal rod 3 cross section of at least 16 mm2 0 025 in2 Connect the free end of the cable with a clamp 1 Attach the clamp to the main boom or to 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 stations...

Page 730: ...orking range of the truck crane have these cables disconnected from the source of power 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 regu lations B Risk of accident due to electric shock This truck crane is not insulated If the truck crane its equipment its load lifting tackle or the...

Page 731: ...t with you check that you are observing the safe distance A Only use guide ropes of non conductive material if the load has to be guided If you have touched the electric cable Keep calm Do not leave the crane cab Tell anyone standing outside not to touch the crane the load or the lifting tackle Move the main boom out of the danger area Voltage Safe distance A up to 1 000 V 1 m 3 3 ft from 1 000 V ...

Page 732: ...Rigging work 12 2 Choosing a suitable site 12 16 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 733: ...m pre tensioning if necessary à p 12 19 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 trailer 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 R...

Page 734: ...e 1 Pull the pin 3 out as far as possible Secure the pin with the lock in the bore 2 and remove the key Pull and secure the pin 3 on the other slew ing gears in the same way Close the valve 5 the slewing gear free wheel is switched off Before slewing Support the truck crane with the necessary outrigger span enter the corre sponding RCL code and derrick the main boom to an angle permissible within ...

Page 735: ... accumulator Switch off the boom floating position à p 12 17 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 Valve III stays closed the lever 3 points downwards S Danger of the hydraulic oil overheating Always switch the valve IV over lever in horizontal posi...

Page 736: ...Rigging work 12 3 Rigging work after driving with a trailer 12 20 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 737: ... for emergencies The ignition can be switched on or off Socket Released operations 1 At the front of the main boom Rigging MWL 2 On the derrick ing cylinder Derricking gear emergency operation 3 At the rear on the turntable Counterweight lifting cylinder Counterweight lock Locking unlocking auxiliary hoist Raising setting down auxiliary hoist catcher 2 Pulling device main boom pivot pin Emergency ...

Page 738: ... on There is a malfunction if the lamp 5 does not light up or flash à p 14 20 Disconnecting the hand held control Open the cap 2 Pull the plug 4 out of the socket 1 the lamps 5 and 6 go out Insert the bridging plug 3 into the socket 1 and secure it with the cap 2 The ignition is turned off unless it is switched on at an ignition lock G Danger due to unauthorised use Always stow the hand held contr...

Page 739: ...ing plug is inserted in all sockets not required 12 5 1 Starting turning off the engine with the hand held control Requirements The following requirements must be met before you can start the engine for driving with the hand held control The ignition is switched off in the crane cab The ignition is switched off in the driver s cab Connect the hand held control to a socket on the carrier à p 12 22 ...

Page 740: ...tons are now active on the hand held control All buttons on the control panel 1 The function buttons 3 All buttons on the control panel 4 The button 6 for the horn on the carrier The button 2 and button 5 are inactive The Outrigger control units are locked after connection of the hand held con trol H You can start the engine from the crane cab but the operating elements for crane operation are dis...

Page 741: ...off and the ignition key is removed The lamp 1 in the crane cab has gone out The superstructure ignition has been switched on for approx 30 seconds Starting the engine All activities and inspections required to start the engine must be carried out before starting the engine à p 4 1 If necessary open the main menu ö and press the 1 button once The Outriggers submenu opens Press the 1 button down on...

Page 742: ...n the event of a warning message on the carrier the lamp 1 flashes Press the 2 button once The Warning submenu carrier opens The corresponding symbol is red à p 11 111 Turning off the engine Your can turn off the engine from the crane cab or using any of the emer gency stop switches on the superstructure or the carrier Press the 1 button up once The carrier ignition is turned off and the engine is...

Page 743: ...before you can start the engine for driving from the outrigger control units The ignition in the driver s cab is switched on The ignition is switched off in the crane cab The lamp in the button 1 lights up Starting the engine All activities and inspections required to start the engine must be carried out before starting the engine à p 4 1 Press the 3 button once the engine starts Turning off the e...

Page 744: ...Rigging work 12 5 Starting the engine for driving for rigging work 12 28 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 745: ...stment system and lower it as far as possible à p 5 60 2 Switch off lock the suspension The symbol 1 must be red suspension off à p 5 15 3 Extend all outrigger beams to the required span à Permissible outrigger spans p 12 32 à Setting the outrigger spans p 12 34 à Extending retracting outrigger beams p 12 37 4 Move the outrigger pads into working position and secure them à p 12 43 s G Danger of cr...

Page 746: ...he ground bearing area p 12 44 6 Extend the supporting cylinders until none of the wheels are touching the ground à p 12 45 7 Level the truck crane with the outriggers The lamp 1 lights up in the measuring range 1 à p 12 50 8 Turn off the engine After operating it with the hand held control à p 12 24 After operating it from the control units à p 4 25 After operating it from the crane cab à p 12 26...

Page 747: ...y instructions specified there 1 Retract the outrigger cylinders as far as possible à p 12 45 2 Move the outrigger pads into driving position and secure them à Moving them into driving position p 12 43 3 Fully retract and secure all outrigger beams à Permissible outrigger spans p 12 32 à For on road driving p 12 36 à Extending retracting outrigger beams p 12 37 4 Stow away packing material safely ...

Page 748: ...igger spans in metre x metre feet x feet The first value represents the outrigger length 1 e g 8 70 m 28 5 ft The second value specifies the required out rigger span 2 e g 8 50 m 27 9 ft G Risk of overturning when slewing the superstructure With some outrigger spans slewing is only permissible with certain coun terweight combinations and boom positions à Slewing with rigged counter weight p 12 89 ...

Page 749: ... elements for the outriggers are only released if the suspen sion is switched off If the suspension is switched off the wheels are lifted when the crane is put on outriggers Outriggers control units You can switch the Outrigger control units on and off from the crane cab If necessary open the main menu ö and press the 1 button once This opens the Settings submenu The current status is displayed Sy...

Page 750: ...eams p 12 37 Outrigger span 8 70 x 8 50 m 28 5 x 27 9 ft A Requirements Pin 1 is removed Pin 2 inserted in holder 3 B Setting and securing Extend the outrigger beam up to the mark ing 4 Secure the outrigger beam with the pin 1 and 2 Set the outrigger span on the other outrig ger beam in the same way G Danger of overturning if the outrigger beams are not correctly extended Always extend all outrigg...

Page 751: ...am up to the mark ing 4 Secure the outrigger beam with the pin 1 and 2 Set the outrigger span on the other outrig ger beam in the same way Outrigger span 8 70 x 6 30 m 28 5 x 20 4 ft A Requirements Pin 1 is removed Pin 2 is inserted B Setting and securing Extend the outrigger beam up to the mark ing 3 Secure the outrigger beam with the pin 1 Pin 2 remains inserted Set the outrigger span on the oth...

Page 752: ...ments Pin 1 is removed Pin 2 inserted in holder 3 B Setting and securing Completely retract the outrigger beam Secure the outrigger beam with the pin 1 and 2 Set the outrigger span on the other outrig ger beam in the same way For on road driving Set an outrigger span of 8 70 x 2 71 m 28 5 x 8 9 ft on all outrigger beams and secure them Secure all the outrigger pads in the driving position à p 12 4...

Page 753: ...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 the outrigger beams and always extend them to the spans corresponding to the RCL code This also applies if you are working on one si...

Page 754: ...hts up after opening the door Press any button The lights are switched on Moving the supports H You can only operate the outrigger beams to the left and right of the oper ating unit on the operator s side Observe the safety instructions for operating the outrigger beams à p 12 37 Press the button Additionally press the button for the desired outrigger beam The outrigger beams move until you let go...

Page 755: ...ontrol to the required socket 1 or 2 Information on connecting à Connecting the hand held control p 12 22 Starting the engine Press the button 1 the engine starts à p 10 15 Pre selecting high speed mode normal speed Press the 2 button Lamp 1 lights up high speed mode pre selected Lamp 1 goes out normal speed pre selected s 1 For the right hand outrigger beam 2 For the left hand outrigger beam ...

Page 756: ...corresponding button lights up e g the lamps 5 After about 10 seconds the pre selection is switched off Extending retracting outrigger beams Observe the safety instructions for operating the outrigger beams à p 12 37 Press the button combination for the desired movement The pre selected outriggers move until you let go of the respective button or until the respective end position has been reached ...

Page 757: ...pen the main menu ö and press the 1 button once The Outriggers submenu opens Pre selecting outriggers H Only pre select one outrigger If you pre select several outriggers operation of the outriggers is not enabled Press the button once next to the symbol for the desired outrigger Pre selection is switched on The dot in the symbol turns green e g in symbol 5 The symbols 1 and 2 turn black After abo...

Page 758: ...s 1 and 2 remain grey Switch off the slewing gear Extending retracting outrigger beams Observe the safety instructions for operating the outrigger beams à p 12 37 Press the button below the symbol for the desired movement The pre selected outrigger moves until you let go of the respective button or until the respective end position has been reached 1 Retract 2 Extend ...

Page 759: ...ll the outrigger pad outwards by the handles 2 Secure the outrigger pad with the pin 1 Secure the pin 1 Move the other outrigger pads into working position in the same way Securing pin Plug the pin with the peg 1 through the cut out 2 Turn the grip 3 downward Moving them into driving position A Pull out the pin 1 B Push the outrigger pad by the handles 2 as far as possible back onto the clamp 3 Se...

Page 760: ...gle Ensure that the outrigger pressure is evenly distributed over the packing The outrigger pad must be positioned in the centre of the packing The outrigger pad must cover all the wooden planks If 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 G Risk of accident if the packin...

Page 761: ...ot withstand the result ing outrigger pressure This prevents the ground under the outrigger pad from giving way and causing the truck crane to tilt and overturn G Risk of accident if supporting cylinders cannot be seen 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 ...

Page 762: ...fety instructions for operat ing the supporting cylinders à p 12 45 The operation is the same for all supporting cylinders Press the button Also press the button for the desired sup porting cylinder e g for 4 1 You can also operate several supporting cylin ders at the same time The outrigger cylinders move until you let go of the respective button or until the respective end position has been reac...

Page 763: ... button Lamp 1 lights up high speed mode pre selected Lamp 1 goes out normal speed pre selected Pre selecting outriggers Press the button for the required outriggers once Pre selection is switched on and the lamp in the corresponding button lights up e g the lamps 6 After about 10 seconds the pre selection is switched off H Combinations of the buttons 1 to 4 are also possible e g buttons 1 and 2 i...

Page 764: ...vement The pre selected supporting cylinders move until you let go of the respec tive button or until the respective end position has been reached From the crane cab The following operating elements are found in the Outriggers submenu Starting the engine Start the engine from the crane cab à p 10 8 Switch off the slewing gear Opening the submenu If necessary open the main menu ö and press the 1 bu...

Page 765: ... this means that the slewing gear is switched on the symbols 2 and 3 remain grey Switch off the slewing gear Extending retracting supporting cylinders Observe the safety instructions for operating the supporting cylinders à p 12 45 Press the button below the symbol for the desired movement The pre selected supporting cylinders move until you let go of the respec tive button or until the respective...

Page 766: ...ching between measuring ranges You can change the measuring range between 1 and 5 Press the 2 button once The current measuring range 1 is dis played Reading 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 ECOS hand held control display The assignment to the carrier is given by the directional indicator ...

Page 767: ...erequisites apply to manual and automatic alignment The main boom must be resting on the boom rest or The main boom must be raised The load has been set down The superstructure is 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 deformation of the carr...

Page 768: ...the packing may slip Check after you have levelled the truck crane Whether all the wheels are lifted off the ground Whether the ground under one of the outrigger pads has given way Whether the packing is correct for the enlarged ground bearing area If slewing is permissible in the current rigging mode Slew the superstructure within the permissible slewing range Perform the specified checks again C...

Page 769: ...Extend the supporting cylinders until the outrigger pads are just above the ground Starting procedure Depending on the truck crane s equipment you can start the procedure from the hand held control and the Outrigger control units On the hand held control Press the 1 button once Press the 2 button once The lights in the buttons go on Press the button combination 3 for automatic alignment The proced...

Page 770: ...cally levelled 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 alignment is no longer possible e g when a supporting cylinder is extended as far as possible G Danger of overturning if the truck crane is not level When ECOS ends the automatic alignment proc...

Page 771: ...g range 1 Switching on the suspension In the driver s cab open the Level adjustment system submenu button t Press the 2 button once dot is green The symbol 1 is green if the suspension is switched on s 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 from overturning when operati...

Page 772: ...n the right position for the horizontal alignment To switch off the suspension Press the 2 button once dot is black The symbol 1 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 extended ...

Page 773: ...tend outrigger cylinders In the Outriggers submenu The assignment of the displays to the carrier is given by the directional indicator 5 On the outrigger control units The assignment of the displays to the carrier corresponds to the top view G Risk of accident when misused A displayed outrigger pressure over 0 t does nor guarantee protection against overturning or overloading For this reason never...

Page 774: ...Rigging work 12 6 Outriggers 12 58 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 775: ... on the execution there is version A or B Version A The counterweight combinations can be comprised of One 15 t base plate 1 Six 10 t counterweight sections 2 Four 10 t counterweight sections 3 Two 10 t counterweight sections1 4 Two tensioning devices 5 Version B The counterweight combinations can be comprised of One 15 t base plate 1 Two 10 t counterweight sections 2 Eight 10 t counterweight sect...

Page 776: ...base plate and the counterweight sections are labelled with the serial number 1 Version B The base plate and the counterweight sections are labelled with the 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 777: ...sion B p 1 12 In versions A and B the slinging points 1 are designed differently Version A Attach the counterweight sections to the slinging points 1 Version B Attach the counterweight sections to the slinging points 1 G Risk of accident if used improperly Attach the various counterweight sections only to the intended slinging points and use lifting gear of sufficient lifting capacity Only lift th...

Page 778: ...ent rigging mode on the RCL à p 11 23 3 Assemble the required combination of counterweights Lower 15 t base plate on the counterweight platform à p 12 70 If the auxiliary hoist is to be installed then you may now only assem ble the counterweight combination up to 75 t Lift and set down counterweight sections individually one after the other à p 12 67 4 If required assemble the auxiliary hoist à Ri...

Page 779: ...0 to the rear position and lock à Braking the slewing movement p 11 102 à Locking unlocking the superstructure p 11 13 8 Establish the hydraulic and electrical connections between the 15 t base plate and the turntable à Establishing disconnecting the hydraulic connection p 12 100 à Making breaking the electrical connection p 12 101 9 Connect the hand held control to the rear right of the turntable...

Page 780: ...e lifting cylinder à Rigging counterweight p 12 83 11 Disconnect the hand held control à Connecting disconnecting the hand held control p 12 21 12 Enter the current rigging mode with the newly rigged counterweight version on the RCL à p 11 23 13 Only switch on the slewing gear if slewing is permissible for the current outrigger span à Slewing with rigged counterweight p 12 89 ...

Page 781: ...ans p 12 32 2 Slew the superstructure into the 0 to the rear position with the RCL set accordingly à Slewing with rigged counterweight p 12 89 3 Connect the hand held control to the rear right of the turntable and start the crane engine à Connecting disconnecting the hand held control p 12 21 4 Extend the lifting cylinder unlock the counterweight and lower the counterweight onto the counterweight ...

Page 782: ... the hand held control à Connecting disconnecting the hand held control p 12 21 8 Remove the hydraulic and electrical connections between the 15 t base plate and the turntable à Establishing disconnecting the hydraulic connection p 12 100 à Making breaking the electrical connection p 12 101 9 Release the counterweight sections à p 12 79 10 Lift counterweight sections Lift 10 t counterweight sectio...

Page 783: ...g 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 Danger of crushing when slewing the superstructure Anyone who climbs onto the carrier using one of the access ladde...

Page 784: ...to the counterweight blocks When rigging with an installed auxiliary hoist you require special lifting gear à Raising and lowering 10 t counterweight blocks with a mounted auxiliary hoist p 12 88 Always place the 10 t sections and 10 t blocks alternately at the left and right sides 1 Additional equipment 2 à Securing 10 t blocks p 12 80 S Risk of overturning if counterweight rigging sequence is in...

Page 785: ...inations can be combined on the coun terweight platform 15 t 33 069 lbs 15 t base plate 35 t 77 162 lbs 15 t base plate Two 10 t sections s G Risk of accident due to an incorrect counterweight mass Only combine the counterweights in such a manner that the counterweight mass corresponds to the specifications in this section and in the Lifting capacity table Other combinations are not permitted ...

Page 786: ...rweight 12 70 3 112 993 en Operating manual GMK 6400 12 07 2013 55 t 121 254 lbs 15 t base plate Four 10 t sections 75 t 165 347 lbs 15 t base plate Four 10 t plates Two 10 t blocks 95 t 209 439 lbs 15 t base plate Four 10 t plates Four 10 t blocks ...

Page 787: ...ng unrigging the counterweight Operating manual GMK 6400 3 112 993 en 12 71 12 07 2013 115 t 253 532 lbs 15 t base plate Four 10 t plates Six 10 t blocks 135 t 297 624 lbs 15 t base plate Four 10 t plates Eight 10 t blocks s ...

Page 788: ...trated in the diagram with the maximum counterweight mass of 135 t 297 624 lbs The base plate 1 must always be at the bot tom The counterweight sections 2 can be exchanged among each other The counterweight sections 3 can be exchanged among each other The counterweight blocks 4 can be exchanged among each other The counterweight blocks 5 can be exchanged among each other ...

Page 789: ... Remove the cover 2 from the recesses 3 of the slinging points Place the covers 2 into the holders 1 and secure them If necessary remove the 10 t plates G Risk of accident due to uncovered openings Cover the recesses of the slinging points with the covers provided In this way you avoid stepping into the recesses and injuring yourself Do not just place the cover on the last pair of 10 t plates When...

Page 790: ...sides 1 Additional equipment 2 à Securing 10 t blocks p 12 80 S Risk of overturning if counterweight rigging sequence is incorrect When rigging always place raise the 10 t blocks alternately on the left and right sides Otherwise the truck crane will be overloaded at one side or the counterweight may fall from the carrier Counterweight Counterweight section 15 t 1 25 t 1 and 1 x 2 35 t 1 and 2 or 1...

Page 791: ...binations can be combined on the coun terweight platform 15 t 33 069 lbs 15 t base plate 25 t 55 116 lbs 15 t base plate One 10 t block s G Risk of accident due to an incorrect counterweight mass Only combine the counterweights in such a manner that the counterweight mass corresponds to the specifications in this section and in the Lifting capacity table Other combinations are not permitted ...

Page 792: ...igging the counterweight 12 76 3 112 993 en Operating manual GMK 6400 12 07 2013 35 t 77 162 lbs 15 t base plate Two 10 t blocks 45 t 99 208 lbs 15 t base plate Three 10 t blocks 55 t 121 254 lbs 15 t base plate Four 10 t sections ...

Page 793: ...gging the counterweight Operating manual GMK 6400 3 112 993 en 12 77 12 07 2013 75 t 165 347 lbs 15 t base plate Six 10 t blocks 95 t 209 439 lbs 15 t base plate Eight 10 t blocks 115 t 253 532 lbs 15 t base plate Ten 10 t blocks s ...

Page 794: ...se plate Twelve 10 t blocks All counterweight sections with additional equipment are illustrated in the diagram with the maximum counterweight mass of 135 t 297 624 lbs The base plate 1 must always be at the bot tom The counterweight blocks 2 can be exchanged among each other The counterweight blocks 3 can be exchanged among each other ...

Page 795: ...ning devices are identical and interchangeable Securing the counterweights is identical for versions A and B A tensioning device consists of When the counterweight is unrigged Always store the tensioning device in the compartment 5 on the counterweight base plate s G Risk of accident from falling counterweight blocks Secure the 10 t blocks with the tensioning device This prevents the blocks from s...

Page 796: ...her side in the same way Releasing 10 t blocks Before you can lift the blocks you must release them Loosen the chain tensioner 1 turn counter clockwise until you can remove the pin 3 and the tensioning bearing 4 Pull the chain tensioner 1 with the chain 2 upwards out of the counterweight combina tion Release the blocks on the other side in the same way Store the tensioning device in the compart me...

Page 797: ...nection Establishing Remove the caps from the ports 3 Remove the hoses 2 from the brackets 1 and connect them to the ports 3 Disconnecting You must disconnect the hydraulic connection before lifting the 15 t base plate from the carrier Remove the hoses 2 from the connections 3 Close all the hoses and connections with the caps Fit the hoses 2 into the brackets 1 ...

Page 798: ...ket 1 with the cap Disconnecting The connection must be separated before lifting the 15 t base plate from the carrier Remove plug 2 from socket 3 and insert it into socket 1 Cover the socket 3 with the cap S Risk of malfunction in the superstructure electronics Always turn off the ignition in the crane cab before you establish or break the electrical connection This prevents malfunctions and error...

Page 799: ...re raising and lowering remove all objects that could become jammed or crushed G Risk of accident from falling counterweight When the counterweight is locked to the turntable always check that the safety valve is closed before moving the lifting cylinder à Counterweight safety valve p 12 87 This prevents the counterweight from being inadvertently unlocked and falling due to getting the switches mi...

Page 800: ... lights up Press the key combination 2 until the counterweight is fully raised Locking the counterweight Open the safety valve à p 12 87 Press the button 1 The lamp lights up Press the key combination 2 until the lamps 3 are lit The counterweight is now locked at the turntable If a locking pin has not yet reached the Locked end position the correspond ing lamp will flash S Risk of damage when rais...

Page 801: ... in order to lower the counterweight onto the counterweight platform Extending the lifting cylinders Press the button 1 The lamp lights up Press the key combination 2 until the lifting cylinders are extended into the cylinder mounts on the counterweight platform s G Risk of accident from falling counterweight Always close the safety valve if the counterweight is locked to the turntable This preven...

Page 802: ...ights up Press the key combination 2 until the lamps 3 are lit If a locking pin has not yet reached the Locked end position the correspond ing lamp will flash Close the safety valve à p 12 87 Retracting the lifting cylinders Press the button 1 The lamp lights up Press the key combination 2 until the lifting cylinder is fully retracted The counterweight is now lowered onto the counterweight platfor...

Page 803: ...d against acciden tal activation Opening the safety valve Before extending or retracting the locking pins Open the valve lever 1 parallel to the line The locking pins can now be moved using the hand held control Close the safety valve after extending the locking pins G Risk of accident when the safety valve is open Always close the safety valve if the counterweight is locked to the turntable This ...

Page 804: ...arts p 1 10 Release and remove the securing devices on the 10 t counterweight blocks à p 12 79 Attach the lifting gear 1 to the slinging points provided on the 10 t counterweight blocks à p 12 61 Attach the lifting gear into the hook block Carefully raise the 10 t counterweight blocks and set them down on a suitable base Secure the new counterweight combination à p 12 79 S Risk of damage to the au...

Page 805: ...radii Disabled with the correct rigging mode s G Danger of overturning when slewing with an incorrectly set RCL The RCL only disables the slewing operation if you have entered the RCL code correctly and if the RCL is not overridden Therefore always check before slewing whether the RCL code valid for the current rigging mode is displayed This prevents slewing operations from being released within i...

Page 806: ... m 27 9 ft 1 00 m 3 3 ft auxiliary support 1 Rigged counterweight 0 t 0 lbs 15 t 33 069 lbs 35 t 77 162 lbs 55 t 121 254 lbs Slewing permissible1 Slewing not per missible 75 t 165 347 lbs 95 t 209 439 lbs Slewing not per missible 115 t 253 532 lbs 135 t 297 624 lbs 1 Outrigger span for removable outrigger box 2 Slewing only permitted if the radius permitted in the working range is observed at leas...

Page 807: ...y crane The auxiliary hoist must be removed for on road driving with a maximum of 12 t axle load Scope of delivery Auxiliary hoist 1 with rope Lower hook block 2 Upper hook block 3 Lifting limit switch 12 8 1 Identification The auxiliary hoist may only be operated together with a GROVE truck crane GMK 6400 whose serial number is identical with the serial number of the auxiliary hoist The serial nu...

Page 808: ...e auxiliary hoist to the slinging points 1 The catcher is fitted with two slinging points 1 on which the catcher is slung together with the upper hook block Only attach the catcher to the slinging points 1 G Risk of accident if used improperly Only attach the auxiliary hoist to the slinging points provided Always use lifting gear with sufficient lifting capacity à Dimensions and weights of removab...

Page 809: ... hook block 3 is secured in the catcher à p 12 106 The auxiliary hoist rope is fastened to the holder 4 Be aware of the dimensions and weight of the auxiliary hoist when trans porting à p 1 11 G Risk of damage to the auxiliary hoist Attach the auxiliary hoist to the separate vehicle so that it cannot slip off Insert the hydraulic hoses and the electric cable into the specially designed shaft G Ris...

Page 810: ...2 The required counterweight version is assembled on the counterweight platform and is connected electrically and hydraulically à CHECKLIST Counterweight rigging p 12 62 The current rigging code of the truck crane is entered in the RCL à Entering the rigging mode p 11 23 The railings on the auxiliary hoist are folded in à p 12 106 1 Sling the auxiliary hoist with the truck crane and lift up to the...

Page 811: ...t base plate to the auxiliary hoist à p 12 102 6 Continue rigging the counterweight à CHECKLIST Counterweight rigging p 12 62 point 5 and point 6 7 Raise the catcher and block it with the support à p 12 99 8 Check the auxiliary hoist for correct functioning à p 12 105 9 Disconnect the hand held control à p 12 22 10 Reeve the hoist rope and connect the lifting limit switch à Reeving and unreeving t...

Page 812: ...according to the Lifting capacity chart à Permissible outrigger spans p 12 32 The counterweight and the auxiliary hoist are connected electrically and hydraulically à p 12 81 à p 12 100 The current rigging code of the truck crane is entered in the RCL à Entering the rigging mode p 11 23 The railings on the auxiliary hoist are folded in à p 12 106 1 Unreeve the auxiliary hoist rope roll onto the re...

Page 813: ...nd the 15 t base plate using the hand held control à Locking unlocking the auxiliary hoist p 12 102 7 Disconnect the hand held control à p 12 22 8 Detach the electrical connection to the auxiliary hoist à p 12 101 Detach the hydraulic connection to the auxiliary hoist à p 12 100 9 Sling the auxiliary hoist and place it on the separate vehicle à Slinging points and transport p 12 92 10 Check the tr...

Page 814: ...iliary hoist onto the 15 t base plate Sling the auxiliary hoist à Slinging points p 12 92 Hoist the auxiliary hoist onto the 15 t base plate When doing this ensure that Both hooks 1 grip round the holders 2 The fork elements on both sides 3 align with the eyes 4 Now the auxiliary hoist is in the correct posi tion for locking ...

Page 815: ...r hook block is secured when it lies in the catcher à p 12 106 Raising Connect the hand held control à p 12 21 When the upper hook block lies in the catcher Check that the upper hook block is secured à p 12 106 Press the button 1 The lamp lights up Press the key combination 2 until the catcher is fully raised Setting down Connect the hand held control à p 12 21 When the upper hook block lies in th...

Page 816: ...lished before the auxiliary hoist can be locked and operated Remove the caps from the ports 3 Remove the hoses 2 from the brackets 1 and connect them to the ports 3 Disconnecting The connection must be disconnected before the auxiliary hoist is hoisted from the 15 t base plate Remove the hoses 2 from the connections 3 Close all the hoses and connections with the caps Fit the hoses 2 into the brack...

Page 817: ...ed before the auxiliary hoist can be locked and operated Remove plug 2 from socket 1 and insert it into socket 3 Cover the socket 1 with the cap Disconnecting The connection must be disconnected before the auxiliary hoist is hoisted from the 15 t base plate Remove the plug 2 from the socket 3 Wind the cable onto the bracket 4 and insert the plug 2 into the socket 1 Cover the socket 3 with the cap ...

Page 818: ...oist on the 15 t base plate Close the valve handle 1 at right angles to the line The pins are secured against accidental activa tion Opening the valve Before the locking pins are extended or retracted you have to open the safety valve Open the valve handle 1 parallel to the line The pins can now be moved using the hand held control Close the valve after extending the pins G Risk of accident when t...

Page 819: ...ht is now locked at the turntable If a locking pin has not yet reached the Locked end position the correspond ing lamp will flash Close the safety valve à p 12 102 s G Risk of accident from falling counterweight Always close the safety valve when the auxiliary hoist is locked to the coun terweight This prevents the locking pins from e g being unintentionally retracted when a button is erroneously ...

Page 820: ...he locking pin Open the safety valve à p 12 102 Press the button 1 The lamp lights up Press the key combination 2 until the lamps 3 are lit If a locking pin has not yet reached the Unlocked end position the corres ponding lamp will flash Close the safety valve for the transport à p 12 102 Releasing the locking pin ...

Page 821: ...tion 2 The hoist must now drum the cable Press the button 1 The lamp lights up Press the key combination 2 The hoist must now reel up the cable In the crane cab Switch on the auxiliary hoist à p 11 59 Move the left hand control lever forward and then back letting the auxil iary hoist run for about one half revolution in each direction Check whether the direction of rotation for the particular cont...

Page 822: ... follows Remove the retaining pins from both sides and pull the pins 3 out of the holders 2 Insert the locking pins on both sides into the holders 1 Secure the pins using the retaining pins 12 8 12 Railings on the auxiliary hoist You must also observe the railing notice on the turntable à p 12 135 A Folding out Lift the railing 1 and fold it outwards B Folding in Lift the railing 1 and fold it inw...

Page 823: ...acement for the main hoist For main boom operation For operation with the lattice extension à Lattice extension operating instructions To do so reeve the auxiliary hoist rope in the same way as the main hoist rope à Reeving and unreeving the hoist rope Attach the lifting limit switch and the lifting limit switch weight exactly as for operation with the main hoist à Installing removing the lifting ...

Page 824: ...nstalling the lifting limit switch p 12 126 Enter the current reeving for both hoists at the RCL à Entering the reeving value p 11 29 Switch on the hoist with which you wish to lift the load à Hoists display p 11 32 The correct hoist is now set on the RCL and crane operation is secured by the RCL The maximum loads are reduced by the value of the weight of the second hook block G Risk of accident d...

Page 825: ...main boom is fully retracted Enter the current rigging mode on the RCL Slacken the hoist rope and derrick the main boom simultaneously Derrick 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 Danger of accident if the view is obstructed Have someone instruct you when raising the main boom since the view of the hook...

Page 826: ...tch is deactivated while you tighten the hoist rope you can override the shutdown of the lifting limit switch à p 11 63 G Danger of accident if the view is obstructed The reeved rope lines obstruct the view of the runway The number of legally permissible rope lines can vary depending on the country in which you are working According to EU regulations the hook block may not be reeved more than four...

Page 827: ...ter an RCL code for the 360 working range if the slewing operation is not released This prevents the superstructure from being slewed into impermissible areas and the truck crane tipping over as a result S Risk of damage to the separate vehicle Only raise the hook block from the separate vehicle if the main boom head is directly above the hook block This prevents the hook block from swinging and d...

Page 828: ...he 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 12 114 Raise the hook block off the separate vehi cle Setting down the hook block Depending on the driving mode the hook block must be placed on a sepa rate vehicle à Driving modes p 6 1 With the RCL set accordingly fully retract the main boom Ra...

Page 829: ...for transport Set down the main boom on the boom rest Fastening the hoist rope to the bumper Do not attach the rope end fitting to the front towing coupling The towing coupling must be free for a tow rod in emergencies Attach the rope end fitting 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 830: ...vings and the corresponding lifting capacities à p 12 119 Rope end fitting To reeve and unreeve the hoisting rope you must remove the rope end fit ting After reeving you must reattach the rope end fitting Removing the rope end fitting Pull the pin 2 and remove the fork element 1 Slide the holder 3 back and remove it from the hoist rope 4 Reattaching the rope end fitting Insert the holder 3 and sli...

Page 831: ...rope Rope grab Feed the main hoist rope 3 through under the sheave 4 Feed the auxiliary hoist rope 5 through under the sheave 4 Feed the main hoist rope 3 to the head sheave 1 Feed the auxiliary hoist rope 5 to the head sheave 2 Lay the hoist rope under the sheave 4 also when working with the lattice extension s G Danger due to slack rope Only use hook blocks and sling gear of the minimum weight p...

Page 832: ... rear over the next required head sheave 4 etc Reeve the hoist rope with the required number of lines Possible reeving methods à p 12 119 Fastening the hoist rope The fixed point used depends on the number of reeved rope lines Fixed point for an even number of lines The rope end fitting is fastened to the fixed point 1 for 2 fall 4 fall 6 fall reevings etc Fixed point for an odd number of lines Th...

Page 833: ...rt the rope end fitting 5 at the fixed point 1 and secure the pin 2 Securing the hoist rope Pull the rod 3 and fold the bracket 4 downwards Insert the rods 3 5 and 6 7 Secure all rods using the retaining pins Closing the hook block Fold up the sheet metals 1 on both sides Insert the rods 2 and secure them with the linchpins s ...

Page 834: ...cket 4 upwards Insert the rod 3 Fold down the sheet metals 1 à p 12 115 Remove the rope end fitting from the fixed point 2 or 6 Unreeve the hoist rope Depending on the driving mode you can Fasten the hoist rope to the bumper à p 12 113 Pull out the rods 1 and 2 and roll the hoist rope onto the drum Secure the main hoist rope 5 using the clamp 4 on the sheave 3 Secure the rods 1 and 2 using the ret...

Page 835: ...It is lower than the lifting capacity of the hook block H Please note that the maximum lifting capacities already include the weight of the hook block and the lifting gear You must subtract these weights in order to obtain the actual payload H The indicated lifting capacities apply to the wire cable of the main hoist When using the auxiliary hoist you have to increase the reeving for the same lift...

Page 836: ...city with the GMK 6400 3 sheave hook block Maximum lifting capacity of the hook block 100 t 220 462 lbs Max lifting capacity with the GMK 6400 Reeving Maximum lifting capacity A 11x 123 3 t 271 800 lbs B 10x 112 1 t 247 100 lbs C 9x 100 9 t 222 400 lbs D 8x 89 7 t 197 700 lbs Reeving Maximum lifting capacity A 7x 78 5 t 173 000 lbs B 6x 67 3 t 148 300 lbs C 5x 56 1 t 123 600 lbs D 4x 44 9 t 98 900...

Page 837: ...city of the hook block 40 t 88 185 lbs Max lifting capacity with the GMK 6400 Hook tackle Maximum lifting capacity of the hook tackle 16 t 35 274 lbs Max lifting capacity with the GMK 6400 Reeving Maximum lifting capacity A 3x 33 6 t 74 000 lbs B 2x 22 4 t 49 300 lbs C 1x 11 2 t 24 700 lbs Reeving Maximum lifting capacity A 1x 11 2 t 24 700 lbs ...

Page 838: ... with the GMK 6400 In case of additional equipment the hoist rope can be reeved 21 times à Maximum reeving p 12 125 9 sheave hook block Maximum lifting capacity of the hook block 250 t 551 155 lbs Max lifting capacity with the GMK 6400 Reeving Maximum lifting capacity A 20x 224 t 493 000 lbs Reeving Maximum lifting capacity A 19x 213 0 t 469 600 lbs B 18x 201 8 t 444 900 lbs C 17x 190 6 t 420 200 ...

Page 839: ...ith the GMK 6400 5 sheave hook block Maximum lifting capacity of the hook block 160 t 352 740 lbs Max lifting capacity with the GMK 6400 s Reeving Maximum lifting capacity A 15x 168 2 t 398 600 lbs B 14x 157 0 t 346 100 lbs C 13x 145 8 t 321 400 lbs D 12x 134 6 t 296 700 lbs Reeving Maximum lifting capacity A 11x 123 3 t 271 800 lbs B 10x 112 1 t 247 100 lbs C 9x 100 9 t 222 400 lbs D 8x 89 7 t 19...

Page 840: ... Max lifting capacity with the GMK 6400 1 sheave hook block Maximum lifting capacity of the hook block 40 t 88 185 lbs Max lifting capacity with the GMK 6400 Reeving Maximum lifting capacity A 7x 78 5 t 173 000 lbs B 6x 67 3 t 148 300 lbs C 5x 56 1 t 123 600 lbs D 4x 44 9 t 98 900 lbs Reeving Maximum lifting capacity A 3x 33 6 t 74 000 lbs B 2x 22 4 t 49 300 lbs C 1x 11 2 t 24 700 lbs ...

Page 841: ... require an auxiliary single sheave boom top and a hook block with at least 10 sheaves Rig the auxiliary single sheave boom top à Lattice extension operating instructions Guide the main hoist rope over the head sheave A over the auxiliary single sheave boom top B around the first sheave C of the hook block Max lifting capacity with the GMK 6400 Reeving Maximum lifting capacity A 1x 11 2 t 24 700 l...

Page 842: ... 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 Fit the lifting limit switch 4 onto the holder 3 and secure it with the retaining pin Remove the bridging plug 2 from the socket 1 Lay the cable 5 in such a way that it will not be damaged during crane operation and connect it to the socket 1 On the righ...

Page 843: ...witch to which no lifting limit switch weight has been attached If the lifting limit switch weight has for example been attached to the left lifting limit switch 1 you must lock the right lifting limit switch 2 à Locking p 12 131 Otherwise the movements Raise hosting gear Telescope out and Lower the boom will be locked H If two hoist ropes are reeved you must also use two lifting limit switch weig...

Page 844: ...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 through th...

Page 845: ... 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 other side...

Page 846: ...l GMK 6400 12 07 2013 Removing the right lifting limit switch Pull the plug from the socket 1 Remove the bridging plug 3 from the dummy socket 2 and plug it into the socket 1 Remove the lifting limit switch 5 from the bracket 4 Fasten the retaining pin to the lifting limit switch 3 5 ...

Page 847: ...the lifting limit switch is locked and can no longer be triggered Unlocking You must always remove the lock 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 lock is removed B Fit the cap 1 onto the lifting limit switch S Risk of damage if the lifting limit switch is locked The lifting limit switch to which the lifting limit swit...

Page 848: ...etaining 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 such 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 849: ...ng on the road à p 12 132 Switch off the air traffic control light press the switch 1 upwards and inwards Remove the plug and close the sockets 4 and 5 with the protective caps Wind the cables onto the holders 2 Take the rod 1 out of the holder 3 For transportation fasten the retaining pins to the rod 1 If necessary store the rod in the storage compartment 1 Switching on Press in switch 1 at the b...

Page 850: ...Rigging work 12 9 Rigging work on the main boom 12 134 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 851: ...oist to perform rigging work You must also observe the railing notice on the auxiliary hoist à p 12 106 A Folding out Release the locking bar 2 and swing the railing 1 outward until it engages B Folding in Release the locking bar 2 and swing the railing 1 inward until it engages G Risk of accidents when railings are not folded out The railings provide protection from falling Always fold out the ra...

Page 852: ... monitor 2 in the crane cabin Switching on the monitor Turn on the ignition Press the button 3 once The lamp 4 lights up The image appears on the monitor after a few seconds If an image does not appear à p 14 14 Switching out the monitor Press the button 3 once The lamp 4 and the image go out Switching the monitor Alternate between the cameras using the button 1 for main hoist C1 lights up or posi...

Page 853: ... receiver are coor dinated and identified with the same number on the model plate Before installation compare the numbers on the model plates Switch off the ignition in the crane cab s G Risk of accident if the wrong camera is installed If you install the wrong camera in your truck crane you will not see an image If your camera is installed in a neighbouring truck crane you will see the wrong imag...

Page 854: ...t is not damaged Removing Pull the plug out of the socket 3 and close the socket with the cap Remove the camera 2 from the clamp 1 and put the retaining pin in the holder 1 Switching on Switch the ignition on Press switch 3 down Press the 2 button once The lamp 1 lights up The image appears on the monitor after a few seconds If an image does not appear à p 14 9 Switching off Press the 2 button onc...

Page 855: ... 2 Permissible rigging modes and axle loads 13 2 13 3 Before driving 13 4 13 3 1 Securing the superstructure against slewing 13 4 13 3 2 Checking tyre pressure and wind speed 13 5 13 3 3 Putting the truck crane on the wheels 13 6 13 3 4 Transmission connections 13 8 13 4 While driving 13 8 13 5 After driving 13 10 ...

Page 856: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 857: ...e permissible load on the ground the surface area of the tyres must be increased by packing stable material e g wooden planks G Risk of accident by 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 boom in 0 to the rear G Risk of overturning by slewing super...

Page 858: ... capacity table Bring the superstructure and the main boom into a position that is indi cated in the following table for the specified counterweight rigged Tie down the hook block so that it cannot swing around 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 axle lines G Risk of accident if the R...

Page 859: ...40 8 35 0 77 162 88 0 0 0 15 front 13 5 29 8 19 7 43 4 0 0 0 44 82 rear 13 6 30 0 19 6 43 2 45 99 208 88 0 0 0 5 front 10 3 22 7 23 9 52 7 0 0 0 44 82 rear 16 2 35 7 20 9 46 1 55 0 121 254 not permitted front 0 0 0 44 82 rear 18 7 41 2 22 1 48 7 75 0 165 439 not permitted front 0 0 0 44 82 rear 23 8 52 5 24 5 54 0 95 0 209 439 not permitted front 0 0 0 44 75 rear 26 8 59 1 28 0 61 7 over 95 0 209 ...

Page 860: ...structure p 11 13 Switch off the slewing gear so that the slewing gear brake is engaged The lamp in the 1 button must be dimly lit The 2 lamp must light up à Switch off the slewing gear p 11 103 G Danger of overturning by the superstructure slewing while driving the truck crane Always secure the superstructure before driving the rigged truck crane to prevent it from slewing Slewing the superstruct...

Page 861: ...to driving the truck crane Check the wind speed à p 11 54 S Risk of damage to the tyres You may only drive the truck crane if the tyres are at the prescribed pres sure level Never reduce the tyre pressure in order to increase the tyres bearing sur face G Risk of accident from excessively high wind speeds You may not drive the rigged truck crane if the wind speed exceeds the maximum permissible val...

Page 862: ...he desired movement G Danger of overturning by unevenly retracting the outrigger cylinders Retract the outrigger cylinders evenly This prevents the truck crane from overturning when retracting each outrigger cylinder 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 when switching on the suspension You...

Page 863: ...ven axle load Securing 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 S Risk of damage to the tyres and suspension struts Do not exceed the maximum permissible axle load of 32 t when levelling the truck crane Monitor the display while levelling and adjust the axle loads as necessary G Dange...

Page 864: ...arate steering p 5 66 13 4 While driving Only drive at the lowest possible speed max 1 5 km h 1 mph The turning radius should be as great as possible when driving around corners Only steer the truck crane when it is rolling and avoid sudden steering changes 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 ...

Page 865: ... of 210 bar 3045 psi in the suspension has been exceeded In this case you must re level the truck crane using the Raise axle function as described in the Putting the truck crane on the wheels section à p 13 6 G Danger of overturning by switching on the suspension The suspension must be deactivated locked while the rigged truck crane is on wheels Switching on the suspension would cause the suspensi...

Page 866: ...2013 13 5 After driving Switch separate steering off after driving à p 5 69 Engage the parking brake Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise it until none of the wheels touches the ground à Permissible outrigger spans p 12 32 ...

Page 867: ...oil cooler 14 20 14 4 9 Malfunctions when inclining the crane cab 14 20 14 4 10 Malfunctions when operating with the hand held control 14 20 14 4 11 Malfunctions on the outriggers 14 21 14 4 12 Troubleshooting on the RCL 14 22 14 4 13 Malfunctions ECOS superstructure 14 31 14 4 14 Malfunctions on the CraneSTAR system 14 34 14 5 Emergency operations and programmes 14 39 14 5 1 Mechanical emergency ...

Page 868: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 869: ...tting the emergency stop switch p 4 26 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 Only actuate the emergency stop switch if it is no longer possible to stop the crane movements with the normal operating elements The emergency stop swi...

Page 870: ...Malfunctions during crane operation 14 1 Emergency stop switch 14 2 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 871: ... 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 lowered Secure the danger zone using cordons and warning signs Notify Manitowoc Crane Care G Risk of accident when carrying out repairs with loads lifted Repa...

Page 872: ...Malfunctions during crane operation 14 2 What to do when a malfunction occurs during crane operation 14 4 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 873: ...se has to be replaced S Risk of damage when the ignition is switched on Switch off the ignition whenever a fuse has to be replaced This prevents the new fuse from being damaged by the increased starting current imme diately after being installed S Risk of damage by overloading Replace blown fuses only with new fuses of the same amperage This pre vent parts from being overloaded and damaged or the ...

Page 874: ...à p 14 5 Fuse groups F1 F2 F3 The following tables show the designations of the individual fuses includ ing their amperage and functions The designations 1 to 8 in the tables correspond to the order from top to bot tom fuse 1 is the top fuse Designation Amperage A Function F1 1 20 ESX 0 supply ESX 4 supply F1 2 20 I O 4 circuit board ESX 1 supply F1 3 10 Central lubrication Lattice extension F1 4 ...

Page 875: ...lewing gear brake F2 4 20 Flame start system1 F2 5 3 ESX 4 supply F2 6 3 Emergency operation with hand held control F2 7 20 Oil cooler F2 8 20 Additional oil cooler1 Designation Amperage A Function F3 1 3 ESX2 control unit ECOS control unit supply F3 2 2 ESX3 control unit F3 3 10 RCL and RCL control unit supply F3 4 5 Remote control1 Heating pump F3 5 20 ESX2 control unit F3 6 5 ESX2 control unit ...

Page 876: ...during crane operation 14 3 Fuses 14 8 3 112 993 en Operating manual GMK 6400 12 07 2013 Fuse arrangement Pos Designation Amperage A 1 ESX 1 UE 3 2 ESX 1 D 3 3 ESX 1 8 5 V 2 4 ESX 0 UE 3 5 ESX 0 D 3 6 ESX 0 8 5 V 2 ...

Page 877: ...mperage and functions The designations 1 to 8 in the tables correspond to their order from left to right fuse 1 is always the left fuse Observe the instructions on changing fuses à p 14 5 s Designation Amperage A Function F3 1 3 ESX 2 supply ECOS control unit supply F3 2 2 ESX 2 supply F3 3 10 RCL and RCL control unit supply F3 4 5 Remote control1 Heating system F3 5 20 ESX 2 supply F3 6 5 ESX 2 s...

Page 878: ...he main boom1 F4 4 25 Air conditioning system1 F4 5 Unassigned F4 6 15 Auxiliary heater1 F4 7 Unassigned F4 8 20 CraneSTAR system Designation Amperage A Function F5 1 15 Spotlight F5 2 15 Spotlight RCL status display F5 3 15 Windscreen wiper washing system Cigarette lighter F5 4 10 Fan1 Camera on the turntable1 Camera on the main boom1 F5 5 5 Instrument panel lighting F5 6 5 Voltage monitoring Eng...

Page 879: ...ng error code is displayed à Error codes table p 14 27 Loosen the screws 2 and remove the cover 1 Loosen the screws 4 and fold down the plate 3 to the front Observe the instructions regarding fuse changes à p 14 5 Fuse arrangement on the RCL control unit Pos Designation Amperage A 1 Fuse F1 5 2 Fuse F2 5 3 Fuse F3 5 4 Fuse F11 5 5 Fuse F12 5 6 Fuse F6 5 ...

Page 880: ...s section does not include all malfunctions When a lamp 1 lights up à Warning submenu p 11 111 14 4 1 Malfunctions on the engine H All specifications in the section Malfunctions in the engine also apply à p 7 27 Malfunction Cause Solution Engine does not start Starter does not turn Driving mode switched on Switch over to crane opera tion ...

Page 881: ...ction works Lowering limit switch approached Leave the shutdown range and lift the main hoist Only the lowering function works Lifting limit switch approached lamp lights up Leave the shutdown range and lower the main hoist RCL shutdown lamp lights up Leave the shutdown range à p 11 37 Fuse F3 3 blown Replace blown fuse à p 14 9 Lifting lowering or high speed mode function not working Function dis...

Page 882: ...acturer s oper ating manual Connection between camera and monitor is disconnected Check cable connection and notify Manitowoc Crane Care if necessary Malfunction Cause Solution No image appears on the monitor after it is switched on Fuse on the crane cab blown Replace blown fuse à p 14 7 Fuse blown in camera or monitor Check fuses and replace as nec essary à Manufacturer s oper ating manual Radio ...

Page 883: ...sists notify Manitowoc Crane Care Fuse F3 7 blown Replace blown fuse à p 14 6 Lowering function not working Lifting limit switch approached lamp lights up Leave the shutdown range and lower the auxiliary hoist RCL shutdown lamp lights up Leave the shutdown range à p 11 37 Fuse F3 3 blown Replace blown fuse à p 14 9 Derricking function not working Function disabled by ECOS If necessary acknowledge ...

Page 884: ...ce blown fuse à p 14 9 Telescopic section and tele scoping cylinder locking unlocking function not work ing Faulty valve Note the error code à p 14 32 and notify Manitowoc Crane Care Extending function not working Fuse F3 3 blown Replace blown fuse à p 14 9 RCL shutdown lamp lights up Leave the shutdown range à p 11 37 Lifting limit switch approached lamp lights up Leave the shutdown range retract...

Page 885: ...ECOS If necessary acknowledge error once and briefly turn off the ignition if error persists notify Manitowoc Crane Care Fuse RCL F6 blown Replace blown fuse à p 14 11 Fuse F3 3 blown Replace blown fuse à p 14 9 Telescoping not possible or only at low speed Speed limited Increase limit à p 11 107 Telescoping cannot be switched off ECOS malfunction Emergency stop switch à p 14 1 The main boom can n...

Page 886: ...ntact Manitowoc Crane Care if none of these are the cause Telescope status divergence ECOS has detected a difference between the displayed and the current tele scope status Enter the current telescope status à p 14 53 Emergency programme access The telescoping mechanism can only be operated with the emergency pro gramme à p 14 43 Emergency programme The Telescoping emergency programme is open à p ...

Page 887: ...rror persists notify Manitowoc Crane Care Fuse RCL F6 blown Replace blown fuse à p 14 11 Fuse F3 3 blown Replace blown fuse à p 14 9 Slewing function not working Enter RCL code for the 0 to the rear position Enter RCL code for a slewing range Function disabled by ECOS If necessary acknowledge error once and briefly turn off the ignition if error persists notify Manitowoc Crane Care Slewing only po...

Page 888: ...the hydraulic system error message is dis played Have the temperature sensor replaced Symbol g is red Corresponding hydraulic oil filter soiled Change hydraulic oil filter à Maintenance manual Malfunction Cause Solution Crane cab inclination function not working Fuse F1 1 F1 7 blown Replace blown fuse à p 14 6 Mega Wing Lift in rigging position End rigging à Separate oper ating manual Malfunction ...

Page 889: ...ld control Driver s cab Fuse A2F3 blown Replace blown fuse à p 7 20 When operating from the crane cab Hand held control connected to the superstructure or a bridging plug not inserted Disconnect hand held control or insert bridging plug à p 12 22 When operating from the con trol units Display fields switched off Switch on display fields à p 12 33 Hand held control connected to the superstructure o...

Page 890: ...rane if an error message is displayed The RCL may only be repaired by trained and qualified personnel G Risk of accident by faulty or overridden RCL In the event of a faulty RCL first try to correct the error with the information in this section Only override the RCL if it becomes absolutely necessary in order to lower the load in the event of an emergency Do not carry out any movements which incr...

Page 891: ...buzzer tone sounds once Lamps 1 and 2 light up Display 3 shows an error code and the associated symbol flashes You can have all existing error messages dis played by repeatedly pressing the button 6 Try to correct the error by turning off the ignition and turning it on again after about 15 seconds If the error is displayed again check whether the error code is contained in the Error codes tables T...

Page 892: ...e error A continuous buzzer tone sounds After five seconds you can switch off the buzzer tone using button 5 Lamps 1 and 2 light up Lamps 3 and 4 light up Display 7 shows an error code and the error symbol flashes You can have all existing error messages dis played by repeatedly pressing the button 6 Check whether the Error codes tables contain the error These tables contain information on how to ...

Page 893: ...d display 1 shows which error is displayed 3 5 for example means Error 3 is shown There is a total of 5 errors If the error shown is not acknowledged the lamp next to the button 3 lights up Acknowledging the error Press the 3 button once The next pending error is displayed and can be acknowledged You can call up all current errors with the buttons 1 and 2 Every time you press the next error will b...

Page 894: ...ror These tables contain information on how to remedy errors à p 14 27 Exiting the submenu You can exit the Errors submenu at any time Press the 1 button once The same menu opens that was open before the Errors submenu opened H All errors remain saved until you switch off the ignition even those errors of which the cause has been eliminated in the meantime All existing errors are treated as new er...

Page 895: ...on 1 goes out Error code Cause Solution 1 01 1 7 Error pressure sensor 1 Lower chamber Switch off pressure sensor 1 à p 14 30 1 01 8 Pressure sensor 1 switched off Have malfunction corrected 1 02 1 7 Error pressure sensor 2 Lower chamber Switch off pressure sensor 2 à p 14 30 1 02 8 Pressure sensor 2 switched off Have malfunction corrected 1 04 1 7 Error angle sensor 1 Main boom Switch off pressur...

Page 896: ...o steep Lower the main boom 5 02 1 There is no RCL code availa ble for the entered rigging mode Re enter the current rigging mode If the error is displayed again check whether the current rigging mode is permissible 5 02 4 Lattice extension inclination is too small Raise the lattice extension 5 02 5 Lattice extension inclination is too large Lower the lattice extension 5 02 6 Current load greater ...

Page 897: ...ble overall working radius exceeded1 Raise or retract 8 14 3 Maximum permissible overall slewing range exceeded1 Slew into a permissible working range 8 14 4 Shutdown area of a moni tored object reached1 Move into a permissible working range 8 17 2 Rigged outrigger span not correct Check the outrigger span and rig the required outrigger span 8 17 3 Current outrigger span not permissible Check the ...

Page 898: ...1 02 5 After switching off the faulty sensor tachogenerator you should check whether the other sensor tachogenerator is functioning correctly Checking the pressure sensor function Lift the hook block without a load Check whether the display 1 indicates the approximate weight of the hook block Checking the angle sensor function Set down the main boom on the boom rest Check whether the display 1 sho...

Page 899: ...are in the event of a malfunction If required open the main menu ö The display 1 shows the number of the current programme version General malfunctions The following table contains information on troubleshooting and possible solutions H Other malfunctions on the ECOS generate corresponding error messages s Malfunction Cause Solution The ECOS display remains dark although the ignition is switched o...

Page 900: ... means Error 3 is shown There is a total of 5 errors If the error shown is not acknowledged the lamp next to the button 3 lights up Acknowledging the error Press the 3 button once If there are further errors the next error is dis played and can be acknowledged When all errors have been acknowledged you can retrieve any pending errors using the buttons next to the symbols 1 and 2 Every time you pre...

Page 901: ...symbols stand for The error code 5 consists of four digits e g 2332 Always note the error code before contact ing Manitowoc Crane Care Exiting the submenu You can exit the Errors submenu at any time Press the 1 button once The same menu opens that was open before the Errors submenu opened H All errors remain saved until you switch off the ignition even errors that have since been resolved All exis...

Page 902: ... be reported externally e g by Manitowoc Crane Care If an error occurs check The fuses The antenna plugs The lamps on the TCU Fuses Loosen the screws 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 9 Loosen the screws 4 and fold down the plate 3 to the front S Risk of damage if procedure is incorrect Observe the following ...

Page 903: ...rating manual GMK 6400 3 112 993 en 14 35 12 07 2013 Check the fuses 1 and replace them if nec essary Antenna plugs Check whether the plugs 1 and 2 are plugged in s Designation Amperage F3401 5 A F3402 5 A 1 Plugs for GSM GPS antenna 2 Plug for satellite antenna ...

Page 904: ...sed for troubleshooting Each lamp can show four different functions Observe the functions of the lamps and forward the information to Manitowoc Crane Care if necessary A TCU display B GPS display C GSM display D Satellite display E Can bus display F GSM or satellite display On Lamp lights up Off Lamp goes out Quick flash Flashes four times per second Slow flash Flashes once per second ...

Page 905: ...Quick flash A 24 V DC from battery 24 V DC from ignition 0 V DC from battery or ignition off for a long time 24 V DC from battery 0 V DC from ignition B 3D GPS fix GPS error Weak signal C Connected No connection D No message queued and satel lite in view No message queued and no sat ellite in view Message queued and no satellite in view Message queued and satellite in view E Receiving data on CAN ...

Page 906: ...Malfunctions during crane operation 14 4 Troubleshooting 14 38 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 907: ...erations and programmes This section contains all the information about possible emergency opera tions and emergency programmes The following are available Mechanical emergency operation for retracting Telescoping emergency programme submenu Entering the telescoping after an emergency operation Operation of the power units with the hand held control ...

Page 908: ... The corresponding RCL code according to the Lifting capacity table must be displayed 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 order to reach the locking p...

Page 909: ...t be locked or unlocked manually There are two M8 screws for every telescopic section 200 mm length for telescopic section I 150 mm length for telescopic section II 110 mm length for telescopic sections III and IV Screw 3 into the locking pins 1 to unlock Pins located further inside are reached through the holes 4 You will need a suitable socket wrench 2 with one shank being at least 200 mm long T...

Page 910: ...elescopic sec tion as well Locking the telescopic section A Retract until the locking pin 2 is in the middle of the opening Screw the set screw out of the bore 1 until the locking pin is fully extended Take the set screw out of the bore hole B Retract further until the telescopic sec tion is set down S Risk of damage due to a mechanically released lock Under no circumstances may you operate the te...

Page 911: ...e Starting the emergency programme Only start the emergency programme when the symbol 1 is displayed à Telescoping mechanism error messages p 14 17 Press the right dead man s switch 3 Also press button 2 once symbol 4 appears Press the buttons 1 in the following order ÆÅÆÇ The symbols 5 confirm the entry If your input was incorrect all symbols 5 go out and you need to re enter You can cancel the e...

Page 912: ...ble for the current error If the display 1 shows no value there is an error on the length indicator If a symbol 2 is violet there is an error on the proximity switch The buttons next to the symbols 3 are active After pressing the button locking or unlocking is performed immediately Note the error code 4 first if you intend to contact Manitowoc Crane Care before exe cuting the emergency programme G...

Page 913: ...ction Error on length indicator First register the current status of the telescoping mechanism Check the positions of the locking pins as usual i e on the displays 1 and 2 Check whether the display 3 shows the RCL measured value for the extended length of the telescoping cylinder Check the telescoping on the RCL s G Risk of damage to the main boom Never telescope the main boom if there is an error...

Page 914: ...green Retracting and locking a telescopic section During telescoping you may not select Lock Under no circumstances should you press the button 2 G Risk of accidents from sudden retraction of a telescopic section Press the button for unlocking the telescopic section not more than twice If this does not start the unlocking procedure contact Manitowoc Crane Care S Risk of damage to the main boom If ...

Page 915: ...ock the telescoping cylinder If the telescopic section is locked you can now unlock the telescoping cylinder Press the button 1 1x at the most 2x The telescoping cylinder is unlocked In Unlocked position The locking pins 3 are red the symbol 1 is yellow The symbol 2 is grey You can now move the telescoping cylinder into the next telescopic section s G Risk of accidents from sudden retraction of a ...

Page 916: ... arrows 4 are green the display 5 shows the length for the cur rent locking point à p 14 51 Press the button 2 once The telescoping cylinder is locked In Locked position the locking pins 3 are green the symbol 1 is grey the symbol 2 is yellow You can now retract this telescopic section à p 1 S Risk of damage to the main boom If you select Lock while the telescoping cylinder is moving the locking p...

Page 917: ...responding arrows are not shown on the display C When an error occurs you can determine the current position more pre cisely based on the other fault free proximity switches The proximity switches show the following positions Display C Telescoping cylinder at the locking point Display B Telescopic section locked Display A Telescoping cylinder locked For fault free proximity switches the following ...

Page 918: ...locking point à Locking points for the telescoping cylinder p 14 51 à Locking points for the telescopic sections p 14 52 Move the telescoping cylinder to the required length display 1 Terminating emergency programme The emergency programme is terminated If the displayed time has expired When the ignition is turned off H The current telescoping status does not correspond to the telescoping sta tus ...

Page 919: ...points for the telescoping cylinder The following table shows the extended length for locking the telescoping cylinder s 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 44 88 100 30 4930 9830 11175 0 10 16 22 32 34 36 76 Telescopic section II 0 44 88 100 410 5310 10210 11520 1 ...

Page 920: ...he following table shows the extended length 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 44 88 100 33 4958 9858 11203 0 11 16 31 32 43 36 86 Telescopic section II 0 44 88 100 413 5338 10238 11548 1 36 17 57 33 68 37...

Page 921: ...g the values from the RCL display If necessary open the main menu ö and press the 1 button once This opens the Settings submenu Entering target values The display 7 shows the values for telescopic sections I to IV Press one of the buttons 1 to 4 the val ues in the display 6 turn yellow Each time you press a button the correspond ing value in the display 6 switches continu ously between the fixed l...

Page 922: ...ct all symbols 5 go out and you need to re enter If the target values entered are not permissi ble the values on the display 2 turn red If the target values entered are permissible the values on the display 2 turn green The display 1 shows the symbol for the cur rent status S Risk of damage due to incorrect input Before working with the crane check whether ECOS indicates the current telescoping an...

Page 923: ...ng the truck crane into a safe state or to shut it down Preparations You have to connect up the hand held control and start the engine Connecting the hand held control Connect the hand held control to the con nector 1 All power units can be operated from this con nection Information on connecting à p 12 22 Starting the engine Press the 1 button once the engine starts à p 10 15 s G Danger of overtu...

Page 924: ...g for Lift main hoist press button 1 first and then also button 2 The further you press button 2 the quicker the movement is The maxi mum speed is limited to about 50 for all power units 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 and ensure that the maximum permissible working radius is not e...

Page 925: ...inations Engaged buttons are shown in black s Pre selected power unit Button combination Telescoping mechanism Derricking gear Slewing gear Hoists Lattice extension c e f a b d None1 Lower boom None Lower Lower boom Retract Raise boom None Lift Raise boom None None Slew to right None None None None Slew to left None None 1 If the telescoping cylinder is unlocked it will extend ...

Page 926: ...on or the end position is reached Stopping movements in emergencies You can stop operations with the emergency stop switch if they do not stop by letting go of the function buttons à p 10 18 Turning off the engine You can only turn off the engine with the hand held control In this case it is not possible to turn off the engine via the ignition lock Stop all crane movements Press the button 1 the e...

Page 927: ...and slewing gear Emergency supply of another truck crane that also has a hydraulic emer gency operation BGR 159 Emergency operation A transformer 1 serves as a power source for the crane s hydraulic system The transformer is powered by the carrier s hydraulic system or by the emergency supply of another truck crane The hydraulic circuits are switched with the valves 2 The control levers 3 regulate...

Page 928: ...rane à Emergency supply of another crane p 14 68 14 6 2 Connecting disconnecting hoses Switch off the engine Establishing The hoses are assigned according to the various diameters On the carrier Attach the transformer 3 to the superstruc ture Connect the hoses 2 to the connections 1 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 fr...

Page 929: ... superstructure Connect the thicker hose 2 to the connec tion 1 Connect the thinner hose 4 to the connec tion 3 Disconnecting After the emergency operation you must disconnect the hoses and the transformer On the superstructure Remove the hoses 3 and 4 from the con nections 1 and 2 Close the hoses and the connections with the caps s ...

Page 930: ...the connections 1 Close the hoses and the connections with the caps Remove the transformer 3 14 6 3 Switching emergency operation on off The emergency operation or emergency supply of another crane is switched on and off in the driver s cab Remove the cover 1 Start the engine for driving Switching on Press switch 2 down Switching off Press switch 2 up ...

Page 931: ...ulic circuits To establish an hydraulic circuit switch over the required valves Switching over valves The valves 1 to 7 are numbered For crane operation Switch the valves 1 to 7 inwards s G Danger from mutual interference of the power units For crane operation always switch all the valves 1 to 7 inwards This pre vents the power units from suddenly starting to move ...

Page 932: ...he valves 1 2 4 5 and 7 must be switched inward G Danger from mutual interference of the power units Always only switch valves for one crane movement up diagonally at a time This prevents wrong crane movements from being performed and several movements from being performed unintentionally at the same time Emergency operation for crane movements Valves inward crane operation Valves outward emergenc...

Page 933: ...ssible to control the slewing movements with the control lever for emergency operation with the same degree of sensitivity as with the control lever in the crane cab Slowly move the control lever 1 in the required direction s G Risk of accident during slewing Do not stand on the carrier This prevents you from being pushed off the carrier or being crushed by the carrier during slewing S Risk of dam...

Page 934: ...asuring tape to check Move the control lever 2 towards B Raising the boom Move the control lever 1 towards B 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 ...

Page 935: ... its original state after finishing emer gency operation Switching off emergency operation Switch off emergency operation à p 14 62 Switch off the engine Switching over to crane operation After every emergency operation Switch valves 1 to 7 to crane operation à p 14 63 Disconnecting the hoses Disconnect the hoses à p 14 61 Close all the connections and hoses with the caps Remove the transformer ...

Page 936: ...h the transformer 3 Attach the hoses 4 à Operating manual of the other crane On the GMK 6400 Turn off the engine for driving Connect the hoses 2 to the connections 1 Switch on the hydraulic emergency opera tion à p 14 62 After emergency supply Switch off the hydraulic emergency operation à p 14 62 On the GMK 6400 Remove the hoses 2 from the connections 1 On the crane that was supplied Remove the h...

Page 937: ...Operating manual GMK 6400 3 112 993 en 12 07 2013 15 15 Index ...

Page 938: ...3 112 993 en Operating manual GMK 6400 12 07 2013 ...

Page 939: ...ear we have not included every single element from the instrument panel Those elements such as switches and buttons lamps and displays are de scribed and named in detail in the overviews of chapter 3 and chapter 9 Truck Crane Description From there you will as usual be referred to more detailed descriptions of these elements ...

Page 940: ...Index 15 2 3 112 993 en Operating manual GMK 6400 12 07 2013 Blank page ...

Page 941: ...12 107 Raise onto the 20 t base plate 12 98 Raising and setting down the catcher 12 99 Securing the upper hook block in the catcher 12 106 Short description of the operating elements 9 76 Slinging points 12 92 Switching off 11 61 Switching on 11 59 Transport 12 93 Axle loads Required speed limit 6 5 B Battery master switch 4 12 Boom pre tensioning Switching off 12 17 12 19 Switching on 6 8 6 9 Bra...

Page 942: ...wing crane operation 12 5 Checks Before driving 5 6 Safety equipment 11 9 Vehicle height 5 8 Choosing a site 12 9 Compressed air system Building supply pressure 5 9 Counterweight 12 59 Assembling counterweight combination 12 67 CHECKLIST Counterweight rigging 12 62 Counterweight unrigging 12 65 Counterweight sections 12 59 Establishing disconnecting the hydraulic connection 12 81 Identification 12...

Page 943: ...w 9 4 Standard heating system 11 130 Ventilating 11 131 Windows 9 112 Crane operation CHECKLIST checks before operating the crane 11 1 Permissible slewing ranges 11 55 Rigging CHECKLIST 12 1 Unrigging CHECKLIST 12 5 What to do in the event of malfunctions 14 3 Cruise control 5 40 5 41 D DEF system Operating elements in the driver s cab 3 37 Derricking gear 11 64 Raising and lowering 11 65 Short de...

Page 944: ...ering wheel 3 13 Transmission 3 14 Overview 3 4 Standard heating system 5 70 Windows 3 62 Driving at low temperatures CHECKLIST 4 4 Brakes Additional brakes 5 44 Checks before driving 5 6 Checks before driving CHECKLIST 5 1 Checks while driving 5 37 Downhill 5 42 Off road 5 57 Uphill 5 46 What to do in the event of malfunctions 7 3 With cruise control 5 40 5 41 Driving modes Tables for maximum axl...

Page 945: ...e driver s cab in the errors submenu 5 53 in the Monitoring submenu 3 23 in the Settings submenu 3 22 Operating hours 5 21 in the warning submenu 5 47 Electrical system Checks in the crane cab 11 6 Checks in the driver s cab 5 6 Display and operating elements in the crane cab 9 105 Fuses in the superstructure 14 6 Operating elements in the driver s cab 3 39 RCL fuses 14 11 Emergency operation Emer...

Page 946: ...ting 10 8 Switching on the ignition 10 4 Turning off During normal operation 10 17 in emergencies 10 18 Engine for crane operation Switching off Economy mode 10 13 Engine for driving Air intake inhibitor 4 27 Diagnostics 3 61 Malfunctions 7 27 Operation in the driver s cab Resetting the emergency stop switch 4 26 Operation in the driver s cab Checking after starting 4 19 Inspections before startin...

Page 947: ...s 12 21 Malfunctions 14 20 Heating system Crane cab Auxiliary air heater 11 141 Auxiliary water heater 11 134 Standard heating system 11 130 Driver s cab Auxiliary water heater 5 75 Standard heating system 5 70 High speed mode 11 96 Derricking gear telescoping mechanism high speed mode 11 96 High speed mode for hoists 11 97 Switch on function 11 96 Hoist rope Checking the position 11 6 Positioning...

Page 948: ...tion Conversion table for US measuring units 1 29 for operations planning 1 28 Notes on the operating instructions 1 21 Installing removing the air traffic control light 12 132 Installing removing the anemometer 12 132 K Keys for the carrier 3 63 for the superstructure 9 113 L Ladders and access ladders 4 4 Level adjustment system Changing the vehicle level 5 62 Exiting the submenu 5 63 Opening th...

Page 949: ...Lifting off on the turntable 6 29 Retracting fitting the derricking cylinder head pin 6 21 Securing releasing the derricking cylinder 6 31 Slinging points 6 18 Transporting the main boom 6 32 Main boom removing installing disconnecting connecting hydraulics electrical 6 27 extending retracting the boom pivot pin 6 24 Main hoist 11 56 Folding hoist mirror out in 12 136 Lifting and lowering 11 57 Sh...

Page 950: ...igging for driving with a trailer 6 6 Switching on boom floating position 6 8 Switching on the slewing gear freewheel 6 7 Switching the superstructure driving lights on off 6 10 Main boom removing installing 6 11 Rear outrigger 6 53 Removing installing outrigger beams 6 35 Reverse camera installing 6 68 Supporting box CHECKLIST Assembly 6 57 Removal 6 54 Crane movements during installation and rem...

Page 951: ...ng the truck crane on outriggers Automatic 12 53 Inclination indicators 12 50 Manual 12 52 Outrigger pads Moving into driving position 12 43 Moving into working position 12 43 Outrigger pressure display 12 57 Permissible outrigger spans 12 32 Preparing the truck crane for rigging 12 33 Removing installing outrigger beams 6 35 CHECKLIST Assembly 6 38 Removal 6 36 Disconnecting establishing the conn...

Page 952: ...it 9 38 Overriding the RCL 11 40 RCL early warning 11 37 RCL shutdown 11 37 Due to error message 14 24 Due to overload 11 37 Switching on 11 20 Troubleshooting 14 22 Error messages 14 23 Errors submenu 14 25 General malfunctions 14 22 Rear outrigger Assembly 6 57 Removal 6 54 Slinging points 6 70 Rear outrigger box Control elements on the carrier 3 54 Reeving unreeving the hoist rope Rope end fitt...

Page 953: ...t adjusting in the crane cab 11 7 in the driver s cab 5 11 Separate steering 5 66 Steering with separate steering 5 67 Switching to normal steering mode 5 69 Switching to separate steering 5 66 Settings before driving Adjusting the brightness of the display 4 15 Settings during crane operation Adjusting display brightness 10 7 Adjusting the power unit speeds 11 107 Adjusting the wiper stroke inter...

Page 954: ... lock houselock submenu Short description of the operating elements 9 89 Supporting box Establishing disconnecting the electrical connection 6 63 Establishing disconnecting the hydraulic connection 6 64 Establishing disconnecting the pneumatic connection 6 62 Hanging lifting on the truck crane 6 65 Transportation on a separate vehicle 6 73 Suspension Locking switching off 5 14 Operating elements i...

Page 955: ...tatus RCL display 11 74 Telescoping process 11 69 Telescoping sequence 11 74 Telescoping the main boom for maintenance 11 95 Telescoping the main boom when horizontal 11 95 Telescoping with teleautomation 11 91 Telescoping ECOS display 11 88 Towing 7 5 After engine transmission damage 7 6 Compressed air supply after engine failure 7 6 Electric power supply 7 7 Parking brake 7 8 Towing the truck cr...

Page 956: ...3 V Voltage monitoring Superstructure 9 105 W Warning plates for vehicle width 5 8 Welding work Safety instructions 2 4 Wheels and tyres Inflating the tyres yourself 7 17 Wheel change 7 13 Windscreen wiper 3 55 Crane cab 9 107 Driver s cab 3 55 Windscreen wiper washing system 9 105 Work break 11 128 in case of short work breaks 11 128 in case of work breaks of more than 8 hours 11 129 Working rang...

Page 957: ...Index Operating manual GMK 6400 3 112 993 en 15 19 12 07 2013 Shutdown 11 127 Switching monitoring function on off 11 126 View current settings 11 116 ...

Page 958: ...Index 15 20 3 112 993 en Operating manual GMK 6400 12 07 2013 ...

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