Page 1 Operating manual 3 302 690 en 23.11.2017...
Page 2 Important note Any type of duplication or excerpt from this document, even in electronic form, is not subject to the revision service of Manitowoc Crane Group Germany GmbH © Copyright reserved by Manitowoc Crane Group Germany GmbH Industriegelände West D-26389 Wilhelmshaven, Germany...
Page 3 Outrigger spans Overview metres (feet) / per cent The display RCL (1) shows the outrigger spans in metres (feet). The control units (2) indicate the outrigger spans in per cent. The percentage values in the enclosed lifting capacity table and the enclosed operating instruc- tions deviate from the percentage values actu- ally displayed on the control units (2) as they are based on different principles.
Page 4 GMK5150/GMK5150L Length specifications Percentages Lifting Control Overall widths Individual widths capacity unit table 7.600 m (24.9 ft) 3.800 m (12.5 ft) 100% 100% 6.700 m (22.0 ft) 3.350 m (11.0 ft) 5.900 m (19.4 ft) 2.950 m (9.7 ft) 5.100 m (16.7 ft) 2.550 m (8.4 ft) 2.500 m (8.2 ft) 1.250 m (4.1 ft)
Page 5 Driving from the crane cab Changed operational step These additional pages are only valid for truck cranes equipped with the Driving from the crane cab additional equipment. There is a modified Driving menu that differs from the information specified in the operating manual .
Page 6 Overview of Driving menu 3 302 710 en Additional pages GMK4100L-1...
Page 7 à 1 Transmission mode RM p. 8 à 2 Transmission mode R p. 7 à 3 Neutral position N p. 7 à 4 Transmission mode D p. 7 à 5 Transmission mode DM p. 8 6 Current transmission mode display à...
Page 8 Blank page 3 302 710 en Additional pages GMK4100L-1...
Page 9 Brief description of the operating elements Driving menu Driving menu – Opening: Select symbol (1) and confirm – menu is opened The menu is also opened the first time the parking brake is à released; p. 11 – Applying: – The parking brake must be engaged –...
Page 10 Steering lock display White: Driver's cab: Ignition key in position 1 Crane cab: Operating elements for driving active Red: Driver's cab: Ignition key not in position 1 Crane cab: Operating elements for driving without function à p. 17 Change-over between crane operation and driving modes –...
Page 11 Transmission Operating the transmission when driving with rigged truck crane, à Operating the transmission , p. 26. The following applies to all operating elements: – Driving mode must be switched on – The Service brake pedal must be applied – The truck crane must be stationary. Neutral position N –...
Page 12 Transmission mode DM – To switch on: Select and confirm symbol – letter is white – Gear 1 forwards on – transmission will not shift – Crane's hydraulic system Driving mode on – Crane movements released – To switch off: Shift to a different gear – letter is blue Transmission mode RM –...
Page 13 Final drive Driving menu Opening: Select symbol (1) and confirm – menu is opened Transverse differential locks on/off – To switch on: Select symbol (1) and confirm – symbol is red – To switch off: Select symbol (1) and confirm – symbol is green When a symbol (1) is selected all transverse differential locks are switched on or off.
Page 14 Brakes Service brake The pedal acts on the carrier brakes – for continuously variable adjustment of the braking force. CCS display Supply pressure brake circuits 1 and 2 display – Red: Supply pressure less than approx. 5 bar – Green: Supply pressure greater than 5.5 bar Parking brake indicator lamp –...
Page 15 Applying/releasing the parking brake – Applying: – Press down once – lamp (1) lights up, parking brake is closed – Releasing: Releasing for the first time after ignition on – Press up once – Driving menu opens – Apply the service brake –...
Page 16 CCS display Changing the steering direction Display 1 Steering direction Steering wheel 2 Steering direction Reversed (compared to steering wheel) To switch over: Select the desired symbol and confirm; the setting will be saved – Steering direction Steering wheel Function –...
Page 17 Switching steering modes on and off The selected symbol must be confirmed within 2 seconds, otherwise the steering mode remains unchanged. Automatic separate steering for driving around corners on/off – To switch on: Select symbol (1) and confirm – symbol (2) is displayed –...
Page 18 Control panels The information in this section is based on the steering direction setting Steering wheel . Steering with separate steering – manual The symbol (3) is displayed. Steer 1st and 2nd axle lines with the button (1). Press and hold button (2) –...
Page 19 Driving from the crane cab Risk of accidents when driving with a lifted load The truck crane may be driven with a lifted load only when it is in the Free on wheels working position and the current rigging mode has been entered and confirmed on the RCL.
Page 20 Preparing to drive • Make sure that the rigging mode for driving with a load or without a load à Supplied operating manual . is set correctly; In the driver's cab – The ignition key must be in position 1 so that the steering cannot block. –...
Page 21 Opening/closing the Driving menu Opening menu • Select and confirm the symbol (1). The menu opens automatically the first time you release the parking brake after switching on the ignition. The display will show (A) or (B) depending on the current slewing angle; Carrier display , p.
Page 22 In crane operation The symbol (2) is white. The gear indicator (1) indicates gear 15 (shift position for supplying the crane's hydraulic system). The operating elements (3) are disabled. The buttons (4) are assigned the High-speed function. The crane's hydraulic system Driving mode is switched off –...
Page 23 Crane's hydraulic In driving mode, the crane's hydraulic system is driven by a different energy system Driving source from the one used in crane operation. mode The switchover is automatic, and the current status is displayed. 1 Arrow orange – crane's hydraulic system Driving mode on The transmission mode RM, DM or neutral position N is selected –...
Page 24 Steering Switching on Switching over to Driving mode switches on the normal steering mode. Display and The display of the carrier depends on the current slewing angle; à Carrier display , p. 5. steering direction The steering direction depends on whether the superstructure is in the front semi-circle or in the rear semi-circle.
Page 25 Switching the The steering direction switched on is saved and is retained even after a steering direction restart. The display shows the currently set steering direction. 1 Steering direction Steering wheel 2 Steering direction Reversed (compared to steering wheel) Switching over •...
Page 26 3 Automatic – crab travel mode 3rd and 4th axle lines steered automat- ically The symbol (4) indicates the selected steering mode, e.g. driving around corners . If the error symbol is displayed, contact Manitowoc Crane Care 3 302 710 en Additional pages GMK4100L-1...
Page 27 Steering with separate steering – automatic The symbol (2) or (3) is displayed for the desired steering mode. • Steer the 1st and 2nd axle lines with the button (1). • – To turn to the left: Press button (1) to the left. •...
Page 28 Steering with separate steering – manual The symbol (3) is displayed. • Steer the 1st and 2nd axle lines with the button (1). • Steer the 3rd and 4th axle lines with the button (2). • – To turn to the left: Press buttons (1), (2) to the left.
Page 29 • Select and confirm the symbol (3) – symbol (4) is displayed. If the error symbol is displayed, contact Manitowoc Crane Care Steering in normal steering mode The symbol (2) is displayed. • Steer the 1st and 2nd axle lines with the button (1).
Page 30 Operating the transmission When the Driving operating mode is switched on, the transmission is in neutral position – letter N (1) white. Selecting the You can select transmission modes with crane functions and transmission transmission modes without crane functions. mode Risk of accidents when driving with a lifted load Secure the load when driving so that it cannot swing and use the transmis- sion mode DM or RM so that the transmission does not shift.
Page 31 While driving DM and RM trans- The truck crane drives in 1st gear only, and the transmission does not shift. mission mode Risk of accidents when driving with a lifted load The maximum permissible speed for driving with a lifted load is 1.5 km/h (1 mph).
Page 32 Possible connections Risk of damage to the differential locks Leave the transverse differential locks switched on only for as long as necessary. Always switch off the transverse differential locks before driving on a hard surface! You can make the following connections, one after the other: –...
Page 33 – first symbol (2) – yellow, then symbol (3) – green, differential locks off. If symbol (3) is not green then drive back and forth slowly. If the error symbol is displayed, contact Manitowoc Crane Care Additional pages GMK4100L-1 3 302 710 en...
Page 34 After driving • Bring the truck crane to a halt with the brake pedal (1). • Restore the original condition: – Switch the transmission to neutral position (1) – Switch off longitudinal differential lock (3) – Switch off transverse differential locks (2) –...
Page 35 The operating instructions consist of the following chapters: 1 Overview 2 Basic safety instructions 3 Operating elements for driving 4 Starting the engine for driving / switching it off 5 Driving 6 Driving modes 7 Transport 8 Malfunctions in driving mode 9 Operating elements for crane operation 10 Starting/switching off the engine –...
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Page 37: Table Of Contents
Manitowoc Crane Care ........
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Page 39 Basic safety instructions Intended use ............4 - 2.1.1 Improper use .
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Page 41 Operating elements for driving Overview of the operating elements ........5 - 3.1.1 On the outside of the truck crane .
Page 42 3.2.22 Front flap ............5 - 73 3.2.23 Windows and doors .
Page 43 Starting the engine for driving / switching it off Starting the engine from the driver's cab ....... . 6 - 4.1.1 CHECKLIST: Starting the engine .
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Page 45 Driving Before driving ............7 - 5.1.1 CHECKLIST: Checks before on-road driving.
Page 46 5.6.2 Air-conditioning system ..........7 - 68 5.6.3 Auxiliary water heating system .
Page 47 Driving modes Driving modes ............8 - 6.1.1 How to use the tables .
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Page 49 Transport Transport with transport vehicle ........9 - 7.1.1 CHECKLIST: Checks before transport .
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Page 51 Malfunctions in driving mode Emergency stop switch ..........10 - Procedure during malfunctions .
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Page 53 Operating elements for crane operation Overview of the operating elements ........11 - 9.1.1 Exterior of the truck crane .
Page 54 9.2.17 Derricking gear ..........11 - 120 9.2.18 Telescoping mechanism.
Page 55 Starting/switching off the engine – for crane operation 10.1 When starting the engine for the first time in the day ....12 - 10.2 Starting the engine –...
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Page 57 Crane operation 11.1 Before operating the crane ......... . . 13 - 11.1.1 CHECKLIST: Checks before operating the crane .
Page 58 11.6 Settings and displays for crane operation ......13 - 123 11.6.1 Inclining the crane cab .
Page 59 Rigging work 12.1 Rigging work checklists for crane operation with the main boom ..14 - 12.1.1 CHECKLIST: Rigging ..........14 - 12.1.2 CHECKLIST: Unrigging .
Page 60 12.9.4 Slinging points on the counterweight sections ......14 - 74 12.9.5 CHECKLIST: Rigging the counterweight ......14 - 76 12.9.6 CHECKLIST: Unrigging the counterweight .
Page 61 Driving with a rigged truck crane 13.1 Route ............15 - 13.2 Permissible rigging modes and axle loads .
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Page 63 Malfunctions during crane operation 14.1 Emergency stop switch..........16 - 14.2 What to do when malfunctions occur during crane operation .
Page 64 14.7.3 CHECKLIST: After emergency operation......16 - 60 14.7.4 Connecting/removing transformer – for self-sufficiency ....16 - 61 14.7.5 Switching emergency operation on/off.
Page 65 Index Operating manual 3 302 690 en GMK4100L-1...
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Page 67: Overview
In the event of an accident, contact the relevant branch office of in the country in which you are working and Manitowoc Crane Care 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.
Page 68 Overview 1.1 Accidents Blank page 1 - 2 3 302 690 en Operating manual GMK4100L-1...
Page 69: Branch Offices
Overview 1.2 Branch offices Branch offices 1.2.1 Manitowoc Crane Care If you need help or support with the operation on your truck crane, you can contact our branches at the following addresses Manitowoc Crane Care http://www.manitowoccranes.com 1.2.2 Dealer list Visit the following address for a global list of dealers: http://www.manitowoccranes.com...
Page 70: Terms Used
Overview 1.4 Terms used Terms used 1 - 4 3 302 690 en Operating manual GMK4100L-1...
Page 71 Overview 1.4 Terms used (A) – Carrier 1 Driver's cab 2 Boom rests 3 Counterweight platform 4 Axle lines 5 Outrigger beams 6 Outrigger cylinders 7 Outrigger pads (B) – Superstructure 8 Slewing gear 9 Crane cab 10 Main boom with telescoping mechanism 11 Telescopic sections 12 Hook block 13 Derricking cylinder, derricking gear...
Page 72 Overview 1.4 Terms used Blank page 1 - 6 3 302 690 en Operating manual GMK4100L-1...
Page 73: Technical Data
Overview 1.5 Technical data Technical data GROVE crane GMK4100L-1 Permissible temperature range: -25 °C to +40 °C (-13 °F to +104 °F) Crane designation: Truck crane as per DIN 15 001, Part 1 Crane application: Service crane as per DIN 15 001, Part 2 Crane classification: Hoist class H1 to DIN 15 018, Part 1 Crane class A1 to ISO 4301, Part 2...
Page 74: Dimensions And Weights Of The Truck Crane, Axle Loads
Overview 1.5 Technical data 1.5.3 Dimensions and weights of the truck crane, axle loads All dimensions in the illustration are in mm. 1 - 8 3 302 690 en Operating manual GMK4100L-1...
Page 75 Overview 1.5 Technical data à Dimensions All dimensions relate to on-road mode; Driving modes , p. 6 - 1. Length without auxiliary hoist: 12.69 m (41.6 ft) Height: At on-road level: – 385/95 R25 3.94 m (12.9 ft) – 445/95 R25; 525/80 R25 3.99 m (13.1 ft) Max.
Page 76: Dimensions And Weights Of Removable Parts
Overview 1.5 Technical data 1.5.4 Dimensions and weights of removable parts This section contains the dimensions and weights of the parts that can be à Driving modes , p. 6 - 1. removed for on-road driving; Spare wheel Length x width x height Weight in kg Description in m (ft)
Page 77 Overview 1.5 Technical data Hook blocks and hook tackle Versions as execution as separable hook block Dimensions (m) (ft) and weights (kg) (lbs) 1.98 0.90 1.20 1.98 0.90 1.30 Length (6.50) (2.95) (3.94) (6.50) (2.95) (4.27) 0.70 0.70 0.70 0.70 0.70 0.70 Width...
Page 78 Overview 1.5 Technical data Standard versions Length x width x height Weight Description (L) x (W) x (H) In kg (lbs) in m (ft) Single or double hook, 1.50 x 0.56 x 0.76 1,300 7 sheaves (4.90 x 1.80 x 1.30) (2,866) Single or double hook, 1.50 x 0.55 x 0.40...
Page 79 Overview 1.5 Technical data Versions with ballast plate – Version A Description (1) x (2) x (3) Weight No.: 03296564 in m In kg 1.33 x 0.56 x 0.47 Hook block (4.36 x 1.84 x 1.54) 1 sheave with ballast plates 1,33 x 0.56 x 0.20 Hook block (4.36 x 1.84 x 0.65)
Page 80 Overview 1.5 Technical data Counterweight parts Length x width x Weight Description height in m (ft) in kg (lbs) 0.8 t counterweight section 0.60 x 1.11 x 0.24 (1.97 x 3.64 x 0.79) (1,764) 2.7 t base plate 1.34 x 2.53 x 1.15 2,700 (3.15 x 8.40 x 1.87) (5,953)
Page 81: Carrier
Overview 1.5 Technical data 1.5.5 Carrier Motor Mercedes-Benz: OM 470 LA Engine emission: EUROMOT 3A \ EPA \ 97/68/EG Level 4 (TIER 4 CARB (non-road) Final/Euromot 4) Power 320 kW (435 hp) at 1,700 rpm (80/1269 - 89/491 EEC – including all modifications) AdblueTank –...
Page 82 Overview 1.5 Technical data Steering Dual-circuit hydraulic steering with engine-independent emergency steer- ing pump Tyres 8 x 385/95 R 25 on disc wheels 9.50-25/1.7 8 x 445/95 R 25 on disc wheels 11.00-25/1.7 8 x 525/80 R 25 on disc wheels 17.00-25/1.7 Additional equipment Torque for wheel nuts: 650 Nm (480 lbf ft).
Page 83 Overview 1.5 Technical data Outrigger Design: 4-point telescoping outrigger system Control system: Can be controlled from both sides on the carrier and individ- ually from the crane cab Outrigger span Metre (ft) Per cent (standard): 8.660 x 7.200 m (28.4 x 23.6 ft) 100% 8.660 x 6.250 m (28.4 x 20.5 ft) 8.660 x 5.300 m (28.4 x 17.4 ft)
Page 84 Overview 1.5 Technical data Electrical system Alternator: 28 V/100 A Batteries: 2 each of 12 V/180 Ah Voltage: 24 V Tool 1 tool kit in tool box, wheel chocks (number according to national regulations) Towing couplings Front towing coupling: 100 kN (22,480 lbf) permissible tension Rear tow lug: 75 kN (16,860 lbf) permissible tension à...
Page 85: Superstructure
Overview 1.5 Technical data 1.5.6 Superstructure Main hoist Drum diameter: 371 mm (14.61 in) Rope diameter: 19 mm (0.75 in) Rope length: 255 m (836 ft) Rope pull: 70.6 kN/line (15,872 lbf) Power unit group: M 3 (to ISO 4301 - 2) Load spectrum: Load spectrum factor: Km = 0.125...
Page 86 Overview 1.5 Technical data Main boom Main boom lengths: 11.4 m to 60.0 m (37.4 ft to 196.9 ft) Main boom head: 5 sheaves 6 sheaves Cylinder: One single-level telescoping cylinder with locking/unlocking mechanism Power unit group Telescoping mechanism: M 1 (to ISO 4301 - 2) Additional equipment à...
Page 87: Documentation Supplied
– Documents from other manufacturers Original documentation for parts not manufactured by Manitowoc Crane , such as the engine and central lubrication system, Group Germany GmbH as well as the tachograph, auxiliary heaters, radio and, where appropri- ate, other additional equipment.
Page 88: Questions On Documentation
Dealer list , p. 1 - 3. You can find your responsible dealer here: You can also send questions in either German or English directly to: Email: whv-techpublications@manitowoc.com For repeat orders for documentation, please contact our EMEA service. 1 - 22...
Page 89: Notes On The Operating Manual
Overview 1.7 Notes on the operating manual Notes on the operating manual This operating manual is not a training manual for prospective crane oper- ators! All descriptions are written explicitly for crane operators who have been trained to operate truck cranes! This operating manual is designed as a reference manual.
Page 90 Overview 1.7 Notes on the operating manual 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. This symbol warns you about situations where there is a danger of electric shock.
Page 91: How Is The Operating Manual Structured
Overview 1.7 Notes on the operating manual 1.7.2 How is the operating manual structured? Division – The chapters 1 to 8 contain a description of how to drive the truck crane. – The chapters 9 to 15 contain a description of crane operation. The complete operating manual must always be carried in the truck crane.
Page 92 Overview 1.7 Notes on the operating manual Structure of Each page in the operating manual is divided into a wide text column and a the pages narrow column. The narrow column contains various pieces of information: – Chapter and section numbers –...
Page 93: How Do I Find The Information I Need
Overview 1.7 Notes on the operating manual 1.7.3 How do I find the information I need? The operating manual contains the following guides for orientation. – The Contents lists all chapters in the operating instructions. – The Table of contents provides an overview of the topics. –...
Page 94 Overview 1.7 Notes on the operating manual Cross-references The illustrations, texts and cross-references in this section are only an example example and may differ from the conditions on your truck crane. 1 - 28 3 302 690 en Operating manual GMK4100L-1...
Page 95 Overview 1.7 Notes on the operating manual The parking brake is used as an example to show how the cross-references guide you through the operating manual. A In this example, the general overview is shown on page 3 - 2. The driver's cab is labelled as number 1.
Page 96: What Information Is Available For Operations Planning
Overview 1.7 Notes on the operating manual 1.7.4 What information is available for operations planning? Extensive information is required for operations planning in order to guarantee safe, smooth and efficient operation of the truck crane: The operating manual contains à –...
Page 97: Conversion Table For Us Measuring Units
Overview 1.8 Conversion table for US measuring units Conversion table for US measuring units The following conversion factors will help you convert from metric to US units and vice versa when the truck crane is being used in countries that use US units of measurement.
Page 98 Overview 1.8 Conversion table for US measuring units Blank page 1 - 32 3 302 690 en Operating manual GMK4100L-1...
Page 99: Training - Information
1.9 Training – Information Training – Information For the EMEA area (Europe, Middle East, Africa), Manitowoc Crane Group offers comprehensive training for crane types GMK and GTK. Germany GmbH Our training centre is located in a maritime environment, on Germany's North Sea coast at Wilhelmshaven.
Page 100: Identification
Overview 1.10 Identification 1.10 Identification 1 - 34 3 302 690 en Operating manual GMK4100L-1...
Page 101 Overview 1.10 Identification The following plates and numbers are attached to the truck crane for iden- tification purposes: 1 Serial number and crane type 2 the CE mark, which is only applicable for truck cranes whose equip- ment and configuration complies with the guidelines and standards specified in the supplied EC Declaration of Conformity.
Page 102: Ec Declaration Of Conformity
Overview 1.11 EC Declaration of Conformity 1.11 EC Declaration of Conformity On initial delivery, operators of truck cranes receive a Declaration of Conformity as a sup- plement to the delivery protocol. An illustra- tion of the Declaration of Conformity is shown below.
Page 103: Basic Safety Instructions
The GMK4100L-1 may only be operated with parts of equipment which have been approved by and which are Manitowoc Crane Group Germany GmbH labelled with the serial number of the GMK4100L-1. The manufacturer is not liable for any damage caused by improper or unau- thorized use of the GMK4100L-1 truck crane.
Page 104: Improper Use
2.1 Intended use 2.1.1 Improper use is not liable for damage resulting Manitowoc Crane Group Germany GmbH from improper or unauthorized use of the GMK4100L-1 truck crane. The user alone bears the risk. Improper use includes: – Transporting loads on the carrier –...
Page 105: Organisational Measures
Basic safety instructions 2.2 Organisational measures Organisational measures The operating manual and the lifting capacity table should be kept in the truck crane for immediate access at all times, and must not be removed from the truck crane. You must have read and understood the operation and safety instructions in this operating manual and comply with them when working.
Page 106 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 before any welding work.
Page 107: Personnel Qualifications
Basic safety instructions 2.3 Personnel qualifications Appropriate servicing equipment is absolutely necessary in order to carry out maintenance work. Observe national regulations that apply to transport when loading the truck crane. Also observe the additional safety measures prescribed by the forwarder (e.g.
Page 108: Safety Instructions For Driving The Truck Crane
Manitowoc Crane Group Germany GmbH crane operator courses and technical courses. Safety instructions for driving the truck crane Walk around and inspect the truck crane before you start the vehicle. Check the condition of the truck crane carefully using the checklists in the operat- ing manual.
Page 109: Safety Instructions For Crane Operation
Basic safety instructions 2.5 Safety instructions for crane operation Check 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 unauthorised use. Safety instructions for crane operation Carefully select a safe site for the truck crane, where you can work safely.
Page 110 Basic safety instructions 2.5 Safety instructions for crane operation If necessary, remove any ice and snow from the truck crane before com- mencing crane operation. Keep all handles, steps, step treads and ladders free of dirt, snow and ice. Keep all electric and hydraulic connections free of dirt. Check the connecting points for dust, foreign bodies and moisture before installation.
Page 111 After a lightning strike, always have the truck crane checked by before you operate the truck crane – even if you Manitowoc Crane Care do not notice any impairment to its function. Electronic components may be damaged by a lightning strike and may fail unexpectedly, either immediately or during later operation.
Page 112: Instructions On Transporting Persons
Basic safety instructions 2.6 Instructions on transporting persons Instructions on transporting persons The truck crane is intended for lifting loads. Transporting persons is consid- ered improper use of the truck crane. It is prohibited to: – Transport persons in any way with the lifting tackle or on the load. –...
Page 113 Basic safety instructions 2.6 Instructions on transporting persons The crane operator must have knowledge of and meet the requirements of the relevant legal regulations and standards (e.g. the BGR 159 in Germany or the ASME B30 in the USA). The crane operator must have the necessary knowledge for operating the truck crane and the equipment used for lifting persons.
Page 114 Basic safety instructions 2.6 Instructions on transporting persons The person being transported must be in radio contact with the crane operator. When used for transporting persons, the truck crane must not be used for other tasks. The crane operator is not permitted to exceed the maximum permissible wind speeds and wind loads for transporting persons applicable in the country in which he is working.
Page 115: Operating Elements For Driving
Operating elements for driving 3.1 Overview of the operating elements Operating elements for driving All operating elements for crane operation are described in Chapter 9. Overview of the operating elements This section shows the position and designation of the operating elements for driving.
Page 116: On The Outside Of The Truck Crane
Operating elements for driving 3.1 Overview of the operating elements 3.1.1 On the outside of the truck crane 3 - 2 3 302 690 en Operating manual GMK4100L-1...
Page 117 Operating elements for driving 3.1 Overview of the operating elements à 1 Front flap p. 3 - 73 à 2 Driver's cab p. 3 - 6 1), 2) 3 Hose drum, installing/removing à 4 Engine for driving p. 4 - 1 à...
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Page 119 Operating elements for driving 3.1 Overview of the operating elements à 18 – Outrigger control units p. 3 - 38 à – Emergency stop switch p. 4 - 19 à 19 Fixed ladders p. 3 - 77 à 20 Swing-out ladders p.
Page 120: Driver's Cab
Operating elements for driving 3.1 Overview of the operating elements 3.1.2 Driver's cab Front overview 3 - 6 3 302 690 en Operating manual GMK4100L-1...
Page 121: 15 Steering Column/Steering Wheel
Operating elements for driving 3.1 Overview of the operating elements à 1 Adjusting the passenger seat p. 5 - 14 à 2 Rear overview p. 3 - 8 3 Warning triangle, first-aid kit, warning lamp, high-vis vest à 4 Auxiliary air heater p.
Page 122 Operating elements for driving 3.1 Overview of the operating elements Rear overview à 1 Fold-up berth p. 5 - 48 2 Rest 3 Storage (spare key etc. (on delivery)) 4 Storage compartment (e.g. for battery charger) Additional equipment 3 - 8 3 302 690 en Operating manual GMK4100L-1...
Page 123 Operating elements for driving 3.1 Overview of the operating elements Behind the cover à 1 Fuses in the driver's cab p. 8 - 50 Operating manual 3 302 690 en 3 - 9 GMK4100L-1...
Page 124: Transmission Operating Elements
Operating elements for driving 3.1 Overview of the operating elements 3.1.3 Steering column/steering wheel à 1 Operating the on-board computer p. 3 - 72 2 Control: à – Set idling speed p. 3 - 42 à – Setting cruise control p.
Page 125 Operating elements for driving 3.1 Overview of the operating elements 3.1.4 Instrument panel Left/right à 1 Lighting on/off p. 3 - 66 à 2 Separate manual steering p. 3 - 61 à 3 Battery master switch p. 3 - 45 à...
Page 126 Operating elements for driving 3.1 Overview of the operating elements Middle 3 - 12 3 302 690 en Operating manual GMK4100L-1...
Page 127: On-Board Computer
Operating elements for driving 3.1 Overview of the operating elements à 1 Indicator lamp for turn signal indicator p. 3 - 66 à 2 Indicator lamp for trailer turn signal indicator p. 3 - 66 à 3 Speedometer p. 3 - 70 à...
Page 128 Operating elements for driving 3.1 Overview of the operating elements 3.1.5 Transmission operating elements à 1 Selecting the driving direction p. 3 - 49 à 2 Changing the operating mode p. 3 - 49 à 3 Shift down, manual p. 3 - 49 à...
Page 129 Operating elements for driving 3.1 Overview of the operating elements 3.1.6 On-board computer à 1 Main menu display p. 3 - 72 à 2 Display menu – Name p. 3 - 72 à 3 Submenu display p. 3 - 72 à...
Page 130: Tachograph
Operating elements for driving 3.1 Overview of the operating elements 3.1.7 Tachograph à p. 5 - 18 (A) – Tachograph à 1 Display p. 5 - 21 à 2 Time correction -: p. 3 - 70 à 3 Time correction +: p.
Page 131: Heating And Air-Conditioning System
Operating elements for driving 3.1 Overview of the operating elements 3.1.8 Heating and air-conditioning system Standard à 1 Setting the fan p. 5 - 65 à 2 Air distribution p. 5 - 66 à 3 Setting the temperature p. 5 - 65 à...
Page 132 Operating elements for driving 3.1 Overview of the operating elements Auxiliary water heating system à 1 Auxiliary water heating system p. 5 - 70 à – Preheating the engine p. 5 - 70 à – Preheating the driver's cab p. 5 - 71 3 - 18 3 302 690 en Operating manual...
Page 133 Operating elements for driving 3.1 Overview of the operating elements Auxiliary air heater à 1 Selecting a function p. 5 - 76 2 Menu line 3 Program column 4 Display line à 5 – Switching on p. 5 - 76 à...
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Page 135: Ccs Control Unit
Operating elements for driving 3.1 Overview of the operating elements 3.1.9 CCS control unit 1 CCS display à Overview start menu p. 3 - 23 à 2 Service/diagnostics connection p. 3 - 71 à 3 Exiting the menu/input mode p. 3 - 47 à...
Page 136: Ccs - Menu-Dependent Displays
Operating elements for driving 3.1 Overview of the operating elements 3.1.10 CCS – menu-dependent displays à 1 Transverse differential locks display p. 3 - 56 à Longitudinal differential lock display p. 3 - 57 à 2 Display of retarder function on/off p.
Page 137: Ccs - Start Menu
Operating elements for driving 3.1 Overview of the operating elements 3.1.11 CCS – Start menu 1 Display of crane type 2 Serial number display à 3 Display of transverse and longitudinal differential p. 3 - 28 locks on/off à 4 Voltage monitoring display p.
Page 138: Ccs - Overview Menu Groups
Operating elements for driving 3.1 Overview of the operating elements 3.1.12 CCS – Overview menu groups 3 - 24 3 302 690 en Operating manual GMK4100L-1...
Page 139 Operating elements for driving 3.1 Overview of the operating elements à 1 Carrier menu group p. 3 - 26 – Suspension/ level adjustment menu – Driving menu à 2 Settings menu group p. 3 - 29 – Set display brightness and date/time menu –...
Page 140: Carrier Menu Group
Operating elements for driving 3.1 Overview of the operating elements 3.1.13 Carrier menu group à 1 Suspension/ level adjustment menu p. 3 - 27 à 2 Driving menu p. 3 - 28 3 - 26 3 302 690 en Operating manual GMK4100L-1...
Page 141 Operating elements for driving 3.1 Overview of the operating elements Suspension/ level adjustment menu à 1 Front level pre-selection p. 3 - 68 à 2 Level adjustment system enabled display p. 3 - 68 à 3 Suspension operation pressure gauge p.
Page 142 Operating elements for driving 3.1 Overview of the operating elements Driving menu à 1 Current wheel position display p. 3 - 63 à 2 Steering locking status display p. 3 - 63 à 3 – Transverse differential locks display p. 3 - 56 à...
Page 143: Settings Menu Group
Operating elements for driving 3.1 Overview of the operating elements 3.1.14 Settings menu group à 1 Set display brightness and date/time menu p. 3 - 30 à 2 Switch units menu p. 3 - 31 à 3 Lamp test p. 4 - 10 Operating manual 3 302 690 en 3 - 29...
Page 144 Operating elements for driving 3.1 Overview of the operating elements Set display brightness and date/time menu à 1 Selection setting the display brightness p. 4 - 11 à 2 Increasing/reducing the value p. 4 - 11 à 3 Display in percentage p.
Page 145 Operating elements for driving 3.1 Overview of the operating elements Switch units menu à 1 Display units in: p. 5 - 64 – Metres – Degrees Celsius – Kilograms – Bar à 2 Display units in: p. 5 - 64 –...
Page 146: Menu Group Information
Operating elements for driving 3.1 Overview of the operating elements 3.1.15 Menu group Information à 1 Operating hours menu p. 3 - 33 à 2 Engine error menu p. 3 - 34 à 3 Crane operation error menu p. 3 - 35 3 - 32 3 302 690 en Operating manual...
Page 147 Operating elements for driving 3.1 Overview of the operating elements Operating hours menu à 1 Keycode input p. 5 - 24 à 2 Carrier p. 5 - 24 à 3 Motor p. 5 - 24 à 4 Transmission p. 5 - 24 à...
Page 148 Operating elements for driving 3.1 Overview of the operating elements Engine/transmis- sion error menu à 1 Display of error / total errors p. 8 - 17 à 2 Engine symbol display p. 8 - 17 à 3 Transmission symbol display p.
Page 149 Operating elements for driving 3.1 Overview of the operating elements Crane operation error menu 1 Current errors/total errors display 2 Error code 3 Deleting errors 4 Next error 5 Previous error Since this menu is required for crane operation, it is in the chapter Operating à...
Page 150: Various Controls Menu Group
Operating elements for driving 3.1 Overview of the operating elements 3.1.16 Various controls menu group à 1 Outrigger lighting on/off p. 3 - 67 à 2 Reverse camera on/off p. 3 - 52 3 - 36 3 302 690 en Operating manual GMK4100L-1...
Page 151: Emergency Operations Menu Group
Operating elements for driving 3.1 Overview of the operating elements 3.1.17 Emergency operations menu group à 1 Switching emergency operation on/off p. 14 - 63 à 2 Switching towing mode on/off p. 8 - 30 Operating manual 3 302 690 en 3 - 37 GMK4100L-1...
Page 152: Outrigger Control Units
Operating elements for driving 3.1 Overview of the operating elements 3.1.18 Outrigger control units à Outriggers control units , Contain operating elements for crane operation; p. 9 - 85. 3 - 38 3 302 690 en Operating manual GMK4100L-1...
Page 153: Short Description Of The Operating Elements
If some operating elements do not work, first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care Operating manual 3 302 690 en 3 - 39...
Page 154: Definition Of Information Relating To Directions Of Movement
Operating elements for driving 3.2 Short description of the operating elements 3.2.1 Definition of information relating to directions of movement Basic rule Directions always depend on whether the carrier or the superstructure is being operated. On the carrier The driver's cab is always at the front, which means that: 1: front 2: right 3: rear...
Page 155: General Rules For Buttons And Symbols On The Display
Operating elements for driving 3.2 Short description of the operating elements 3.2.2 General rules for buttons and symbols on the display The symbols shown as an example are not present on all crane types. The following rules apply in all menus: –...
Page 156: Motor
Operating elements for driving 3.2 Short description of the operating elements 3.2.3 Motor Steering column Ignition lock 0 Ignition off, engine off, key can be removed 1 Power supply on for: Heating system, engine/transmission diagnostics, radio/telephone, enabling of steering lock 2 Ignition on, driving position 3 Starting position à...
Page 157 Operating elements for driving 3.2 Short description of the operating elements Setting cruise control The truck crane must be driving at a speed at least 15 km/h (9 mph). 2 Select the Cruise control menu – symbol (1) is grey 3 Switches on or increases the speed –...
Page 158: Adblue System
Operating elements for driving 3.2 Short description of the operating elements 3.2.4 AdBlue system Instrument panel AdBlue warning – Off: Filling level sufficient, no fault – Lit: AdBlue system malfunction – Flashing: Adblue tank empty or fault à p. 5 - 45 Torque reduction indicator lamp –...
Page 159: Battery Master Switch
Operating elements for driving 3.2 Short description of the operating elements CCS display Adblue filling level indicator – 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% –...
Page 160: Electrical System
Operating elements for driving 3.2 Short description of the operating elements 3.2.6 Electrical system 12 V power socket on/off – To switch on: Press in switch (1) at the top – To switch off: Press in switch (1) at the bottom Sockets 12 V/24 V 1 Socket 24 V/max.
Page 161: Crane Control Ccs
Operating elements for driving 3.2 Short description of the operating elements 3.2.7 Crane control CCS The GMK4100L-1 truck crane is equipped with the CCS electronic crane control system (Crane Control System). CCS includes a control unit in the driver's cab and several control units (MWSCM and MWCCM) distributed over the superstructure and carrier.
Page 162 Operating elements for driving 3.2 Short description of the operating elements Exiting the menu/input mode 1 Press: – The opened menu closes – the menu from the next higher level is opened – Input mode is deactivated. Overview menu groups 1 Press: –...
Page 163: Transmission
Operating elements for driving 3.2 Short description of the operating elements Selecting / deselecting favourites Several symbols can be selected as favourites. The cursor jumps directly from favourite to favourite when scrolling through the menu groups. Select A symbol is selected, such as symbol (2). 1 Press The symbol is marked as a favourite.
Page 164 Operating elements for driving 3.2 Short description of the operating elements – Position R: When at a standstill – Select reverse starting gear When driving in reverse – No gear change When driving forwards – Select neutral Gearshift lever The truck crane may be stationary or driving. Change over between automatic and manual –...
Page 165 Operating elements for driving 3.2 Short description of the operating elements Display, driving mode, Transmission display 1 Currently engaged gear – forwards (1 to 16), e.g. 6 2 Neutral position switched on 3 Gear currently engaged – 1st reverse gear 4 Gear currently engaged –...
Page 166: Reverse Camera
Operating elements for driving 3.2 Short description of the operating elements 3.2.9 Reverse camera The reverse camera (1) displays the area behind the truck crane on the CCS display in the driver's cab. Switching on – Automatically, when reversing (1), –...
Page 167: Birdview System 270
Drive with due care and attention! The sole responsibility lies with the crane operator. explicitly states that no liability is Manitowoc Crane Group Germany GmbH accepted for damage resulting from a failure to observe these instructions. Risk of damage in driving mode Obstacles in the driving area above the height of the camera are not displayed.
Page 168 Operating elements for driving 3.2 Short description of the operating elements The cameras must not be removed or misadjusted. If a camera is mounted on the storage box then the storage box must not be removed. There may be no spare wheel installed on the rear of carrier. Switching on •...
Page 169: Transfer Case
Operating elements for driving 3.2 Short description of the operating elements 3.2.11 Transfer case Driving menu To open: Select symbol (1) and confirm – menu is opened Transfer case for off-road gear on/off – To switch on: Select symbol (2) and confirm – off-road gear engaged –...
Page 170: Final Drive
Operating elements for driving 3.2 Short description of the operating elements 3.2.12 Final drive à Longitudinal and transverse differential locks , p. 5 - 51 Driving menu To open: Select symbol (1) and confirm – menu is opened Transverse differential locks on/off –...
Page 171 Operating elements for driving 3.2 Short description of the operating elements Longitudinal differential lock on/off – To switch on: Select symbol (1) and confirm – symbol is red – To switch off: Select symbol (1) and confirm – symbol is green For drive 8 x 8 x 8 –...
Page 172: Brakes
Operating elements for driving 3.2 Short description of the operating elements 3.2.13 Brakes Service brake Display of supply pressure in brake circuits 1 Current supply pressure in brake circuit 1 2 Current supply pressure in brake circuit 2 3 Red – supply pressure insufficient White –...
Page 173 Operating elements for driving 3.2 Short description of the operating elements Parking brake indicator lamp – Lit: Parking brake applied – Out: Parking brake released Additional brakes Engine retarder/transmission retarder à Additional brakes , p. 5 - 43 Multipurpose switch The braking effect is the least in position (1) and the greatest in position (5).
Page 174: Steering/Separate Steering
Operating elements for driving 3.2 Short description of the operating elements 3.2.14 Steering/separate steering à Separate steering , p. 5 - 59 Instrument panel Steering circuit 1 warning Steering circuit 2 warning – Lit: Engine off – ignition on Engine on – fault, stop – check oil loss –...
Page 175 Operating elements for driving 3.2 Short description of the operating elements Steering system warning 1 After switching on the ignition – Lit – goes out after about three seconds if there is no error Whilst driving – Lit – symbol (2) red Steering system faulty! 3.
Page 176 Operating elements for driving 3.2 Short description of the operating elements Steering mode display The display (2) is shown in the Start menu and in the Driving menu. 2 – Orange: Steering mode switched on indicator – Blue: Automatic alignment of the steering angle is active The following applies to all steering modes: The selected symbol must be confirmed within 2 seconds, otherwise the type of steering remains unchanged.
Page 177 Operating elements for driving 3.2 Short description of the operating elements Steering locking status display The current status is shown using different symbols: 1 Green – locked 2 Red – unlocked 3 Yellow – intermediate position 4 Error Current wheel position display The current status is shown using different symbols: 1 Straight ahead...
Page 178: Suspension
Operating elements for driving 3.2 Short description of the operating elements 3.2.15 Suspension CCS display Suspension display Suspension on/off – To switch on: Select symbol (1) and confirm – Symbol (2) green (on-road driving) Suspension on – enabled for on-road driving –...
Page 179: Lighting/Windscreen Wipers/Horn
Operating elements for driving 3.2 Short description of the operating elements 3.2.16 Lighting/windscreen wipers/horn Steering column Multipurpose switch Headlight flasher/headlight – full beam 1 Parking light/headlight: Middle position 2 Flash the headlights: Upwards The parking light/headlight must be switched on: 3 Headlight –...
Page 180 Operating elements for driving 3.2 Short description of the operating elements Indicator lamp for turn signal indicator 1 – Flashing: Turn signal indicator on – Out: Turn signal indicator off, or turn signal indicator on and filament lamp faulty Indicator lamp for trailer turn signal indicator 1 –...
Page 181 Operating elements for driving 3.2 Short description of the operating elements Checking headlight – Lit: Headlight on – Out: Headlight off Rotating beacon on/off – To switch on: Push up – To switch off: Push down CCS display Outrigger lighting on/off –...
Page 182: Level Adjustment System
Operating elements for driving 3.2 Short description of the operating elements 3.2.17 Level adjustment system à Operating the level adjustment system , p. 5 - 53. Suspension/level adjustment menu – To open: Select symbol (1) and confirm – menu is opened Lift/lower preselection level The suspension must be switched on Select and confirm the corresponding symbol.
Page 183 Operating elements for driving 3.2 Short description of the operating elements Vehicle level display The current status is shown using different symbols. 1 On-road level 2 Off-road level 3 Error 4 Operation pressure in the suspension struts à p. 5 - 53 Setting the on-road level The suspension is switched on.
Page 184: Tachograph/Speedometer
Operating elements for driving 3.2 Short description of the operating elements 3.2.18 Tachograph/speedometer à Setting the tachograph , p. 5 - 18. Tachograph Time correction occurs for both the Tachograph and on-board computer 1 Open the time menu: Press the button – the time correction menu opens 2 Time correction +: Press the button –...
Page 185: Diagnostics
3.2 Short description of the operating elements 3.2.19 Diagnostics The diagnostics connections may only be operated by service staff from the engine manufacturer/transmission manufacturer, or by Manitowoc Crane Care The following connections are below the cover (4) 1 Carrier electronics diagnostics 2 Transmission diagnostics 3 Engine diagnostics 3.2.20...
Page 186: On-Board Computer
Operating elements for driving 3.2 Short description of the operating elements 3.2.21 On-board computer Click here for more information on the on-board computer menus. Operating the on-board computer On the steering wheel: 1 Previous menu window, menu entry upwards 2 Next main menu, select next entry, increase or reset value 3 Next menu window, one menu entry downwards...
Page 187 Operating elements for driving 3.2 Short description of the operating elements Tour data menu 1 Total mileage 2 Daily mileage 3 Time 4 Outside temperature 3.2.22 Front flap Opening • Fold up the front flap (1). • Fasten the support (2) in the clamp (3). Closing •...
Page 188 Operating elements for driving 3.2 Short description of the operating elements 3.2.23 Windows and doors Window winder Risk of crushing when closing the windows If the window winders encounter resistance, they do not stop but keep on moving at reduced power. Button assignment A Window winder, driver's door B Window winder, passenger door...
Page 189 Operating elements for driving 3.2 Short description of the operating elements Doors The same key is used for the driver's and passenger's door. Always take the ignition key with you before closing the door from outside with the handle pressed in (2). Once closed in this manner, the door can only be opened again using the ignition key.
Page 190 Operating elements for driving 3.2 Short description of the operating elements Blank page 3 - 76 3 302 690 en Operating manual GMK4100L-1...
Page 191 Operating elements for driving 3.2 Short description of the operating elements 3.2.24 Access ladders and ladders Different access ladders and ladders are on the truck crane depending on the version. Hazard due to unsecured ladders Always secure the ladders before driving. The prevents the ladders falling down or folding out whilst driving and thus endangering other vehicles.
Page 192 Operating elements for driving 3.2 Short description of the operating elements – Folding in • Release the spring latch (5) and push in the access ladder (4). • Lift the locking bar (3) for releasing and fold the ladder (2) upwards. •...
Page 193 Operating elements for driving 3.2 Short description of the operating elements Folding ladder – shelf under the driver's cab à For the shelf on the rear of carrier; p. 3 - 78. – For the use Ladder (1) – to erect and fold out. •...
Page 194 Operating elements for driving 3.2 Short description of the operating elements Blank page 3 - 80 3 302 690 en Operating manual GMK4100L-1...
Page 195: Starting The Engine For Driving / Switching It Off
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Starting the engine for driving / switching it off Starting the engine from the driver's cab This section describes how to start the engine from within the driver's cab. à...
Page 196 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab à 4. Switch on the battery master switch; p. 4 - 9. à 5. Check that all emergency stop switches have been reset; p.
Page 197 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 10. Check the fluid supply: à – Fuel tank , p. 4 - 5, à – AdBlue tank , p. 4 - 7 à...
Page 198: Checklist: At Low Temperatures
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.2 CHECKLIST: At low temperatures You must also observe the following points when operating the truck crane in low outside temperatures: 1. The fuel and engine oil must be suitable for use at the respective à...
Page 199: Filling Up
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.3 Filling up à Fuel tank Only use permissible consumables; Separate engine operating instructions, provided by the manufacturer . Danger of fire due to flammable gases Switch off the engine, the heater and all additional heaters before refuelling.
Page 200 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Dual tank The dual tank system makes it possible to operate the truck crane in driving mode and crane operation mode with different types of fuel, provided this complies with the local regulations in the country in which you are working.
Page 201 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab AdBlue is a consumable for exhaust gas treatment. For AdBlue, there are AdBlue tank registered trademarks of Kruse GmbH & Co KG, BASF SE and the German Association of the Automotive Industry.
Page 202: Checks Before Starting The Engine
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab If the AdBlue tank is empty, a warning will be output and the engine torque à Overriding torque reduction , p. 5 - 45. will be reduced;...
Page 203: Switch The Ignition On
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab Battery master You can only start the engine when the battery master switch is switched on. switch • Press switch (1) up – the battery master switch will be switched on.
Page 204: Lamp Test/Equalisation Of The Switching States
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.6 Lamp test/equalisation of the switching states Lamp test After the ignition has been switched on, a lamp test is performed. Risk of accident from faulty lamps! The lamps that are used to provide warnings and information during operation light up for control purposes whenever the ignition is switched on.
Page 205: Display - Setting The Brightness
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.7 Display – setting the brightness Brightness of the displays The brightness of the displays is regulated automatically by the CCS , depending on the ambient brightness. You can set a minimum brightness that may be reached.
Page 206 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab You can cancel the entry at any time using the (1) or (2) buttons. The settings are then reset. 4 - 12 3 302 690 en Operating manual GMK4100L-1...
Page 207: Starting The Engine
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.8 Starting the engine This section describes only how to start the engine from the driver's cab. à You can also start the engine from the outrigger control units; p.
Page 208 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab This section pertains to starting a warm and cold engine. Danger of explosion when using starter fuel The engine may never be started with the aid of starter fuel. The starter fuel sprayed into the intake manifold can ignite.
Page 209: Checks After Starting The Engine
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.9 Checks after starting the engine Risk of damage to the engine Observe the symbols and messages in the display area of the main menu and in the on-board computer.
Page 210 Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab • Check the display (1) in the Start menu or in the Driving menu. If the symbol is blue, then the steering angle is not correct based on the 1st and 2nd axle lines.
Page 211: Setting The Idling Speed
Starting the engine for driving / switching it off 4.1 Starting the engine from the driver's cab 4.1.10 Setting the idling speed After the engine is started, the idling speed is regulated automatically. If necessary, you can adjust the idling speed manually. You can only set the idling speed when the truck crane is stationary.
Page 212: Switch Off The Engine
Starting the engine for driving / switching it off 4.2 Switch off the engine Switch off the engine 4.2.1 At the ignition lock and with the outrigger control units Risk of accidents because the truck crane cannot be steered! Switch the engine off only once the truck crane has come to a standstill. If you remove the ignition key, the steering will lock and you will lose control of the moving truck crane.
Page 213: Using The Emergency Stop Switches
Starting the engine for driving / switching it off 4.2 Switch off the engine 4.2.2 Using the emergency stop switches Emergency stop switch Three emergency stop switches are provided for emergency use: 1 On the carrier 2 On the hand-held control unit 3 In the crane cab •...
Page 214: Air Intake Inhibitor
Starting the engine for driving / switching it off 4.3 Air intake inhibitor Air intake inhibitor If the air intake inhibitor is triggered, a flap in the air intake line will close and the engine will stop running – symbol (1) red – in the start menu display à...
Page 215: Driving
Driving 5.1 Before driving Driving Before driving 5.1.1 CHECKLIST: Checks before on-road driving This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1. For on-road driving without a dolly –...
Page 216 Driving 5.1 Before driving 2. When the main boom is resting on a dolly – All telescopic sections must be locked together. à – The slewing gear is switched off; p. 11 - 120. à – The boom floating position must be switched on; p.
Page 217 Driving 5.1 Before driving à 7. All ladders are secured; p. 3 - 77. à 8. All railings must be folded in; p. 12 - 129. 9. Check the tyres: à – Tyre pressure when tyres are cold in on-road mode; p.
Page 218 Driving 5.1 Before driving 12. The warning signs for marking the vehicle width are folded down (only for vehicle widths of over 2.75 m (9.0 ft)); à Vehicle width; p. 1 - 8, à Warning signs; p. 5 - 8. 13.
Page 219 Driving 5.1 Before driving à 18. Adjust the driver's seat; p. 5 - 13. à 19. Adjust the steering column; p. 5 - 15. à 20. Adjust the mirrors; p. 5 - 7. à 21. Set the tachograph, insert the diagram sheet; p.
Page 220 Driving 5.1 Before driving à 23. Check the electrical system; p. 5 - 7. 24. Check the fluid supply: à Fuel tank , p. 4 - 5, – à AdBlue tank , p. 4 - 7. – à 25. Check the compressed-air system and the brakes; p.
Page 221: Check The Condition Of The Truck Crane
Driving 5.1 Before driving 5.1.2 Check the condition of the truck crane • Electrical system Check the following functions and arrange for faulty parts to be repaired: – Parking light/headlight, rotating beacons, fog tail light, side marker lights – Hazard warning system, –...
Page 222 Driving 5.1 Before driving Electrical adjustment • Turn the button to position A Neutral position B Mirror on the driver's side or C Mirror on the passenger side. • Press the button (5) – the mirror moves. 1 Up 2 Right 3 Down 4 Left Mirror heating...
Page 223 Driving 5.1 Before driving Checking the The vehicle height given at on-road driving level is only maintained when à vehicle height the main boom is resting in the boom rest; p. 1 - 8. Risk of accidents by exceeding total permissible height Check whether the main boom is resting on the boom rest.
Page 224 Driving 5.1 Before driving Supply pressure The brake system and some consumers (e.g. differential locks, driver's seat, etc.) require sufficient supply pressure in order function properly. • Check that the supply pressure is about 8 bar (116 psi). If the supply pressure is too low, such as after repairs, you can build it up as follows.
Page 225 Driving 5.1 Before driving Parking brake Check the function of the parking brake. • Activate the service brake. Risk of accidents by truck crane moving unintentionally Always apply the service brake before releasing the parking brake. This prevents the truck crane rolling in an uncontrolled manner when the parking brake is released.
Page 226 Driving 5.1 Before driving Blank page 5 - 12 3 302 690 en Operating manual GMK4100L-1...
Page 227: Adjusting The Seat And The Steering Column
Driving 5.1 Before driving 5.1.3 Adjusting the seat and the steering column Adjusting the The seat height and lumbar support are adjusted pneumatically. You can driver's seat only make these adjustments when: – the switch (1) on the driver's seat is switched off (not pressed in), –...
Page 228 Driving 5.1 Before driving Settings for body shape 1 Lower lumbar area support 2 Upper lumbar area support 3 Lateral support The settings are made pneumatically. The following applies to all buttons: Empty the air cushion: Press – Fill the air cushion: Press + Adjusting the The passenger's seat is adjusted mechanically.
Page 229 Driving 5.1 Before driving Adjusting the The steering column is unlocked pneumatically. steering column Risk of accidents by unlocked steering column Always stop the truck crane before you unlock the steering column. Once the steering column is unlocked you can no longer steer safely. The steering column can be unlocked only when sufficient supply pressure à...
Page 230: Switching The Suspension On/Off
Driving 5.1 Before driving 5.1.4 Switching the suspension on/off The suspension is switched off whenever the ignition is switched off. The suspension must be switched on for on-road driving. The current switching state of the suspension is shown on the display (1) in all the menus. Symbol green: Suspension is switched on Symbol red:...
Page 231 Driving 5.1 Before driving Switching the The suspension cylinders are enabled when the suspension is switched on. suspension on This state must be established for on-road driving. Danger of overturning when switching on the suspension Do not switch the suspension on unless the truck crane has been rigged for on-road driving and the main boom has been set down.
Page 232: Setting The Tachograph
Driving 5.1 Before driving 5.1.5 Setting the tachograph Diagram sheets (24-hour discs) can be inserted into the tachograph for two drivers simultaneously. As a crane operator, you are obligated to set each activity on the tachograph. This section only describes the basic operation of the tachograph (inserting diagram sheets, setting time groups, operating errors).
Page 233 Driving 5.1 Before driving Setting the To set the tachograph, you must first open the drawer and check the time tachograph setting. You can then insert the diagram sheets and set the time groups. Opening the drawer • Press the button (6) once. First the symbol (5) and the running bar (4) appear, then the drawer (3) opens.
Page 234 Driving 5.1 Before driving inserting diagram sheets Only insert diagram sheets that are properly marked. The diagram sheets are always inserted with the front facing upwards. Risk of malfunctions in the electronics If a diagram sheet has been damaged by being marked several times, this might cause malfunctions in the electronics.
Page 235 Driving 5.1 Before driving Display If no malfunction has occurred, the tachograph display now shows the basic display: – Date (4) and time (5) – Driver 1 time group (1.1) – Driver 1 diagram sheet inserted (1.2) – Total kilometres of the truck crane (3) –...
Page 236 Driving 5.1 Before driving The different time groups are shown with the following symbols: Driving times: As soon as the vehicle starts to move, the tachograph auto- matically switches to the symbol for driver 1 driving time. If there are two diagram sheets inserted, the tachograph automatically switches to stand-by time for two-drivers operation.
Page 237: Setting The Time
Driving 5.1 Before driving 5.1.6 Setting the time • Open the Set display brightness and date/time menu (1). • Select and confirm the symbol (1). Setting the time • Select and confirm the symbol (2). • Select the current time – expressed as a deviation from UTC time.
Page 238: Displaying And Resetting Operating Hours
Driving 5.1 Before driving 5.1.7 Displaying and resetting operating hours You can view the total operating hours for all power units in the Operating hours menu. You can also delete the recorded operating hours. The total operating hours cannot be deleted. •...
Page 239: Operating The Transmission
Driving 5.2 Operating the transmission Operating the transmission The transmission automatically controls all gear changes. However, gears can be changed manually at any time. 5.2.1 Switching on When the ignition is switched off, the transmission must always be in the neutral position N.
Page 240: Switching The Transmission To The Neutral Position
Driving 5.2 Operating the transmission 5.2.2 Switching the transmission to the neutral position You can switch the transmission to neutral position at any time. Risk of accidents when switching while driving If you switch the transmission to neutral position while driving, the drive line will be interrupted.
Page 241: Selecting The Direction Of Travel And Starting Gear
Driving 5.2 Operating the transmission 5.2.3 Selecting the direction of travel and starting gear à Selecting the Before driving at temperatures below -20 °C (-4 °F); p. 5 - 34. driving direction The following requirements must be met before selecting the driving direc- tion: –...
Page 242 Driving 5.2 Operating the transmission For reversing The reversing camera and the reversing lamp are switched on. The display (1) shows the area behind the truck crane. When you exit the transmission mode R, the reversing lamp and camera are switched off and the display (1) shows the CCS menu.
Page 243: Changing The Operating Mode
Driving 5.2 Operating the transmission 5.2.4 Changing the operating mode The display shows which operating mode is switched on. – Symbol (1) – Automatic operating mode on. – Symbol (2) – Manual operating mode on. It is possible to switch between the operating modes whilst the vehicle is stationary or whilst on the move.
Page 244: Starting
Driving 5.2 Operating the transmission 5.2.5 Starting Risk posed by unexpected rolling Also apply the parking brake before starting on sloping ground. The gear will be engaged only once you depress the accelerator. This can lead to the truck crane starting to move (perhaps backwards) whilst you are moving your foot from the brake pedal to the accelerator.
Page 245: Driving And Changing Gears
Driving 5.2 Operating the transmission 5.2.6 Driving and changing gears • When driving, always leave the switch in the position for the current driving direction, e.g. in position D for forward travel. Risk of accidents due to changing transmission direction whilst driving If whilst driving in one direction you select a gear for the opposite direction, the transmission shifts into the neutral position.
Page 246 Driving 5.2 Operating the transmission In manual In this operating mode, the transmission only shifts when you actuate the operating mode gearshift lever. Manual upshifting To upshift, you must pull the gearshift lever upwards briefly: – Upshifting one gear: Push up once –...
Page 247: Changing The Driving Direction
Driving 5.2 Operating the transmission 5.2.7 Changing the driving direction • Stop the truck crane. • Shift to the position for the opposite direction. At a standstill, you can shift two levels in succession immediately. You do not need to wait for the intermediate position N to appear. The newly engaged gear will be shown in the display.
Page 248: On The Roller Type Dynamometer
Driving 5.2 Operating the transmission 5.2.9 On the roller type dynamometer Danger of unexpected moving off rollers Always shift to the neutral position on the roller type dynamometer. In position D or R, a suitable gear is engaged for the speed. The engine braking power is applied against the rollers and the truck crane can drive out of them.
Page 249: Driving The Truck Crane And Switching It Off
Driving 5.3 Driving the truck crane and switching it off Driving the truck crane and switching it off Risk of accidents because the truck crane cannot be steered! Never switch off the ignition or remove the ignition key while the truck crane is moving This precaution prevents the steering locking and consequent loss of control of the moving truck crane.
Page 250 Driving 5.3 Driving the truck crane and switching it off • Steering Always pay attention to all the indicator lamps and all information in this and subsequent sections. Risk of accident due to mobile crane that cannot be steered and leaking oil If a warning message occurs, be sure to follow the instructions in this sec- tion and take all the measures specified.
Page 251 Driving 5.3 Driving the truck crane and switching it off • Monitoring Also pay attention to the monitoring elements. elements Tachometer 1 Green: Economic consumption 2 Yellow: Engine brake active 3 Red: Engine speed too high – danger; à Checks when driving downhill , p. 5 - 42 Fuel level display à...
Page 252: Cruise Control
Driving 5.3 Driving the truck crane and switching it off 5.3.2 Cruise control Cruise control enables you to drive at a constant speed without pressing the accelerator. Risk of accidents due to carelessness Be ready to brake at all times when cruise control is switched on! Switch cruise control on only if the traffic situation permits a constant speed.
Page 253 Driving 5.3 Driving the truck crane and switching it off Switching off • Press the button (1) once. The cruise control is now switched off. The symbol (2) goes out in the Driving display. Cruise control is also switched off, –...
Page 254: Temposet
Driving 5.3 Driving the truck crane and switching it off 5.3.3 Temposet You can use Temposet to limit the maximum speed. Switching on You can switch on Temposet only at speeds greater than 15 km/h (9 mph). • Press the button (1) once. Temposet is now switched on.
Page 255: Driving Downhill
Driving 5.3 Driving the truck crane and switching it off 5.3.4 Driving downhill Risk of accidents when driving in neutral position Never switch into neutral position whilst driving. In neutral position, the truck crane may accelerate and the engine retarder is ineffective.
Page 256 Driving 5.3 Driving the truck crane and switching it off Checks when While driving, the engine speed may not exceed 2,300 rpm. The engine driving downhill speed is not limited automatically. Risk of damage due to excessive engine speed If the maximum permissible engine speed is reached, shift up to a higher gear or slow the truck crane down.
Page 257 Driving 5.3 Driving the truck crane and switching it off Additional brakes Engine retarder The truck crane has an engine flap brake which it uses as an engine retarder. The engine retarder only becomes effective at an engine speed of 950 rpm and can be used up to a maximum speed of 2,300 rpm.
Page 258: Driving Uphill
Driving 5.3 Driving the truck crane and switching it off 5.3.5 Driving uphill Starting The engine must be running. Danger of the truck crane starting to roll away unexpectedly When starting to move forwards, always keep the truck crane stationary with the parking brake until the transmission is engaged.
Page 259: Overriding Torque Reduction
Driving 5.3 Driving the truck crane and switching it off 5.3.6 Overriding torque reduction If the AdBlue tank is empty, torque reduction is activated via the engine control system. You can override torque reduction up to 3 times. – If the level in the AdBlue tank falls to the reserve level, then the symbol (1) is displayed.
Page 260: Switching The Truck Crane Off
Driving 5.3 Driving the truck crane and switching it off 5.3.7 Switching the truck crane off To switch the truck crane off, you must: 1. Stop the truck crane 2. Apply the parking brake à 3. Switch to neutral position; p.
Page 261 Driving 5.3 Driving the truck crane and switching it off Additional chocks can be transported in the storage compartment on the turntable or at the rear of the truck crane. • When stationary Switch off all current consumers, e.g. auxiliary heaters. for more than 8 •...
Page 262: Fold-Up Berth
Driving 5.3 Driving the truck crane and switching it off 5.3.8 Fold-up berth The berth must always be folded up and secured for driving. Risk of accidents due to the berth folding down Check that the locking bar has engaged and put up the back rest of the seats before driving.
Page 263: Off-Road Driving
Driving 5.4 Off-road driving Off-road driving This section describes adjustments, connections and procedures for adapt- ing the vehicle handling to off-road conditions. Adjustments to If you drive continuously for short periods of time with different loads or on the transmission a slippery surface, the transmission may switch gears too late or too early.
Page 264: Transfer Case - Switching The Off-Road Gear On/Off
If the error symbol is displayed, contact Manitowoc Crane Care Neutral position For towing away, you can also switch the transfer case to the neutral à...
Page 265: Longitudinal And Transverse Differential Locks
Driving 5.4 Off-road driving 5.4.2 Longitudinal and transverse differential locks – The longitudinal differential locks prevent individual axle lines spinning when driving on a slippery surface. With the 8 x 8 x 8 drive, the 2nd axle line drive is switched on and off. –...
Page 266 – first symbol (2) – yellow, then symbol (3) – green, differential locks off. If symbol (3) is not green then drive back and forth slowly. If the error symbol is displayed, contact Manitowoc Crane Care 5 - 52 3 302 690 en Operating manual GMK4100L-1...
Page 267: Operating The Level Adjustment System
– Set the on-road driving level – Pre-select the suspension struts and change the vehicle level. If the symbol (3) is shown for an error during a level adjustment, refer to Manitowoc Crane Care Operating manual 3 302 690 en 5 - 53 GMK4100L-1...
Page 268 Driving 5.4 Off-road driving Setting the For on-road driving, you must always set the on-road level in order to on-road level adhere to the specified overall height. • Park the truck crane on a level surface. • Straighten the steering. •...
Page 269 Driving 5.4 Off-road driving Changing the You can extend or retract the pre-selected suspension struts to change the vehicle level vehicle level. Risk of accidents by exceeding total permissible height Always bring the truck crane to on-road level before driving on roads after changing the level.
Page 270 Driving 5.4 Off-road driving Viewing the cur- The inclination indicator shows the current alignment. rent inclination Switching over the measuring range The measuring range is automatically switched between 1° and 5°. (A) – When the truck crane is level the marking (1) is in the middle.
Page 271: Freeing Truck Crane Stuck In Terrain
Driving 5.4 Off-road driving 5.4.4 Freeing truck crane stuck in terrain Rocking the truck If the truck crane is stuck in terrain, you can try to free it by driving back and crane free forth (rocking it free): If you are trying to rock the crane free, you should switch on the transverse differential locks and the longitudinal differential lock.
Page 272 Driving 5.4 Off-road driving • Towing free Fasten a steel rope to the front towbar coupling. forwards Risk of damage to the chassis Only tow the truck crane free while observing the procedure given for the pulling direction. Jerking the truck crane or pulling it at an angle can cause damage to the chassis.
Page 273: Separate Steering
Driving 5.5 Separate steering Separate steering There are two steering modes with separate steering. – Driving around corners: When the separate steering is switched on, the steering angle is larger than for normal steering mode – the turning circle is smaller. –...
Page 274: Switching To Separate Steering
When separate steering is switched on, the speed is limited to approx. 20 km/h (12 mph). à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care 5 - 60 3 302 690 en Operating manual GMK4100L-1...
Page 275 Driving 5.5 Separate steering Automatic separate steering • Steer the 1st and 2nd axle line with the steering wheel. The electronics will register the steering angle on the 1st and 2nd axle lines and steer the wheels of the 3rd and 4th axle lines correspondingly. (A) –...
Page 276 Driving 5.5 Separate steering (A) – for driving around corners • Steer the 3rd and 4th axle lines in the oppo- site direction to the 1st and 2nd axle lines. (B) – For crab travel mode • Steer the 3rd and 4th axle line in the same direction as the 1st and 2nd axle line.
Page 277: Switching To Normal Steering Mode
Depending on the steering mode, steer using the steering wheel (5) or the button (4) until the symbols (1) turn green à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care Operating manual 3 302 690 en 5 - 63 GMK4100L-1...
Page 278: Switching Units Of Measure
Driving 5.5 Separate steering 5.5.3 Switching units of measure You can display the crane control values in metric units or US units. • Open the Switch units menu (1). • Select and confirm the symbol: 1 To display metric units 2 To display US units The symbol (3) shows the respective confirmed selection.
Page 279: Heating And Air-Conditioning System
Driving 5.6 Heating and air-conditioning system Heating and air-conditioning system 5.6.1 Standard heating system • Switching on Start the engine. The heating output is only provided when the engine is running. Heating You must set the blower and the temperature. Setting the fan Setting the fan You can regulate the air volume with the switch (1) for:...
Page 280 Driving 5.6 Heating and air-conditioning system Air distribution You can direct the air to flow out of various air vents. • Turn the switch (5) to the position for the required air vents. A Air vents (1), (2) – front windscreen, side B Air vents (1) to (4) C Air vents (2), (3), (4) –...
Page 281 Driving 5.6 Heating and air-conditioning system Examples This section only contains examples of the settings. Always adjust the setting to the current conditions (warm, cold, damp). (A) – Ventilating – Turn the switches to the positions shown. – If necessary, open the air vents for the side and centre.
Page 282: Air-Conditioning System
Driving 5.6 Heating and air-conditioning system 5.6.2 Air-conditioning system You can cool the driver's cab and dry the air using the air-conditioning system. Information Do not cool the air too much. The difference between the outside temperature and the inside temperature should be at the most 10 °C to 14 °C (18 °F to 25 °F).
Page 283 Driving 5.6 Heating and air-conditioning system Cooling The illustration shows only a sample setting. Always adjust the setting to the current conditions. • Switch the air-conditioning on – the lamp (4) lights up. • Turn the switch (3) as far as it will go, to Cold . •...
Page 284: Auxiliary Water Heating System
Driving 5.6 Heating and air-conditioning system 5.6.3 Auxiliary water heating system The batteries will be drained if you operate the auxiliary heater with the engine switched off. You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently. Further information on the operation of the auxiliary water heating system is provided at the address Webasto.com .
Page 285 Driving 5.6 Heating and air-conditioning system Preheating the Adjust the heating system as follows if the driver's cab is to be preheated in driver's cab addition to the engine: • Switch (1) pushed in at the top. • Switch (2) to the required fan level Recirculated air .
Page 286 Driving 5.6 Heating and air-conditioning system This section describes how to switch on manually. The auxiliary heater can à Storing the heating start , p. 5 - 74. also be switched on automatically; à • Switch the ignition on , p. 4 - 9. Switch on the ignition;...
Page 287 Driving 5.6 Heating and air-conditioning system Always switch the auxiliary heater off if you switch off the truck crane whilst the battery master switch is switched on. In this way, you prevent the auxil- iary heater from restarting and the batteries from running down after the engine has cooled down.
Page 288 Driving 5.6 Heating and air-conditioning system • At the flashing display, set the minutes and confirm the selection. The time and day of the week have now been set. Storing the Heating is started automatically on schedule only if the time and the day of à...
Page 289 Driving 5.6 Heating and air-conditioning system • Select and confirm the desired heating mode. – economical (1) – comfortable (2) – quick (3) • Select and confirm the desired temperature. After the desired temperature has been input, the set values are saved and shown in the display: –...
Page 290: Auxiliary Air Heater
Driving 5.6 Heating and air-conditioning system 5.6.4 Auxiliary air heater You can use the auxiliary heating to preheat the driver's cab or provide additional heating. The auxiliary heater is supplied from the fuel tank. The batteries will be drained if you operate the auxiliary heater with the engine switched off.
Page 291 Driving 5.6 Heating and air-conditioning system This section describes how to switch on manually. The auxiliary heater can à Auxiliary water heating system , also be switched on automatically; p. 5 - 70. à • Switch the ignition on , p. 4 - 9. Switch on the ignition;...
Page 292 Driving 5.6 Heating and air-conditioning system Setting the day Always set the current time and current day of the week. These settings are and time required for the correct activation point of the automatic heating start. If the electric power supply is interrupted, you have to reset the time and day of the week.
Page 293 Driving 5.6 Heating and air-conditioning system • Use button (1) or (2) in program column (3) to select storage location 1, 2 or 3 and confirm with button (4). • Use button (1) or (2) in program column (3) to select a day of the week and confirm with button (4).
Page 294: Radio
Driving 5.7 Radio If you have set a preselection time (departure time) of, for example, 12.00 and a heating period of 30 minutes, the auxiliary heater starts at 11.30, for example. Deleting preselec- tion times • To delete the preselection times, repeat the steps for setting preselection à...
Page 295: Towing A Trailer
Driving 5.8 Towing a trailer Towing a trailer When towing a trailer, a towbar coupling is fitted to the back of the carrier. Please observe the permissible trailer load of your truck crane. Risk of accidents by trailer moving unintentionally Before coupling or uncoupling the trailer, it must be secured with the trailer parking brake as well as with chocks to prevent it rolling away.
Page 296 Driving 5.8 Towing a trailer Coupling the trailer Risk of injury when the automatic closing device is triggered Do not put your hand into the coupling jaw when the towbar coupling is open. This may activate the automatic closing device, causing the cotter pin to move down with great force, seriously injuring your hand.
Page 297 Driving 5.8 Towing a trailer Risk of accidents if the trailer is coupled improperly If the pin is protruding from the guide bushing, the trailer is not coupled properly and could become disengaged from the towbar coupling while driving. Connecting the supply lines •...
Page 298 Driving 5.8 Towing a trailer Removing supply lines Risk of accidents due to trailer moving unintentionally Always first remove the hose from the supply line so that the trailer is braked. This prevents the trailer moving when you remove the brake hose. •...
Page 299 Driving 5.8 Towing a trailer Risk of injury when closing the towbar coupling by hand When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.
Page 300 Driving 5.8 Towing a trailer Checking the When a trailer is coupled and connected, you can check whether the braking braking force force of the truck crane alone is sufficient for braking the truck crane and the trailer on uphill or downhill roads (e.g. when a brake hose has burst). To check this, you can release the parking brake of the trailer on its own.
Page 301: Driving Modes
12 t (26,500 lbs). notes that Manitowoc Crane Group Germany GmbH driving with an axle load exceeding 12 t (26,500 lbs) the brake system can overheat and the braking deceleration required by the EU partial type- approval cannot be ensured.
Page 302: How To Use The Tables
This section only shows some standard driving modes. For further information on additional or individual driving modes, please contact Manitowoc Crane Care The tables consist of two parts: – The driving mode of your truck crane is specified in the top part, next to Equipment.
Page 303 Driving modes 6.1 Driving modes 6.1.2 Table for a maximum axle load of 12 t (26,500 lbs) à 385/95 R25 tyres Also observe the effects on the axle loads when towing a trailer; p. 5 - 81. Driving modes ✔ ✔...
Page 304 Driving modes 6.1 Driving modes Driving modes ✔ ✔ ✔ ✔ ✔ 385/95 R25 tyres Drive 8 x 6 x 8 ✔ ✔ ✔ ✔ ✔ Drive 8 x 8 x 8 ✔ ✔ ✔ ✔ Tansmission retarder Auxiliary hoist or 0.8 t counterweight installed ✔...
Page 305 Driving modes 6.1 Driving modes 445/95 R25 tyres Also observe the effects on the axle loads when towing a trailer; à p. 5 - 81. Driving modes ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 445/95 R25 tyres ✔ ✔ ✔...
Page 306 Driving modes 6.1 Driving modes à 525/80 R25 tyres Also observe the effects on the axle loads when towing a trailer; p. 5 - 81. Driving modes ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 525/80 R25 tyres Drive 8 x 6 x 8 ✔...
Page 307: Maximum Permitted Speeds With An Axle Load Of Over 12 T (26,500 Lbs)
Driving modes 6.1 Driving modes 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26,500 lbs) Should your national regulations allow driving with axle loads over 12 t (26,500 lbs), you may under no circumstances exceed the maximum permitted speed given here.
Page 308 Driving modes 6.1 Driving modes Blank page 6 - 8 3 302 690 en Operating manual GMK4100L-1...
Page 309: Weighing The Truck Crane
Driving modes 6.2 Weighing the truck crane Weighing the truck crane Weighing error The most precise method for determining the total weight of the GMK4100L-1 is to use calibrated scales of appropriate capacity and a weighbridge on which all the wheels of the truck crane can stand at the same time. All other weighing procedures are subject to various factors which can lead to weighing errors.
Page 310 Driving modes 6.2 Weighing the truck crane – Determining the axle loads All the axle lines belonging to an axle group must always be weighed. In addition, all the wheels must be on the same level. If for instance only the axle group A1 is to be weighed, then the axle groups A2 must be equalised on a support plate U which has the same height as the scales W1 and W2.
Page 311 Driving modes 6.2 Weighing the truck crane Weighing procedure Perform the weighing procedure only with the crane truck standing on solid and horizontal ground. All scales must be at the same height. • Position the scales W1 to W4 (or the necessary support plate) directly in front of the truck crane, so that the distances between the scales are exactly the same as the distances between the axle groups 1 and 2.
Page 312 Driving modes 6.2 Weighing the truck crane Evaluation In the example shown you receive four weighing results. Assume you had made a note of the values listed here. Passenger side: W1 = 10 t, W3 = 12 t Driver's side: W2 = 10 t, W4 = 12 t These values allow you to determine the total weight of the truck crane and the axle loads for the individual axle lines.
Page 313: Rigging Work For Driving With A Dolly
Driving modes 6.3 Rigging work for driving with a dolly Rigging work for driving with a dolly To reduce the axle loads to the specifications applicable in the country in which you are working, you can set the main boom onto a dolly when driving. For this purpose, the truck crane must be fitted with a slewing gear freewheel, boom floating position and if necessary, with a boom pre-tensioning device.
Page 314: Switching On The Slewing Gear Freewheel
Driving modes 6.3 Rigging work for driving with a dolly 6.3.1 Switching on the slewing gear freewheel When the main boom is set down on a dolly, the superstructure must be able to slew when driving around corners. You must switch on the slewing gear freewheel for this purpose.
Page 315: Switching On The Boom Floating Position
Driving modes 6.3 Rigging work for driving with a dolly 6.3.2 Switching on the boom floating position If the main boom has been placed on a dolly, the boom floating position must be switched on so that the main boom can move up and down. Risk of accidents from the boom floating position being switched off Always switch on the boom floating position when the main boom is on a dolly.
Page 316: Switching On Boom Pre-Tensioning
Driving modes 6.3 Rigging work for driving with a dolly 6.3.3 Switching on boom pre-tensioning If the main boom has been set down on a dolly, you can change the axle loads on the rear axle lines by switching on the boom pre-tensioning. •...
Page 317: Rigging The Auxiliary Hoist
Driving modes 6.4 Rigging the auxiliary hoist Rigging the auxiliary hoist You will require the following equipment with a sufficient load bearing capacity: – An auxiliary crane – Suitable lifting gear and guide ropes, – A separate vehicle. à Transport dimensions and weight; p.
Page 318: Checklist: Installing The Auxiliary Hoist
Driving modes 6.4 Rigging the auxiliary hoist 6.4.2 CHECKLIST: Installing the auxiliary hoist – The superstructure is slewed to the front. – The main boom is resting in the boom rest. 1. Attach the auxiliary hoist at the centre of gravity and remove the bolts à...
Page 319: Checklist: Removing The Auxiliary Hoist
Driving modes 6.4 Rigging the auxiliary hoist 6.4.3 CHECKLIST: Removing the auxiliary hoist – The main boom must be resting in the boom rest. – The hoist rope is unreeved. 1. Wind on the auxiliary hoist rope, using the rigging aid if necessary; à...
Page 320: Making/Breaking The Connection Between The Auxiliary Hoist And The Turntable
Driving modes 6.4 Rigging the auxiliary hoist 6.4.4 Making/breaking the connection between the auxiliary hoist and the turntable Making the connection • Lift the auxiliary hoist on to the turntable so that the connection points (2) are lined up. • Use a washer on each side and tighten the bolts (1) with the nuts (3) at all the connec- tion points.
Page 321: Establishing/Disconnecting The Hydraulic Connections
Driving modes 6.4 Rigging the auxiliary hoist 6.4.5 Establishing/disconnecting the hydraulic connections Making the connection The assignment is given by the size and colour designations. • Connect the hoses (1) to the ports (2). Undoing the connection • Remove the hoses (2) from the connec- tions (1).
Page 322: Disconnecting/Establishing The Electrical Connection
Driving modes 6.4 Rigging the auxiliary hoist 6.4.6 Disconnecting/establishing the electrical connection Making the connection • Remove the plug (2) from the dummy socket (3) and plug it into the socket (1). • Close the dummy socket (3). Undoing the connection •...
Page 323: Making/Breaking The Connection To The Central Lubrication
Driving modes 6.4 Rigging the auxiliary hoist 6.4.7 Making/breaking the connection to the central lubrication Making the connection • Connect the hose (1) to the connection (2) Undoing the connection • Remove the hose (1) from the connec- tion (2). •...
Page 324: Transporting The Auxiliary Hoist
Driving modes 6.4 Rigging the auxiliary hoist 6.4.8 Transporting the auxiliary hoist • For transportation, be sure to use a separate vehicle with sufficient load à bearing capacity. Transport dimensions and weight; p. 1 - 19. • Load the separate vehicle in such a way that the weight is evenly distributed.
Page 325: Check That The Auxiliary Hoist Is Functioning Properly
Check the function of the slewing indicator when applying the hoist rope. • You should feel a pulse on the slewing indicator (1) when the auxiliary hoist is rotating. • If no pulse is present, contact Manitowoc Crane Care Operating manual 3 302 690 en 6 - 25 GMK4100L-1...
Page 326: Rigging Aid For The Hoist Rope
Driving modes 6.4 Rigging the auxiliary hoist 6.4.10 Rigging aid for the hoist rope Depending on the version, a rigging aid for the hoist rope is provided with the auxiliary hoist. Scope of delivery 1 Connector, two parts 2 Rope Risk of damage to the hoist rope! Always rig the hoist rope with the rigging aid.
Page 327 Driving modes 6.4 Rigging the auxiliary hoist Rigging the hoist rope The rigging aid is connected to the hoist rope. – When rigging • Guide the rope (1) over the main boom and over the upper head sheave. • Slowly unreel the hoist rope. •...
Page 328 Driving modes 6.4 Rigging the auxiliary hoist Blank page 6 - 28 3 302 690 en Operating manual GMK4100L-1...
Page 329: Installing/Removing The Outrigger Beams
Driving modes 6.5 Installing/removing the outrigger beams Installing/removing the outrigger beams To rig the outrigger beams, the outriggers must be fitted with hydraulic connections (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.
Page 330: Checklist: Removing The Outrigger Beams
Driving modes 6.5 Installing/removing the outrigger beams 6.5.1 CHECKLIST: Removing the outrigger beams This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! à 1.
Page 331 Driving modes 6.5 Installing/removing the outrigger beams à 6. Release the connection to the support box; p. 6 - 42. 7. Sling the outrigger beam and pull it out of the outrigger box until it à reaches the centre of gravity; p.
Page 332: Checklist: Installing The Outrigger Beams
Driving modes 6.5 Installing/removing the outrigger beams 6.5.2 CHECKLIST: Installing the outrigger beams This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! à 1.
Page 333 Driving modes 6.5 Installing/removing the outrigger beams à 6. Screw in the spacers; p. 6 - 40. à 7. If necessary, put supporting pads into position; p. 6 - 36. 8. Mount all necessary outrigger beams in the same way in accordance with this checklist.
Page 334: Centre Of Gravity Data
Driving modes 6.5 Installing/removing the outrigger beams 6.5.3 Centre of gravity data The information in this section relates to a fully retracted outrigger beam package. The centre of gravity is defined by the distance (A). Outrigger pads Without 860 mm (33.85 in) Steel 825 mm (32.48 in) Plastic...
Page 335: Preparations - On The Truck Crane
Driving modes 6.5 Installing/removing the outrigger beams 6.5.5 Preparations – on the truck crane Prerequisites The following requirements must be met before mounting/removing the outrigger beams: – All rigging work which involves slewing the superstructure has been completed. – The parking brake is engaged. –...
Page 336: Removing/Attaching Outrigger Pads
Driving modes 6.5 Installing/removing the outrigger beams 6.5.6 Removing/attaching outrigger pads You only need remove the outrigger pads if the outrigger beams are to be transported lying on their side. For transportation in a suitable holding frame, the outrigger beams can be set down on the outrigger pad.
Page 337 Driving modes 6.5 Installing/removing the outrigger beams Attaching the After mounting the outrigger beam, you must attach the outrigger pad. outrigger pads • (A) – Remove the pin (1). • Remove the bolts/nuts (2). • Extend the outrigger cylinder far enough so that the bearing surface (3) is below the guide (4).
Page 338: Disconnecting/Establishing Hydraulic Connection
Driving modes 6.5 Installing/removing the outrigger beams 6.5.7 Disconnecting/establishing hydraulic connection There is a valve block on each outrigger beam. The position of the valve block may differ from the drawings, depending on the outrigger beam. Undoing the connection Always disconnect all connections (4). •...
Page 339: Disconnecting/Establishing The Electrical Connection
Driving modes 6.5 Installing/removing the outrigger beams 6.5.8 Disconnecting/establishing the electrical connection The electrical connection is only present on truck cranes equipped with an outrigger pressure display or outrigger span monitoring system. Risk of malfunctions in the electronic system! Always turn off the ignition before you disconnect or establish the electrical connection.
Page 340: Unscrewing/Screwing In The Spacers
Driving modes 6.5 Installing/removing the outrigger beams 6.5.9 Unscrewing/screwing in the spacers There are two spacers for each outrigger beam – In the outrigger box – In the outrigger beam on the opposite side. The illustrations show as an example the spacers for the outrigger beam on the front right hand side.
Page 341 Driving modes 6.5 Installing/removing the outrigger beams Screwing in Before you retract/extend an outrigger beam after mounting, you must screw in the spacers. 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.
Page 342: Disconnecting/Establishing The Connections To The Supporting Box
Driving modes 6.5 Installing/removing the outrigger beams 6.5.10 Disconnecting/establishing the connections to the supporting The illustrations show the connecting point for the front right outrigger beam as an example. (A) – Disconnecting the connection • Remove the nut (3). • Remove the bolt (1) from the connecting point (2).
Page 343 Driving modes 6.5 Installing/removing the outrigger beams • Fasten the lifting gear (1) and a chain hoist. • Pull the outrigger beam out so far that the à Centre centre of gravity (2) is accessible; of gravity data , p. 6 - 34. •...
Page 344 Driving modes 6.5 Installing/removing the outrigger beams • Inserting the Only insert the outrigger beam at the correct installation point. Note the outrigger beam information on the label. 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.
Page 345 Driving modes 6.5 Installing/removing the outrigger beams • Lift the outrigger beam as far as possible into the outrigger box. Correct the height so that it does not remain hanging on the edges (1). • Remove the lifting gear from the centre of gravity.
Page 346: Transporting The Outrigger Beams
Driving modes 6.5 Installing/removing the outrigger beams 6.5.12 Transporting the outrigger beams • For transportation, be sure to use a separate vehicle with sufficient load à bearing capacity. Transport dimensions and weight; p. 1 - 10. • Load the separate vehicle in such a way that the weight is evenly distributed.
Page 347: Note On Error Messages With Removed Outrigger Beams
Driving modes 6.5 Installing/removing the outrigger beams 6.5.13 Note on error messages with removed outrigger beams Depending on the outrigger beam, the following error messages can occur after removal. 5801.7.33.2 5809.7.32.96 5801.7.33.98 5803.7.32.2 5807.7.32.96 5803.7.32.98 The error messages indicate only that the electrical connection between the outrigger beams and the crane control is disconnected.
Page 348 Driving modes 6.5 Installing/removing the outrigger beams Blank page 6 - 48 3 302 690 en Operating manual GMK4100L-1...
Page 349: Transport
Transport 7.1 Transport with transport vehicle Transport Transport should be carried out only by qualified heavy transport compa- nies whose personnel are well-acquainted with loads of these dimensions and weights. Transport with transport vehicle Risk of accidents due to improper transport! Assign transportation to only qualified companies and ensure that the reg- ulations applicable in the country in which you are working are adhered to.
Page 350: Checklist: Checks Before Transport
Transport 7.1 Transport with transport vehicle 7.1.1 CHECKLIST: Checks before transport This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1. For on-road driving without a dolly –...
Page 351 Transport 7.1 Transport with transport vehicle 4. The anemometer and air traffic control light must be removed; à Anemometer and air traffic control light , p. 12 - 126. à 5. All railings must be folded in; p. 12 - 129. à...
Page 352: Drive The Truck Crane On To The Transport Vehicle
Transport 7.1 Transport with transport vehicle 9. The detachable equipment parts must be stripped down so that they fulfil the regulations of the country in which you are working as regards permissible weights and axle loads, lengths, widths, height, etc. All additional parts which may be transported must be secured against falling down.
Page 353 Transport 7.1 Transport with transport vehicle Driving on • Drive the truck crane onto the trailer. Apply the parking brake immediately, and switch the engine off. • Close all the doors. Lashing Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided.
Page 354: Transport By Ship
Transport 7.2 Transport by ship Transport by ship Risk of accidents due to falling parts Use only suitable lifting gear with sufficient load bearing capacity and use only the slinging points provided. • Secure the truck crane with the chocks (1). •...
Page 355: Malfunctions In Driving Mode
Malfunctions in driving mode 8.1 Emergency stop switch Malfunctions in driving mode Emergency stop switch Three emergency stop switches are provided for emergency use: 1 On the carrier 2 On the hand-held control unit 3 In the crane cab • Press an emergency stop switch (1), (2) or (3).
Page 356: Procedure During Malfunctions
When in a hazard area, carry out only the repair work required to leave the danger area. If you are unable to repair the damage yourself, notify Manitowoc Crane Care à Towing the truck crane , p. 8 - 29.
Page 357: Procedure During Engine Malfunctions
Do not by any means restart the engine. This will prevent serious damage to the engine. • If necessary, note the error messages and contact Manitowoc Crane Care a qualified specialist repair shop. The coolant temperature is too high – the motor output is automatically reduced.
Page 358: Procedure During Transmission Malfunctions
If the transmission malfunctions, the electronic system will try to establish a secure operating condition with the remaining functions. Even if the transmission still shifts, always notify Manitowoc Crane Care This avoid situations where another small error could lead to transmission failure.
Page 359: Warning And Error Messages
• Always note down the number of the program version and the serial number after a malfunction occurs before notifying Manitowoc Crane Care The crane type (1) and the serial number (2) are shown in the start menu. à The program version is displayed in the crane cab;...
Page 360 If oil has leaked out • Warn any vehicles on the road behind you. • Do not continue driving. Contact Manitowoc Crane Care If no oil has leaked out à • Maintenance manual . Check the hydraulic oil level;...
Page 361 Whether it is possible to continue driving must be decided based on the current situation. Contact Manitowoc Crane Care If necessary, the 3rd axle line can be steered with the emergency operation to the straight running position (for example, after driving in crab travel à...
Page 362 Malfunctions in driving mode 8.3 Warning and error messages AdBlue system • Also check the control elements for the Adblue system; à Faults on the Adblue system , p. 8 - 21. 8 - 8 3 302 690 en Operating manual GMK4100L-1...
Page 363: Warning And Malfunction Messages On The On-Board Computer Display
Malfunctions in driving mode 8.3 Warning and error messages 8.3.2 Warning and malfunction messages on the on-board computer display Messages Messages are shown automatically. There are three types of message. – Warning message Display (1) red, additional text and symbols. •...
Page 364 • Add oil if necessary. If the error message is still displayed, please contact Manitowoc Crane Care Risk of damage to the engine if the oil pressure drops Switch off the engine as soon as possible and look for the cause if the lamp lights up or the warning buzzer sounds.
Page 365 The gear shifting has a malfunction – driving can continue with restrictions. • If necessary, note the error messages and contact Manitowoc Crane Care a qualified specialist repair shop. The clutch has a malfunction – driving can continue with restrictions.
Page 366 Malfunctions in driving mode 8.3 Warning and error messages The maximum permissible operating temperature of the clutch has been reached. • Shift to a lower gear for manoeuvring or starting. • stop the manoeuvring or starting procedure. The oil temperature of the fluid coupling is too high. •...
Page 367: Warning Messages On The Ccs Display
Malfunctions in driving mode 8.3 Warning and error messages 8.3.3 Warning messages on the CCS display A warning message indicates that certain values do not correspond to a target value If CCS detects a warning or a fault then in the display area (1) a symbol is displayed.
Page 368 Malfunctions in driving mode 8.3 Warning and error messages AdBlue tank level too low à Refill the AdBlue tank; p. 4 - 7. Replace hydraulic oil filter Replace the corresponding hydraulic oil filter as soon as possible; à Maintenance manual . Hydraulic oil too hot The hydraulic oil temperature is higher than 80 °C (176 °F).
Page 369 Malfunctions in driving mode 8.3 Warning and error messages Refuelling The fuel tank is filled only to a level of about 5%. à • Refuel before the fuel is used up; p. 4 - 5. If the fuel tank is almost empty, air will be sucked in and you will have to à...
Page 370 8 - 17. • If necessary, note the error messages and contact Manitowoc Crane Care CAN bus malfunction • Switch off the ignition and wait about 15 seconds, then switch it on again. If the malfunction is still present, contact...
Page 371: Engine/Transmission Error Messages
1 Engine 2 Transmission • Always note the error code before contacting Manitowoc Crane Care Exiting the menu You can exit the Engine errors menu at any time. • Press the button (1) once. The next highest menu is opened.
Page 372 Malfunctions in driving mode 8.3 Warning and error messages Blank page 8 - 18 3 302 690 en Operating manual GMK4100L-1...
Page 373: Troubleshooting
Malfunctions in driving mode 8.4 Troubleshooting Troubleshooting 8.4.1 Malfunctions on the engine à Separate engine operating instructions, In addition to this information; provided by the manufacturer . Malfunction Cause Solution Engine does not start – Battery master switch is Switch on the battery à...
Page 374 – the symbol is displayed. The symbol is displayed, Due to a malfunction, the Inform Manitowoc Crane Care the engine output falls power is continuously continuously (coolant reduced. The engine is not temperature is too high)
Page 375: Faults On The Adblue System
– Flashing AdBlue tank empty – AdBlue tank sensor faulty Have the exhaust system – Error on the AdBlue dosing checked by Manitowoc – Light up unit , an authorised Crane Care – AdBlue lines blocked GROVE retailer or an –...
Page 376: Differential Lock Malfunctions
Fuse has blown Replace blown fuses; à p. 8 - 50 Error symbol is displayed CCS malfunction Read out error messages à p. 8 - 17) and notify Manitowoc Crane Care 8 - 22 3 302 690 en Operating manual GMK4100L-1...
Page 377: Malfunctions In The Transmission
Malfunctions in driving mode 8.4 Troubleshooting 8.4.5 Malfunctions in the transmission Malfunction Cause Solution Transmission only shifts up Transmission oil too hot Switch to the neutral to 2nd gear – the symbol is position and wait until the displayed transmission oil has cooled down Transmission oil colder Wait until transmission oil...
Page 378: Malfunctions Of The Steering
Malfunctions in driving mode 8.4 Troubleshooting 8.4.6 Malfunctions of the steering Malfunction Cause Solution Steering wheel hard to Lights can light up; oil level Check the hydraulic oil à Maintenance turn, grating noises when in the hydraulic oil tank too level;...
Page 379: Malfunctions Of The Service Brake
Malfunctions in driving mode 8.4 Troubleshooting 8.4.7 Malfunctions of the service brake Malfunction Cause Solution Lights up while The air pressure in one of the The vehicle can be driven driving or does not two circuits has fallen below slowly to the next repair shop go out after the 5.5 bar (80 psi) engine is started...
Page 380: Malfunctions Of The Level Adjustment System
Malfunctions in driving mode 8.4 Troubleshooting 8.4.9 Malfunctions of the level adjustment system Malfunction Cause Solution à Switching the suspension on , Level adjustment system not Suspension is switched off working p. 5 - 17 Control unit fuse blown Replace blown fuses; à...
Page 381: Emergency Operation And Breakdown Assistance
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Emergency operation and breakdown assistance 8.5.1 Starting the truck crane externally • Start the engine of the auxiliary vehicle. • (A) – Connect the cable (1) to the power supply (24 V) of the auxiliary vehicle. •...
Page 382: Battery Charger
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.2 Battery charger Prerequisites – The engine must not be running and must be secured against unauthorised use. – An external 230 V mains power supply must be available at the location. –...
Page 383: Towing The Truck Crane
Tow the truck crane at a maximum speed of 7 km/h (4 mph) and for a distance of max. 100 m (330 ft). For longer distances, additional measures must be taken, refer to Manitowoc Crane Care Compressed-air If the engine fails, the truck crane must be supplied with compressed air by supply the tractor-vehicle so that the brake system is still operable.
Page 384 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance • Connect the filler connection (2) 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 (1) must not light up in the driver's cab when towing.
Page 385 If the lamp (1) does not go out, there is a malfunction on the parking brake system. Contact Manitowoc Crane Care Risk of accidents due to faulty brakes If the service brake system has been damaged, you may only tow the...
Page 386 • If you need to tow the truck crane further than 100 m (330 ft) contact Manitowoc Crane Care Risk of accidents and damage when towing the truck crane long distances Tow the truck crane at a maximum speed of 7 km/h (4 mph) and for a maximum distance of 100 m (330 ft).
Page 387: Wheel Change
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.4 Wheel change • If a puncture occurs while driving, stop the truck crane, taking the following traffic into account, and secure the truck crane as outlined in the applicable legal stipulations of the country in which you are working. •...
Page 388 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance à • Removing a Switch off the suspension; p. 5 - 17. damaged wheel • Raise the truck crane with the outriggers until the wheel to be changed just barely leaves the ground. Risk of accidents due to a wheel falling over When unscrewing the final lug nuts, the wheel can slip off the hub and fall toward you.
Page 389 Check the wheel rim, tyres, lug nuts and wheel studs for damage before mounting the spare wheel. Damaged parts may not be mounted Mount only the original wheel supplied by Manitowoc Crane Group Germany or an approved wheel of the same size and load bearing capacity! GmbH •...
Page 390 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance • Tighten the wheel nuts (1) and (2) finger-tight to secure the wheel. • Tighten the remaining wheel nuts finger-tight. • Always tighten the wheel nuts in the order (1) to (12). –...
Page 391: Inflating The Tyres Yourself
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.5 Inflating the tyres yourself In an emergency, if an appropriate filling hose is available you can inflate the tyres using the compressed air system of the truck crane. A tyre inflator connection set to a pressure of 10 bar (145 psi) is provided for this purpose.
Page 392 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Inflating the tyres The maximum operation pressure of the compressed air system of 10 bar (145 psi) can only be reached with the engine running. à • Start the engine; p.
Page 393: Emergency Operation, Steering 3Rd Axle Line
Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance 8.5.6 Emergency operation, steering 3rd axle line If there is a warning message in the steering system – lamp (1) lights and symbol (2) is red – the steering of the 3rd axle line is will be locked. The 3rd axle line can then no longer be steered from the driver's cab or from the crane cab.
Page 394 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Take out fuses You must take out two fuses before the emergency operation so that the steering system electronics is deactivated. • Turn off the ignition. à • Fuses in the driver's cab , p. 8 - 50. Take the fuse F2/5 out;...
Page 395 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Check valves – switch off continuous operation • Always switch off the continuous operation for all valves (1). • (A) – Take the nut (2) off of the limit switch (4). •...
Page 396 Malfunctions in driving mode 8.5 Emergency operation and breakdown assistance Blank page 8 - 42 3 302 690 en Operating manual GMK4100L-1...
Page 397: Tilting/Lowering The Driver's Cab
Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Tilting/lowering the driver's cab To tilt the driver's cab (e.g. for maintenance work), the main boom must be raised and the hoisting gear moved. This assumes that the engine can be started. If the engine cannot be started, you must use the hydraulic emergency à...
Page 398: Tilting And Lowering The Driver's Cab
Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab 8.6.2 Tilting and lowering the driver's cab Operating the The driver's cab is tilted and lowered using a hand pump. The lever for the hand pump hand pump is below the seats or in the tool box. •...
Page 399 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab • Tilting the driver's Remove all loose objects from the driver's cab. Close the doors. Risk of accidents from loose objects and doors swinging open Remove all loose objects (e.g. bottles) from the driver's cab so that they do not fall out when the cab is tilted.
Page 400 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab • Continue to pump until the driver's cab tilts no further. • Secure the driver's cab – fold out the fall-back guard strut (1). Risk of accidents due to the driver's cab tilting back. You may only stand under the tilted driver's cab if the fall-back guard strut is folded out.
Page 401 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Risk of accidents if the driver's cab is not locked. Ensure that the driver's cab is locked afterwards every time it is lowered. This prevents the driver's cab tilting forward when braking. •...
Page 402 Malfunctions in driving mode 8.6 Tilting/lowering the driver's cab Blank page 8 - 48 3 302 690 en Operating manual GMK4100L-1...
Page 403: Fuses On The Carrier
This prevents parts being overloaded and damaged or the fuse being immediately blown again. Notify if a fuse with the same amperage blows again Manitowoc Crane Care when the ignition is switched on. Risk of fire Never repair a blown fuse with other electrically conductive materials.
Page 404: Fuses In The Driver's Cab
Malfunctions in driving mode 8.7 Fuses on the carrier 8.7.1 Fuses in the driver's cab The driver's cab contains fuse groups F1 to F6. • Remove the cover (1). The following tables show the designations of the individual fuses, including their amperage and functions.
Page 405 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F2/1 Control unit UB 1 IOL 31 F2/2 Control unit UB 1 IOL 31 F2/3 Control unit UB 2 IOL 31 F2/4 Control unit UB 2 IOL 31 Control unit UB 1 IOL 32 F2/5 Electronic steering system...
Page 406 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F4/1 Cab lighting F4/2 Dual tank switchover CCS display F4/3 F4/4 Unassigned F4/5 Unassigned F4/6 Unassigned F4/7 Unassigned F4/8 Unassigned Designation Amperage (A) Function F5/1 Auxiliary heater Control unit UE CCM 11 F5/2 Control unit UE 2 IOL 31/32/33...
Page 407 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function Engine emergency stop switch F6/1 Tachograph, instrument panel Control unit CCM 11 F6/2 Control unit IOL 31/32/33 Display CCS F6/3 Reverse camera Radio F6/4 air intake inhibitor F6/5 Gearbox control F6/6...
Page 408 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function F8/1 Central lubrication F8/2 Windscreen wiper F8/3 Steering coupling F8/4 ABS trailer F8/5 Horn F8/6 Unassigned Operating the mirror adjustment F8/7 Window winder F8/8 Unassigned Designation Amperage (A) Function Temperature gauge F9/1...
Page 409 Malfunctions in driving mode 8.7 Fuses on the carrier Designation Amperage (A) Function Turn signal indicators F10/1 Light switch F10/2 Rotating beacon carrier/superstructure Parking light F10/3 Side marker lights Side marker lights, front F10/4 Instrument lighting Brake lights F10/5 Trailer brake lights Light switch F10/6 Warning blinkers...
Page 410: Fuses In The Battery Box
Malfunctions in driving mode 8.7 Fuses on the carrier 8.7.2 Fuses in the battery box Fuses F7 to F16 are contained in the battery box. Danger from lead and lead compounds on batteries Battery poles, battery terminals and parts of the battery itself contain lead and lead compounds.
Page 411: Operating Elements For Crane Operation
Operating elements for crane operation 9.1 Overview of the operating elements Operating elements for crane operation All operating elements for driving are described in Chapter 3. Overview of the operating elements This section shows the position and designations of the operating elements for crane operation.
Page 412: Exterior Of The Truck Crane
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.1 Exterior of the truck crane 9 - 2 3 302 690 en Operating manual GMK4100L-1...
Page 413 Operating elements for crane operation 9.1 Overview of the operating elements à 1 – Camera on main boom p. 12 - 132 à – Camera on the hoists p. 12 - 135 à – Camera on the driver's cab p. 12 - 135 à...
Page 414 Operating elements for crane operation 9.1 Overview of the operating elements 9 - 4 3 302 690 en Operating manual GMK4100L-1...
Page 415 Operating elements for crane operation 9.1 Overview of the operating elements à 18 CraneSTAR system p. 11 - 158 19 Drive unit à 20 – Switching on the boom floating position p. 6 - 15 à – Switching off the boom floating position p.
Page 416: Crane Cab
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.2 Crane cab 9 - 6 3 302 690 en Operating manual GMK4100L-1...
Page 417 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Side panel p. 9 - 8 2 Sun visor à 3 Current degree of utilisation display p. 11 - 51 à 4 Door unlocking mechanism p. 9 - 155 à...
Page 418 Operating elements for crane operation 9.1 Overview of the operating elements Side panel 9 - 8 3 302 690 en Operating manual GMK4100L-1...
Page 419 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Applying/releasing the parking brake p. 9 - 162 à 2 – Starting the engine p. 9 - 91 à – Set idling speed p. 9 - 91 3 RCL override –...
Page 420 Operating elements for crane operation 9.1 Overview of the operating elements Crane cab, rear 9 - 10 3 302 690 en Operating manual GMK4100L-1...
Page 421 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Cab lighting p. 9 - 147 2 Sun roller blind 1), 3) 3 Radio-CD/USB 4 Loudspeaker à 5 Sockets 12 V p. 9 - 145 6 Fan with switch à...
Page 422: Control Panels
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.3 Control panels Left à 1 Moving the outrigger p. 9 - 102 à 2 Slewing gear on/off p. 9 - 118 à 3 Lifting limit switch override p. 9 - 115 à...
Page 423 Operating elements for crane operation 9.1 Overview of the operating elements Right à 1 Jog dial (rotary push button) p. 9 - 95 à 2 Main hoist on/off p. 9 - 114 à 3 Derricking gear on/off p. 9 - 120 à...
Page 424: Control Lever Assignment
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.4 Control lever assignment The truck crane can be equipped with two different control lever configura- tions. The current configuration of the control levers is indicated by symbols on the control levers. In version 1, the left control lever is configured with the Telescope function.
Page 425 Operating elements for crane operation 9.1 Overview of the operating elements Version 2 In version 2, the right control lever is configured with the Telescope function. Left control lever Right control lever 1 Slewing to the left Raise/retract 2 Slewing to the right Lower/extend 3 Lower auxiliary hoist Lower the main hoist...
Page 426: Ccs Control Unit
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.5 CCS control unit 9 - 16 3 302 690 en Operating manual GMK4100L-1...
Page 427 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Display CCS p. 9 - 95 à Overview start menu p. 9 - 19 2 Jog dial à 3 Exiting the menu/input mode p. 9 - 98 à...
Page 428: Menu-Independent Displays
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.6 Menu-independent displays à 1 Slewing gear p. 9 - 118 à 2 Telescoping mechanism p. 9 - 122 à 3 Derricking gear p. 9 - 120 à 4 Main hoist p.
Page 429: Ccs - Start Menu
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.7 CCS – Start menu à 1 RCL display p. 9 - 20 à 2 Engine speed display p. 10 - 8 à 3 AdBlue (DEF) filling level indicator p.
Page 430 Operating elements for crane operation 9.1 Overview of the operating elements RCL display à 1 Display Slewing ranges/working radii p. 9 - 21 à 2 Current working radius display p. 9 - 134 à 3 Current slewing angle display p. 9 - 134 à...
Page 431 Operating elements for crane operation 9.1 Overview of the operating elements Display Slewing ranges/working radii A For the Standard slewing range type B For the MAXbase slewing range type à Display of current slewing range divisions p. 9 - 133 à...
Page 432: Ccs - Overview Menu Groups
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.8 CCS – Overview menu groups 9 - 22 3 302 690 en Operating manual GMK4100L-1...
Page 433 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Superstructure menu group p. 9 - 26 – Superstructure lock sub-menu – Counterweight menu à 2 Menu group outrigger/driving p. 9 - 29 – Outrigger menu – Outrigger cylinders menu –...
Page 434 Operating elements for crane operation 9.1 Overview of the operating elements 9 - 24 3 302 690 en Operating manual GMK4100L-1...
Page 435 Operating elements for crane operation 9.1 Overview of the operating elements à 8 Settings menu group p. 9 - 64 – Crane cab menu – Set display brightness and date/time menu – Switch units menu – Set control lever characteristic curve menu –...
Page 436: Superstructure Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.9 Superstructure menu group à 1 Superstructure lock sub-menu p. 9 - 27 à 2 Counterweight menu p. 9 - 28 9 - 26 3 302 690 en Operating manual GMK4100L-1...
Page 437 Operating elements for crane operation 9.1 Overview of the operating elements Superstructure lock sub-menu à 1 Slewing release display – identical to the display in p. 9 - 28 the Counterweight menu à 2 House lock locking status displays p. 9 - 131 à...
Page 438 Operating elements for crane operation 9.1 Overview of the operating elements Counterweight menu à 1 Slewing release display p. 9 - 113 à 2 Display of slewing direction for automatic mode p. 9 - 110 à 3 Current slewing angle display p.
Page 439: Menu Group Outrigger/Driving
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.10 Menu group outrigger/driving à 1 – Outrigger menu p. 9 - 30 à – Outrigger cylinders menu p. 9 - 32 à 2 Driving mode menu p. 9 - 34 Operating manual 3 302 690 en 9 - 29...
Page 440 Operating elements for crane operation 9.1 Overview of the operating elements Outrigger menu 9 - 30 3 302 690 en Operating manual GMK4100L-1...
Page 441 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Slewing gear/movements locked display p. 9 - 101 à 2 Parking brake/movements locked display/warning p. 9 - 101 à 3 Suspension on/off display/warning p. 9 - 101 à...
Page 442 Operating elements for crane operation 9.1 Overview of the operating elements Outrigger cylinders menu 9 - 32 3 302 690 en Operating manual GMK4100L-1...
Page 443 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Slewing gear/movements locked display p. 9 - 101 à 2 Parking brake/movements locked display/warning p. 9 - 101 à 3 Suspension on/off display/warning p. 9 - 101 à...
Page 444 Operating elements for crane operation 9.1 Overview of the operating elements Driving mode menu 9 - 34 3 302 690 en Operating manual GMK4100L-1...
Page 445 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Transmission mode RM p. 9 - 158 à 2 Transmission mode R p. 9 - 158 à 3 Neutral position N p. 9 - 158 à 4 Transmission mode D p.
Page 446 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 36 3 302 690 en Operating manual GMK4100L-1...
Page 447: Rcl/Telescoping Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.11 RCL/Telescoping menu group à 1 Menu enter rigging mode/telescope p. 9 - 38 à 2 Lifting capacity tables menu p. 9 - 44 à 3 Telescoping semi-automation menu p.
Page 448 Operating elements for crane operation 9.1 Overview of the operating elements Menu enter – For the Standard slewing range type rigging mode/ telescope A For boom system main boom B For boom system lattice extension Depending on the version, the top view (2) is shown rotated by 180°. The representation occurs in the same manner as in the RCL Monitoring menu;...
Page 449 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Enter slewing range p. 9 - 136 à 2 Enter outrigger span p. 9 - 139 à Outrigger span monitoring display p. 9 - 140 à 3 Enter counterweight p.
Page 450 Operating elements for crane operation 9.1 Overview of the operating elements – For the MAXbase slewing range type Additional equipment Depending on the version, the top view (2) to (5) is shown rotated by 180°. The representation occurs in the same manner as in the RCL Monitoring à...
Page 451 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Enter slewing range p. 9 - 136 à 2 Input front left outrigger span p. 9 - 139 à 3 Input front right outrigger span p. 9 - 139 à...
Page 452 Operating elements for crane operation 9.1 Overview of the operating elements Pre-selection telescoping menu 9 - 42 3 302 690 en Operating manual GMK4100L-1...
Page 453 Operating elements for crane operation 9.1 Overview of the operating elements Enter desired parameter à 1 Input load p. 9 - 141 à 2 Input working radius p. 9 - 141 à 3 Input main boom length p. 9 - 141 à...
Page 454 Operating elements for crane operation 9.1 Overview of the operating elements à Lifting capacity Displaying the lifting capacity tables , p. 11 - 59 tables menu – For the Standard slewing range type 1 Slewing range display 2 Permissible working range display (range under the curve) I Main hoist display Limitation due to reeving...
Page 455 Operating elements for crane operation 9.1 Overview of the operating elements Telescoping semi- automation menu à 1 Telescopic sections display p. 9 - 124 à 2 Pre-selection for all telescopic sections p. 9 - 124 à 3 Pre-selection individual telescopic sections p.
Page 456 Operating elements for crane operation 9.1 Overview of the operating elements Manual tele- scoping menu à 1 Locking status telescopic section display p. 9 - 126 à 2 Symbol lock/release telescopic section p. 9 - 126 à 3 Telescoping cylinder in the telescopic section display p.
Page 457: Active Working Range Limiter Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.12 Active working range limiter menu group à 1 Overall height menu p. 9 - 48 à 2 Working radius menu p. 9 - 49 à 3 Slewing angle menu p.
Page 458 Operating elements for crane operation 9.1 Overview of the operating elements Overall height menu à 1 Switching monitoring function on/off p. 11 - 146 à 2 Apply current overall height p. 11 - 140 à 3 Input maximum overall height p.
Page 459 Operating elements for crane operation 9.1 Overview of the operating elements Working radius menu à 1 Switching monitoring function on/off p. 11 - 146 à 2 Current working radius display p. 11 - 141 à 3 Maximum working radius display p.
Page 460 Operating elements for crane operation 9.1 Overview of the operating elements Slewing angle menu à 1 Switching monitoring function on/off p. 11 - 146 à 2 Maximum slewing angle A display p. 11 - 139 à 3 Current slewing angle A display p.
Page 461 Operating elements for crane operation 9.1 Overview of the operating elements Hoist rope travel limitation menu à 1 Switching monitoring function on/off p. 11 - 146 à 2 Input confirmation display, top p. 11 - 142 à 3 Input confirmation display, bottom p.
Page 462: Information Menu Group 1
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.13 Information menu group 1 à 1 Hydraulic pressure and fuel consumption menu p. 9 - 53 à 2 Datalogger menu (Menu opens on the display RCL) p. 9 - 81 9 - 52 3 302 690 en Operating manual...
Page 463 Operating elements for crane operation 9.1 Overview of the operating elements Hydraulic pressure and fuel consump- tion menu à 1 Angle gear temperature display p. 9 - 128 à 2 Slewing gear hydraulic circuit pressure display p. 9 - 128 à...
Page 464: Heating/Engine/Additional Equipment Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.14 Heating/Engine/Additional equipment menu group à 1 Economy menu p. 9 - 55 à 2 Remote control menu p. 9 - 56 à 3 Heating/ air-conditioning menu p. 9 - 57 à...
Page 465 Operating elements for crane operation 9.1 Overview of the operating elements Economy menu à 1 Switching Economy mode on/off p. 9 - 92 à 2 Set interval 1 p. 9 - 92 à 3 Set interval 2 p. 9 - 92 à...
Page 466 Operating elements for crane operation 9.1 Overview of the operating elements Remote control menu à 1 Remote control menu p. 9 - 132 à 2 Remote control display p. 9 - 132 9 - 56 3 302 690 en Operating manual GMK4100L-1...
Page 467 Operating elements for crane operation 9.1 Overview of the operating elements Heating/ air-conditioning menu à 1 Outdoor temperature display p. 11 - 151 à 2 Air distribution p. 11 - 152 à 3 Setting the temperature p. 11 - 151 à...
Page 468 Operating elements for crane operation 9.1 Overview of the operating elements Spotlights menu à 1 Switching automatic spotlights on/off p. 9 - 147 à 2 Increase the slewing speed p. 9 - 147 à 3 Reduce the slewing speed p. 9 - 147 à...
Page 469: Telescoping Emergency Program Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.15 Telescoping emergency program menu group à 1 Telescoping emergency program menu p. 9 - 60 à 2 Unknown telescoping menu p. 9 - 62 à 3 Swinging the swing-away lattice emergency p.
Page 470 Operating elements for crane operation 9.1 Overview of the operating elements Telescoping emergency program menu 9 - 60 3 302 690 en Operating manual GMK4100L-1...
Page 471 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Input access code emergency program p. 14 - 31 à 2 Remaining time emergency program display p. 14 - 31 à 3 Telescoping cylinder length displays p. 14 - 31 4 –...
Page 472 Operating elements for crane operation 9.1 Overview of the operating elements Unknown telescoping menu à 1 Input access code unknown telescoping p. 14 - 43 à 2 Input for telescopic section 1 p. 14 - 43 à 3 Input for telescopic section 2 p.
Page 473 Operating elements for crane operation 9.1 Overview of the operating elements Swinging the swing-away lattice emergency operation menu 1 Locked automatic slewing warning message 2 Enable/disable telescoping 3 Telescoping cylinder length display 4 Extending/retracting the swivel ram à Lattice extension operating manual Operating manual 3 302 690 en 9 - 63...
Page 474: Settings Menu Group
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.16 Settings menu group à 1 Crane cab menu p. 9 - 65 à 2 Set display brightness and date/time menu p. 9 - 66 à 3 Switch units menu p.
Page 475 Operating elements for crane operation 9.1 Overview of the operating elements Crane cab menu à 1 Windscreen interval duration selection/display p. 9 - 149 à 2 Selection/display of skylight interval duration p. 9 - 149 à 3 Retract/extend step selection p.
Page 476 Operating elements for crane operation 9.1 Overview of the operating elements Set display This is operated in the same way as in the driver's cab. brightness and date/time menu à 1 Selection setting the display brightness p. 4 - 11 à...
Page 477 Operating elements for crane operation 9.1 Overview of the operating elements Switch units menu 1 Display units in: – Metres – Degrees Celsius – Kilograms – Bar à p. 11 - 128 2 Display units in: – Feet – Degrees Fahrenheit –...
Page 478 Operating elements for crane operation 9.1 Overview of the operating elements Set control lever characteristic curve menu 1 Characteristic curve slewing gear 2 Characteristic curve telescoping mechanism 3 Characteristic curve derricking gear à 4 Characteristic curve main hoist p. 11 - 129 5 Auxiliary hoist characteristic curve 6 Lattice extension...
Page 479 Operating elements for crane operation 9.1 Overview of the operating elements Power unit speeds menu 1 Enter slewing gear speed 2 Enter telescoping mechanism speed 3 Enter derricking gear speed à 4 Enter speed – main hoist p. 11 - 125 5 Enter speed –...
Page 480: Information Menu Group 2
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.17 Information menu group 2 à 1 Operating hours menu p. 9 - 71 à 2 Engine/transmission error menu p. 9 - 72 à 3 Crane operation error menu p.
Page 481 Operating elements for crane operation 9.1 Overview of the operating elements Operating hours menu XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX h XXXX n XXXX h XXXX h XXXX h XXXX n XXXX h...
Page 482 Operating elements for crane operation 9.1 Overview of the operating elements Engine/transmis- This is operated in the same way as in the driver's cab. sion error menu 1 Display of error / total errors 2 Engine symbol display 3 Transmission symbol display à...
Page 483 Operating elements for crane operation 9.1 Overview of the operating elements Crane operation error menu 1 Display of error / total errors 2 Error message display à 3 To acknowledge the error p. 14 - 7 4 Previous error 5 Next error Operating manual 3 302 690 en 9 - 73...
Page 484 Operating elements for crane operation 9.1 Overview of the operating elements Program version menu à 1 Serial number display p. 14 - 3 à 2 Program version display p. 14 - 3 9 - 74 3 302 690 en Operating manual GMK4100L-1...
Page 485: Various Controls
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.18 Various controls à 1 Preheating the hydraulic oil p. 9 - 128 à 2 Camera on/off p. 12 - 136 à 3 Override torque reduction p. 11 - 132 à...
Page 486: Rcl Control Unit
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.19 RCL control unit 1 RCL display à 2 USB connection for data export p. 9 - 142 3 No function à 4 Switch off RCL buzzer p. 9 - 98 à...
Page 487: Menu-Independent Displays
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.20 Menu-independent displays à 1 Warning messages display p. 14 - 9 à 2 Working range limiter displays p. 11 - 136 à 3 RCL status display p. 11 - 51 Operating manual 3 302 690 en 9 - 77...
Page 488: Rcl - Menus
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.21 RCL – menus Monitoring menu Depending on the version, the top view in view A is shown, or is shown rotated by 180° in view B. This operating manual shows view A in the subsequent illustrations.
Page 489 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Display RCL code p. 11 - 45 à 1),2) 2 Current lattice extension inclination display p. 11 - 50 à 1),2) Angle of the lattice extension display p.
Page 490 Operating elements for crane operation 9.1 Overview of the operating elements à Lifting capacity The same menu is displayed as shown on the CCS display; p. 9 - 44. tables menu Either the Monitoring menu or the Lifting capacity table menu is displayed. Additionally, the Datalogger menu can be manually opened (from the CCS display).
Page 491 Operating elements for crane operation 9.1 Overview of the operating elements Datalogger menu à 1 Export data p. 9 - 142 à 2 Display of export progress p. 9 - 142 à 3 USB connection for data export p. 9 - 142 Operating manual 3 302 690 en 9 - 81...
Page 492 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 82 3 302 690 en Operating manual GMK4100L-1...
Page 493: Hand-Held Control
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.22 Hand-held control à 1 Engine control panel p. 9 - 151 à 2 Pre-select emergency operation p. 9 - 152 à 3 Function buttons p. 9 - 152 4 no function 5 no function à...
Page 494 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 84 3 302 690 en Operating manual GMK4100L-1...
Page 495: Outriggers Control Units
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.23 Outriggers control units Menu- This function of the illustrated buttons is the same in all the menus. independent This function of the other buttons depends on the opened menu. buttons à...
Page 496 Operating elements for crane operation 9.1 Overview of the operating elements Outrigger menu 9 - 86 3 302 690 en Operating manual GMK4100L-1...
Page 497 Operating elements for crane operation 9.1 Overview of the operating elements Opposite means: on the side of the carrier opposite to the operator when looking at the control unit. Left and right mean: to the left or the right of the control unit. Outriggers à...
Page 498 Operating elements for crane operation 9.1 Overview of the operating elements Raise axle menu à 1 to 4 Pre-selection display p. 9 - 106 Directional indicator à Wheel load display, opposite p. 9 - 107 à Wheel load display, operator's side p.
Page 499: Short Description Of The Operating Elements
If some operating elements do not work, first read the following chap- ters which are referred to at the respective places before contacting Manitowoc Crane Care 9.2.1 Definition of information relating to directions of movement...
Page 500: General Rules For Buttons And Symbols On The Display
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.2 General rules for buttons and symbols on the display The symbols shown as an example are not present on all crane types. The following rules apply in all menus: –...
Page 501: Engine
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.3 Engine à Side panel Starting the engine – from the crane cab , p. 10 - 3. Ignition lock – 0 Ignition off, engine off, key can be removed –...
Page 502: Adblue System
Operating elements for crane operation 9.2 Short description of the operating elements Economy mode menu – To open: Select and confirm symbol (1) Select symbol and confirm for: 1 Switching Economy mode on/off 2 Set interval 1 3 Set interval 2 4 Average consumption à...
Page 503 Operating elements for crane operation 9.2 Short description of the operating elements AdBlue system fault à Faults on the Adblue system , p. 8 - 21 1 – On: Torque reduction indicator lamp 1 – On: Reduction in torque the next time the engine is started 1 –...
Page 504: Seat Contact Switch And Dead Man's Switch
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.5 Seat contact switch and dead man's switch The seat contact switch and the dead man's switch are safety devices for releasing crane functions. Releasing crane functions – Sit down – seat contact switch (2) on –...
Page 505: Crane Control Ccs
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.6 Crane control CCS The GMK4100L-1 truck crane is equipped with the CCS crane control sys- tem. The crane control system consists of a monitor and control unit in the driver's cab and the crane cab.
Page 506 Operating elements for crane operation 9.2 Short description of the operating elements In the menu area – For selecting and opening menus. One symbol is always selected. Select a menu 1 Slewing 2 Press – The next symbol is marked. Open menu 1 Press 3 Press...
Page 507 Operating elements for crane operation 9.2 Short description of the operating elements In the operating area – For carrying out movements during rigging. The required element is marked, e.g. outrigger cylinder (1). – For turning on/off and switching A symbol for a status is marked, e.g. symbol (2). Executing a movement –...
Page 508 Operating elements for crane operation 9.2 Short description of the operating elements Exiting the menu/input mode Press button (1) or (2) to exit the menu or input mode. – Press the button once: – The opened menu closes – the menu from the next higher level is opened –...
Page 509 Operating elements for crane operation 9.2 Short description of the operating elements Display temperature warning display The temperature of the control unit is measured by an internal sensor. – Blue, flashing: Temperature too low – display will not be switched on Temperature too high: –...
Page 510: Outrigger - Crane Cab
Operating elements for crane operation 9.2 Short description of the operating elements Emergency stop switch May only be used in an emergency. – Press: Engine off – crane functions stop immediately. Switch latches – Turn the latched switch: Switch returns to initial position – crane functions released à...
Page 511 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Outrigger menu – To open: Select and confirm symbol (1) Slewing gear/movements locked display – Red: Slewing gear switched off – symbol (1) out – Green: Slewing gear switched on –...
Page 512 Operating elements for crane operation 9.2 Short description of the operating elements Outrigger control units on/off – Switch on: Select symbol (2) and confirm – symbol (1) is grey – Switch off: Select symbol (1) and confirm – symbol (2) is grey à...
Page 513: Outrigger Control Units
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.8 Outrigger control units à Extending/retracting outrigger beams , p. 12 - 47 à Extending/retracting supporting cylinders , p. 12 - 54 à All directional information relates to the carrier; p.
Page 514 Operating elements for crane operation 9.2 Short description of the operating elements Horn The ignition must be switched on. 1 – Press: Carrier horn on Outrigger menu The operating elements for the outriggers are only active when the Outrigger menu is open. Outrigger menu –...
Page 515 Operating elements for crane operation 9.2 Short description of the operating elements Extending/retracting all outrigger cylinders Button (3) or (4) is pressed. 1 Retract: Press button – all outrigger cylinders retract 2 Extend: Press button – all outrigger cylinders extend Movement stops after the button is released, and when an end position is à...
Page 516: Raise Axle
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.9 Raise axle à Operating the axle raising system , p. 12 - 64 Raise axle menu The suspension is switched off (locked). – To open: Press button (2) repeatedly until display (1) appears. The operating elements for raising the axles are only active when the Raise axle menu is open.
Page 517 Operating elements for crane operation 9.2 Short description of the operating elements Lifting/lowering wheels The axle load on the pre-selected wheels lies in the permissible range. The horn sounds when a button is pressed. 1 Raise: Press the button – the selected axles are raised and the truck crane is lowered 2 Lower: Press the button –...
Page 518: Inclination Indicators
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.10 Inclination indicators à Inclination indicators , p. 12 - 58 Display of current inclination A In the Monitoring menu B In the Outrigger menu C On the outrigger control units 1 Measuring range display 2 Inclination indicator 3 Directional indicator...
Page 519: Outrigger Pressure Displays
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.11 Outrigger pressure displays Outrigger menu Outrigger pressure display – Unit of measurement: Displayed depending on setting – t – tons or – klbs – kilopounds – (1 kilopound = 1,000 lbs) –...
Page 520: Counterweight Menu
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.13 Counterweight menu à Rigging/unrigging the counterweight , p. 12 - 69, à Counterweight hoist unit , p. 12 - 85. – To open: Select and confirm symbol (1) Rigging position display 1 White –...
Page 521 Operating elements for crane operation 9.2 Short description of the operating elements Automatic mode, rigging – Display Yellow: Recognition that the counterweight is rigged Flashing: Automatic mode on Grey: Automatic mode cancelled or No recognition that counterweight is rigged The superstructure is within the rigging range, the slewing gear is switched on and the lifting cylinders are retracted –...
Page 522 Operating elements for crane operation 9.2 Short description of the operating elements Lifting cylinder position display The current position of the counterweight lift- ing cylinders is shown by different symbols: 1 Green – extended 2 Green – retracted 3 Yellow – intermediate position 4 Violet –...
Page 523 Operating elements for crane operation 9.2 Short description of the operating elements Slewing release display 1 Green: Slewing enabled (if no other shutdown has occurred). 2 Red: Slewing disabled by counterweight – the corresponding warning is displayed. The pre-tensioning pressure is too low or the counterweight is not completely lifted.
Page 524: Main Hoist
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.14 Main hoist à Main hoist , p. 11 - 75. Control panels Main hoist on/off There is a lamp in the button. – Press once: – Lamp bright – main hoist on –...
Page 525 Operating elements for crane operation 9.2 Short description of the operating elements High speed monitoring for the hoist – On: High-speed mode on – Out: High-speed mode off à p. 11 - 113 Lift/lower the hoist display – Symbol (1): lifting –...
Page 526: Auxiliary Hoist
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.15 Auxiliary hoist à Auxiliary hoist , p. 11 - 79. Control panels Auxiliary hoist on/off There is a lamp in the button. – Press once: – Lamp bright – auxiliary hoist on –...
Page 527 Operating elements for crane operation 9.2 Short description of the operating elements High speed monitoring for the hoists – On: High-speed mode on – Out: High-speed mode off à p. 11 - 113 Lift/lower the hoist display – Symbol (1): lifting –...
Page 528: Slewing Gear
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.16 Slewing gear à Slewing gear , p. 11 - 115. Control panels Slewing gear on/off There is a lamp in the button. – Press once: – Lamp bright – slewing gear on, Slewing gear brake released –...
Page 529 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Power units display – Green: Slewing gear on – Red: Slewing gear off Slewing gear brake engaged/released 1 On: Slewing gear brake applied 1 Out: Slewing gear brake released à...
Page 530: Derricking Gear
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.17 Derricking gear à Derricking gear , p. 11 - 85. Control panels Derricking gear on/off There is a lamp in the button. – Press once: – Lamp bright – derricking gear on, power units with the same control lever configuration off –...
Page 531 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Power units display – Green: Derricking gear on – Red: Derricking gear off High-speed mode inspection derricking gear – On: High-speed mode on – Out: High-speed mode off à...
Page 532: Telescoping Mechanism
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.18 Telescoping mechanism à Control panels Telescoping mechanism , p. 11 - 89. Telescoping mechanism on/off There is a lamp in the button. – Press once: – Lamp bright – telescoping mechanism on, power units with the same control lever configuration off –...
Page 533 Operating elements for crane operation 9.2 Short description of the operating elements CCS display Telescoping mechanism high-speed mode inspection – On: High-speed mode on – Out: High-speed mode off à p. 11 - 113 Power units display – Green: Telescoping mechanism on –...
Page 534 Operating elements for crane operation 9.2 Short description of the operating elements Telescoping cylinder length display – Display: Current extended length of the telescoping cylinder – Unit of measure- Displayed in % (per cent) and, depending on setting, ment: mm (millimetres) or ft (feet) à...
Page 535 Operating elements for crane operation 9.2 Short description of the operating elements Confirm pre-selection 1 Confirm pre-selected telescoping 2 Telescoping permitted display 3 Telescoping not permitted display à p. 11 - 110 Teleautomation direction display 1 Start telescoping full automation with Retract 2 Start telescoping full automation with Extend à...
Page 536 Operating elements for crane operation 9.2 Short description of the operating elements Locking/releasing the telescoping cylinder – To lock: – Telescopic section locked: Select symbol (2) and confirm – telescoping cylinder is locked – To unlock: – Telescopic section locked: Select symbol (1) and confirm –...
Page 537 Operating elements for crane operation 9.2 Short description of the operating elements Locking point display 1 Extend telescoping cylinder 2 Retract telescoping cylinder Telescoping cylinder in the telescopic section display Displayed telescopic section, e.g. telescopic section 1 Telescoping direction display 1 Start with Retract 2 Start with Extend à...
Page 538: Hydraulic System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.19 Hydraulic system Inclining the crane cab – Press down: Incline forward – Press up: Incline back à p. 11 - 123 In Information menu 1 Angle gear oil temperature Current pressure in bar for movements of: 2 Slewing gear 3 Telescoping mechanism...
Page 539: Superstructure Lock/House Lock Menu
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.20 Superstructure lock/house lock menu – To open: Select and confirm symbol (1) à Locking/unlocking the superstructure , p. 11 - 15. Superstructure lock Locking status displays The current position of the locking pin is shown by different symbols: 1 and 7 Red –...
Page 540 Operating elements for crane operation 9.2 Short description of the operating elements Current slewing angle display Position 0° to the rear – locking point 0°: Position 180° to the front – locking point 180°: + 0.1 to +180.0°: Turned to the right from 0° -0.1 to -179.9°: Turned to the left from 0°...
Page 541 Operating elements for crane operation 9.2 Short description of the operating elements à Houselock Switching the houselock on/off , p. 11 - 17. Locking status displays The current position of the locking pin is shown by different symbols: 1 Unlocked 2 Intermediate position 3 Blocked, locking pin in front of a tooth 4 Locked...
Page 542: Remote Control
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.21 Remote control Operating with the remote control is only enabled for the Standard slewing range type. Remote control menu 1 – Orange: Remote control connected 1 – Green: Remote control switched on.
Page 543: Rated Capacity Limiter (Rcl)
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.22 Rated capacity limiter (RCL) CCS display In the Start menu For the Standard slewing range type Only one slewing range is displayed 1 360° slewing range 2 Restricted slewing range, e.g. ±30° 3 Working position, e.g.0°to the rear The displays for working radius, current slew- ing angle and current position are identical to...
Page 544 Operating elements for crane operation 9.2 Short description of the operating elements Maximum permissible working radius display Shows the maximum permissible working radius (5) for each slewing range. 1 Display area – always corresponds to the largest maximum working radius (5) 2 Maximum permissible working radius in the corresponding slewing range with the currently lifted load...
Page 545 Operating elements for crane operation 9.2 Short description of the operating elements Maximum permissible speed display Separate displays are provided for each direction of movement. 1 Slewing to the left 2 Slewing to the right 3 Lower the main hoist 4 Lift the main hoist 5 Lower the auxiliary hoist 6 Lifting the auxiliary hoist...
Page 546 Operating elements for crane operation 9.2 Short description of the operating elements In the Enter rigging mode/telescope status menu Select and confirm the symbol (1) – the menu opens, and opens automati- cally after Ignition on Enter slewing range In input mode Select slewing range symbol and confirm –...
Page 547 Operating elements for crane operation 9.2 Short description of the operating elements Reeving input mode display 1 Main hoist 2 Auxiliary hoist Orange: Grey: à Enter rigging mode , p. 11 - 32 Enter reeving 1 Main hoist In input mode – select and confirm current reeving 2 Auxiliary hoist –...
Page 548 Operating elements for crane operation 9.2 Short description of the operating elements Boom system display A Main boom display B Lattice extension display C Heavy load lattice extension display 1 Angle of the lattice extension display (for inclinable lattice extension) Boom system entry For the Standard slewing range type only.
Page 549 Operating elements for crane operation 9.2 Short description of the operating elements Accept the measured outrigger span Select and confirm – the outrigger span provided by the outrigger width monitoring is adopted and shown on the Enter outrigger span display; à...
Page 550 Operating elements for crane operation 9.2 Short description of the operating elements Outrigger span monitoring display (standard) Query after confirming the rigging mode. A Measured outrigger width = required width B Measured outrigger span ≠ of required span (query menu) 2 Required outrigger width –...
Page 551 Operating elements for crane operation 9.2 Short description of the operating elements In the Pre-selection telescoping menu à Pre-selecting telescoping , p. 11 - 40 Enter desired parameter In input mode – select and confirm parame- ters (1), (2). 1 Selection of numerical values 2 Selection by marking the segments –...
Page 552 Operating elements for crane operation 9.2 Short description of the operating elements In the Datalogger menu à Datalogger , p. 11 - 68 – To open: Select and confirm symbol (1) In the Datalogger menu RCL display à Datalogger , p. 11 - 68 USB connection for data export 1 Connect the USB stick –...
Page 553 Operating elements for crane operation 9.2 Short description of the operating elements RCL override – This version only applies to RCL programming as per EN 13000. à version A For other RCL programming; p. 9 - 144. Overriding the RCL RCL shutdown overridden –...
Page 554 Operating elements for crane operation 9.2 Short description of the operating elements RCL override – This point only applies to RCL programming deviating from EN 13000. à version B For RCL programming in accordance with EN 13000; p. 9 - 143. Overriding the RCL in an emergency RCL shutdown overridden –...
Page 555: Electrical System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.23 Electrical system Voltage monitoring warning – Display symbol: Engine on – power failure – switch off engine – Out: Engine on – no fault à p. 10 - 8 Sockets 12 V 1 Socket 12 V/max.
Page 556: Lighting, Windscreen Wiper/Washing System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.24 Lighting, windscreen wiper/washing system Lighting Air traffic control light on/off Select symbol (1) and confirm – symbol ON is displayed – Switch on: Select symbol (2) and confirm – symbol OFF is displayed –...
Page 557 Operating elements for crane operation 9.2 Short description of the operating elements Slewable spotlights on/off – Switch on: Push down – lamp in the button on – Switch off: Push up – lamp in the button off à p. 11 - 130 Slew slewable spotlight –...
Page 558 Operating elements for crane operation 9.2 Short description of the operating elements Reading lamp 1 On 2 Off Windscreen wiper/washing system Windscreen wiper on/off – Off: Middle position – Interval: Push up – wiper goes to end position – Continuous operation: Push down Roof window wiper on/off –...
Page 559 Operating elements for crane operation 9.2 Short description of the operating elements Crane cab menu To open: Select symbol (1) and confirm – menu is opened Adjusting the wiper stroke interval 1 Windscreen wiper selection, display (5) 2 Skylight wiper selection, display (6) 7 Changing the interval duration Wiper interval in seconds for 3 Windscreen wiper...
Page 560: Hand-Held Control
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.25 Hand-held control Sockets for hand- The following applies to all sockets: held control – Pull plug: Engine off – ignition off – Insert plug: Switch the ignition on à...
Page 561 Operating elements for crane operation 9.2 Short description of the operating elements à Engine control Starting the engine – with the hand-held control , p. 10 - 10 panel 1 Voltage monitoring – On: Switch the ignition on – Out: Switch the ignition off 2 CAN monitoring –...
Page 562 Operating elements for crane operation 9.2 Short description of the operating elements Pre-select emergency operation 1 Main hoist 2 Telescoping mechanism 3 Derrick lattice extension 4 Auxiliary hoist 5 Derricking gear 6 Slewing gear Lattice extension derricking gear Actuation is the same for all buttons –...
Page 563 Operating elements for crane operation 9.2 Short description of the operating elements Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoists mechanism gear gear extension combination Lower lowering Lower Retract raise lifting raise slew to right slew to left à Emergency operation with the hand-held control , p.
Page 564: Windows And Doors
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.26 Windows and doors Window The handles on the windscreen and the rear window have the same function. Open window (A) • Turn both handles (1) inward. • Push the window forward.
Page 565 Operating elements for crane operation 9.2 Short description of the operating elements Crane cab door From outside Unlocking • Turn the key in direction A. Locking • Turn the key in direction B. Open/close • Pull the handle (1). • Slide the door.
Page 566: Diagnostics
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.27 Diagnostics The diagnostics connections may only be operated by the service personnel. The following connections are below the cover (4) 1 CCS diagnostics – (serial interface) 2 CCS diagnostics – CAN bus 3 RCL diagnostics Additional diagnostic and service connections are present on the CCS and RCL control...
Page 567: Short Description Of The Operating Elements - Driving From The Crane Cab
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Short description of the operating elements – driving from the crane cab 9.3.1 Driving mode menu Driving mode menu – To open: Select symbol (1) and confirm –...
Page 568: Transmission
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.2 Transmission The following applies to all operating elements: – The Driving mode menu is opened automatically – The Service brake pedal must be applied, –...
Page 569: Final Drive
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.3 Final drive Driving mode menu To open: Select symbol (1) and confirm – menu is opened Transverse differential locks on/off – Switch on: Select symbol (1) and confirm –...
Page 570 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Longitudinal differential lock display The current status is shown using different symbols: 1 Green – lock off 2 Red – lock on 3 Yellow –...
Page 571: Brakes
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.4 Brakes Service brake pedal Affects the carrier brakes – the braking force can be steplessly adjusted. CCS display Supply pressure brake circuits 1 and 2 display –...
Page 572 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Side panel from above Parking brake indicator lamp – On: Parking brake applied – Out: Parking brake released Applying/releasing the parking brake –...
Page 573: Steering
Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab 9.3.5 Steering CCS display Changing the steering direction Depending on the superstructure position, the display (1) changes automatically to the appropriate steering direction. à...
Page 574 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Separate steering In the driver's cab: The ignition key must be in position 1. Crane cab – The parking brake must be released. Steering locking status display The current status is shown using different symbols:...
Page 575 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Normal steering mode / on-road driving, on/off – Switch on: Select symbol (1) and confirm – Symbol (2) is displayed – Switch off: Select a different steering mode –...
Page 576 Operating elements for crane operation 9.3 Short description of the operating elements – driving from the crane cab Blank page 9 - 166 3 302 690 en Operating manual GMK4100L-1...
Page 577: Starting/Switching Off The Engine - For Crane Operation
Starting/switching off the engine – for crane operation 10.1 When starting the engine for the first time in the day Starting/switching off the engine – for crane operation You must start the engine from the crane cab for crane operation. If the engine has been started from the carrier, then you must shut it down in the carrier and switch off the ignition before crane operation.
Page 578 Starting/switching off the engine – for crane operation 10.1 When starting the engine for the first time in the day When not driving from the crane cab: • Remove the ignition key. If you want to drive from the crane cab: •...
Page 579: Starting The Engine - From The Crane Cab
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2 Starting the engine – from the crane cab 10.2.1 Check the fuel level and AdBlue level • Check the fuel level and the AdBlue level if necessary, before starting the engine.
Page 580: Checks Before Starting The Engine
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.2 Checks before starting the engine Checks on the All checks and switch positions for the first engine start of the day must be à...
Page 581: Switch The Ignition On
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.3 Switch the ignition on DO not start the engine until the CCS display shows a menu (usually the Enter rigging mode menu). •...
Page 582: Comparison Of Switching States
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.4 Comparison of switching states When the ignition is switched on, the switching states of the differential locks and the separate steering are compared. Differential locks The state last saved is retrieved.
Page 583: Starting The Engine
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.6 Starting the engine This section pertains to starting a warm and cold engine. Danger of explosion when using starter fuel The engine may never be started with the aid of starter fuel. The starter fuel sprayed into the intake manifold can ignite.
Page 584: Checks After Starting The Engine
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.7 Checks after starting the engine • Check the display (1) on the CCS control unit immediately after starting the engine. When a symbol is displayed in the display à...
Page 585: Setting The Idling Speed
Starting/switching off the engine – for crane operation 10.2 Starting the engine – from the crane cab 10.2.8 Setting the idling speed à • Start the engine; p. 10 - 7. • Open the start menu – button (1). The display (2) shows the current engine speed You can increase the idling speed for crane operation.
Page 586: Starting The Engine - With The Hand-Held Control
Starting/switching off the engine – for crane operation 10.3 Starting the engine – with the hand-held control 10.3 Starting the engine – with the hand-held control You can only start the engine when bridging plugs are inserted in all sockets à...
Page 587: Switch Off The Engine
Starting/switching off the engine – for crane operation 10.4 Switch off the engine 10.4 Switch off the engine 10.4.1 At the ignition lock and with hand-held control Risk of accident by suspended loads Never switch off the engine whilst a load is suspended. You must have the control levers at hand in order to intervene at any time.
Page 588: Using The Emergency Stop Switches
Starting/switching off the engine – for crane operation 10.4 Switch off the engine 10.4.3 Using the emergency stop switches Risk of overloading if used improperly Use the emergency stop switches only in an emergency, i.e. if the crane functions no longer respond to the control levers. Stopping crane movements suddenly may cause the truck crane to become overloaded under unfavourable conditions.
Page 589: Crane Operation
Crane operation 11.1 Before operating the crane Crane operation 11.1 Before operating the crane 11.1.1 CHECKLIST: Checks before operating the crane 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 there. This checklist only applies to working with a rigged truck crane (supported and rigged with counterweight).
Page 590 Crane operation 11.1 Before operating the crane à 3. – Switch on the cameras for crane operation; p. 12 - 130. à – Adjust the slewable spotlights if necessary; p. 11 - 130. à 4. Crane cab heater – check the fuel level; p.
Page 591 Crane operation 11.1 Before operating the crane à 9. Check the position of the hoist ropes; p. 11 - 6. 10. Compare current rigging mode with the RCL display – enter and à confirm current rigging mode, if necessary; p. 11 - 32. à...
Page 592 Crane operation 11.1 Before operating the crane à 14. Check hydraulic oil temperature, preheat if necessary; p. 11 - 14. à 15. Adjust the brightness of the CCS display if necessary; p. 10 - 6. Additional information on inspections during crane operation, on permissi- ble working positions and on how to operate the individual power units;...
Page 593: Check The Condition Of The Truck Crane
Crane operation 11.1 Before operating the crane 11.1.2 Check the condition of the truck crane Fuel tank auxiliary Use the same fuel as for the engine or use EL heating oil for refuelling. heater Danger of fire due to flammable gases Turn off the engine and heating systems before refuelling.
Page 594 Crane operation 11.1 Before operating the crane Checking the position of the hoist ropes Risk of crushing due to turning rope drum Keep away from the rope drum while it is turning. This will prevent your limbs being drawn in or crushed. •...
Page 595 Crane operation 11.1 Before operating the crane • Checking the Check the following functions and have faulty parts repaired. electrical system – Working area spotlight – Air traffic control light, rotating beacons – Windscreen wipers, windscreen washing system – Horn. Operating manual 3 302 690 en 11 - 7...
Page 596: Adjusting The Crane Cab Seat And Front Control Panel
Crane operation 11.1 Before operating the crane 11.1.3 Adjusting the crane cab seat and front control panel Crane cab seat You can adjust the crane cab seat to your height. Version 1 1 Control panel right – height 2 Control panel left – height 3 Back rest –...
Page 597 Crane operation 11.1 Before operating the crane Front control You can adjust the height and inclination. panel • Pull and hold the handle (1). • Adjust the front panel to suit your requirements. • Release the handle (1). In addition, the inclination of the display can be adjusted: •...
Page 598: Checking The Safety Equipment
It is prohibited to operate the crane with safety devices that are faulty, overridden or out of service. Have faulty safety devices repaired immediately by Manitowoc Crane Care • Rated capacity Switch on the rated capacity limiter (RCL), do all of the checks and enter à...
Page 599 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 Operating manual 3 302 690 en 11 - 11...
Page 600 3 seconds. If the dead man's switch system is not working correctly, do not start work with the crane but notify Manitowoc Crane Care 11 - 12 3 302 690 en Operating manual...
Page 601: Earthing The Load
Crane operation 11.1 Before operating the crane 11.1.5 Earthing the load à Even if the truck crane is already earthed ( p. 12 - 15), the load may become charged with static electricity. For example, if a hook block with synthetic sheaves or non-conducting sling gear is used.
Page 602: Preheating Hydraulic Oil
Crane operation 11.1 Before operating the crane 11.1.6 Preheating hydraulic oil It may take some time for the solenoid valves to be switched or the power units may be started abruptly if the oil is cold. The current hydraulic oil temperature is displayed in the start menu. For crane operation with loads and without speed limitation, the hydraulic oil temperature must be at 10 °C (50 °F).
Page 603: Locking/Unlocking The Superstructure
Crane operation 11.1 Before operating the crane 11.1.7 Locking/unlocking the superstructure To lock, a pin can extend on the turntable and engage in two locking points on the carrier. Locking points The locking points are at 0° and at 180°. •...
Page 604 (2) and shows symbol (6) when the super- structure is locked. The symbol (7) disappears. If the error symbol (3) is displayed, contact Manitowoc Crane Care Unlocking the The RCL shutdown procedure will be triggered and slewing disabled if you superstructure unlock the superstructure during a rigging mode for 0°...
Page 605: Switching The Houselock On/Off
Crane operation 11.1 Before operating the crane 11.1.8 Switching the houselock on/off If the truck crane is equipped with a houselock, the turntable can be locked in the entire slewing range. For locking, a pin extends and blocks the slew- ing gear.
Page 606 Crane operation 11.1 Before operating the crane Switching on the houselock • Select the symbol (5). • Press the button until the symbol (4) is displayed – Houselock switched on . The display first shows the symbol (1), then (2) and then shows the symbol (4) when the houselock is switched on.
Page 607 Crane operation 11.1 Before operating the crane • Switching off the Check that the slewing gear is switched off, and switch if off if it is not; à Switching off the slewing gear , p. 11 - 17. houselock Risk of damage during slewing! Always switch off the slewing gear before you operate the houselock.
Page 608 Crane operation 11.1 Before operating the crane Blank page 11 - 20 3 302 690 en Operating manual GMK4100L-1...
Page 609: Standard Slewing Range Type
Crane operation 11.2 Standard slewing range type 11.2 Standard slewing range type The MAXbase slewing range type is available in the case of additional equip- à MAXbase slewing range type , p. 11 - 23. ment; The Standard slewing range type is always available. The supplied lifting capacity tables with symmetrical outrigger spans apply.
Page 610 Crane operation 11.2 Standard slewing range type Blank page 11 - 22 3 302 690 en Operating manual GMK4100L-1...
Page 611: Maxbase Slewing Range Type
Crane operation 11.3 MAXbase slewing range type 11.3 MAXbase slewing range type This slewing range type is available in addition to the Standard slewing à Permissible slewing ranges and working positions , p. 11 - 21. range type; You must decide between the two slewing range types when entering the rigging mode.
Page 612: Specifications In The Lifting Capacity Tables
Crane operation 11.3 MAXbase slewing range type 11.3.1 Specifications in the lifting capacity tables The specified lifting capacities are only enabled for specific slewing ranges. The lifting capacity table contains a direction specification for the enabled slewing range, which is assigned to a superstructure position. Positional Superstructure reference...
Page 613 Crane operation 11.3 MAXbase slewing range type 11.3.2 Enabled slewing ranges The enabled angular ranges around the starting point are specified in the lifting capacity table . This section provides an overview of where the enabled slewing ranges begin and end for each slewing angle. Smallest individual width 3.600 m (11.8 ft) This case applies only to a symmetrical outrigger span with a span of 7.200 m (23.6 ft).
Page 614 Crane operation 11.3 MAXbase slewing range type Smallest individual width 2.650 m (8.7 ft) This case applies when one or more outrigger beams is extended to a span of 2.650 m (8.7 ft) and all other outrigger beams are extended to larger spans.
Page 615 Crane operation 11.3 MAXbase slewing range type Smallest individual width 1.170 m (3.8 ft) This case applies when one outrigger beam is extended to a span of 1.170 m (3.8 ft) and all other outrigger beams are extended to larger spans.
Page 616: Lifting Capacities And Slewing Ranges For Outrigger Spans Without Separate Lifting Capacity Tables
Crane operation 11.3 MAXbase slewing range type 11.3.3 Lifting capacities and slewing ranges for outrigger spans with- out separate lifting capacity tables In the case of outrigger spans where the opposing outrigger beams at the right and left sides are extended to different lengths, lifting capacity tables are only available for combinations where the outrigger span at the right side is greater than at the left side.
Page 617: Operation Of The Rated Capacity Limiter
Crane operation 11.4 Operation of the rated capacity limiter 11.4 Operation of the rated capacity limiter The rated capacity limiter is abbreviated to RCL (Rated-Capacity-Limiter) in these operating instructions. If the truck crane's current rigging mode is registered properly, the RCL will prevent the permissible lifting capacity from being exceeded and the truck crane from being overloaded.
Page 618: Switch On The Rcl
Risk of accidents in the event of faulty safety devices! If the lamps or buzzer fail, notify and have the error Manitowoc Crane Care corrected. In the meantime, pay particular attention to the lamps in the event of a fail- ure of the buzzer tone and vice versa.
Page 619 Crane operation 11.4 Operation of the rated capacity limiter Temperature on the display The brightness is reduced automatically if the temperature at the display is too high. Do not cover the sensors (1) and keep them clean to avoid contamination that can affect the brightness adjustment.
Page 620: Enter Rigging Mode
Crane operation 11.4 Operation of the rated capacity limiter 11.4.2 Enter rigging mode Notes on Input You can enter the rigging mode for various different purposes. – Entry for crane operation You enter the current rigging mode, select a telescope status according to the lifting capacity table and confirm the rigging mode to enable the crane functions.
Page 621 Crane operation 11.4 Operation of the rated capacity limiter Enter the slewing Possible types are the Standard slewing range type and, with the corre- sponding equipment, the MAXbase slewing range type. range type Different lifting capacity tables apply depending on the entered slewing range type and these then influence further input of the rigging mode.
Page 622 Crane operation 11.4 Operation of the rated capacity limiter For the Standard slewing range type • Select and confirm the display (1). • Select and confirm the symbol for the desired slewing range. 2 360° slewing range 3 Working position 0° to the rear 4 Limited slewing range 5 Working position –...
Page 623 Crane operation 11.4 Operation of the rated capacity limiter The displayed menu depends on the slewing range type. A Menu for Standard B Menu for MAXbase The selection is not restricted when you adhere to this sequence when entering the data. 1 Slewing range –...
Page 624 Crane operation 11.4 Operation of the rated capacity limiter Outrigger span You can adopt the outrigger span provided by the outrigger width monitor- ing or manually enter the outrigger span. Adopt the outrigger span • Select and confirm the symbol (2). The outrigger span provided by the outrigger width monitoring is adopted and shown on the current display (1).
Page 625 Crane operation 11.4 Operation of the rated capacity limiter Enter outrigger span ( MAXbase ) The outrigger spans are entered as individual widths. If the lifting capacity table specifies an overall width then select the associated individual width. Overall width Individual width 7.200 m (23.6 ft) 3.600 m (11.8 ft)
Page 626 Crane operation 11.4 Operation of the rated capacity limiter Counterweight • Select and confirm the display (1). • Select the rigged counterweight combina- tion, for example, 16.5 t. • Confirm the selection. The display (2) shows the entered counter- weight combination. Boom system For the Standard slewing range type only.
Page 627 Crane operation 11.4 Operation of the rated capacity limiter The confirmed boom system (1) or (2) is displayed. Reeving • (A) – Select and confirm the display for the hoist to be used for lifting the load, for example, display (1) for the main hoist – symbol (3) is orange.
Page 628: Pre-Selecting Telescoping
Crane operation 11.4 Operation of the rated capacity limiter Entering the You must enter the RCL code for the rigging mode according to the lifting capacity table . RCL code • Refer to the lifting capacity table for the current rigging mode. The corresponding RCL code (1) is specified at the bottom of the table (e.g.
Page 629: Confirm The Rigging Mode And Lifting Capacity Table
Crane operation 11.4 Operation of the rated capacity limiter 11.4.4 Confirm the rigging mode and lifting capacity table You must confirm the rigging mode together with the display lifting capac- ity table before commencing crane operation. Some parts of the procedure are different, depending on the entered slewing range type.
Page 630 Crane operation 11.4 Operation of the rated capacity limiter • Select and confirm the symbol (1). If the rigging mode is permissible The rigging mode is accepted together with the display lifting capacity table. The RCL display shows the Monitoring menu. The CCS display shows the Start menu .
Page 631 Crane operation 11.4 Operation of the rated capacity limiter Risk of accident due to incorrectly supported truck crane! A shutdown is not initiated as standard when an outrigger span monitoring error message is issued. When an error message is displayed, compare the rigged outrigger span with the required outrigger span and rig the required outrigger span.
Page 632 Crane operation 11.4 Operation of the rated capacity limiter • Select and confirm the symbol (1). If the rigging mode is permissible The rigging mode is accepted together with the display lifting capacity table. The RCL display shows the Monitoring menu. The CCS display shows the Start menu .
Page 633: Checks Before Operating The Crane
Crane operation 11.4 Operation of the rated capacity limiter 11.4.5 Checks before operating the crane Monitoring menu Crane operation is only enabled when the Monitoring menu is open. The menu is opened and exited automatically only, as a reaction to com- mands on the CCS display.
Page 634 Crane operation 11.4 Operation of the rated capacity limiter Boom system display Shows the boom system corresponding to the confirmed rigging mode. A Main boom B Swing-away lattice extension / boom extension C Heavy load lattice extension For the Standard slewing range type only. The lattice extension must be electrically connected.
Page 635 Crane operation 11.4 Operation of the rated capacity limiter Hoist checking You must check that the RCL uses the correct reeving data. The RCL always uses the reeving data for the first hoist to be switched on. • Check the symbol (1) or (2) for the hoist with which you wish to lift the load.
Page 636 Crane operation 11.4 Operation of the rated capacity limiter Blank page 11 - 48 3 302 690 en Operating manual GMK4100L-1...
Page 637: Display During The Crane Operation
Crane operation 11.4 Operation of the rated capacity limiter 11.4.6 Display during the crane operation Various different information is shown on the RCL display and CCS display. This section describes only the displays that change during crane operation. On the RCL All displays are shown in the Monitoring menu.
Page 638 Crane operation 11.4 Operation of the rated capacity limiter Status display for current main boom angle Shows the current main boom angle in relation to the horizontal. Angles below the horizontal are displayed with a minus sign, for example, -3°. A luffing jib is connected.
Page 639 Crane operation 11.4 Operation of the rated capacity limiter Maximum load display Shows the maximum load that can be lifted in the current rigging mode with the current working radius. Values are displayed in tons (t) or in pounds (lbs) – for the confirmed rigging mode.
Page 640 Crane operation 11.4 Operation of the rated capacity limiter Telescoping cylinder position display The bar (2) shows the telescoping length of the telescoping cylinder – the total bar length corresponds to 100%. Telescoping direction display The display is only active when telescoping with teleautomation and shows the direction in which you must move the control lever for each respective telescoping direction.
Page 641 Crane operation 11.4 Operation of the rated capacity limiter On the CCS After confirming a permissible rigging mode, the Start menu opens automat- display ically. Slewing range type Standard à If the MAXbase slewing range type has been entered; p. 11 - 55. The RCL display differs according to the confirmed slewing range.
Page 642 Crane operation 11.4 Operation of the rated capacity limiter Limited slewing range The diagram (1) shows the enabled slewing range and the slewing range limits (3), for example, +30° and -30°. – When telescoping or derricking The diagram (1) remains at the current posi- tion.
Page 643 Crane operation 11.4 Operation of the rated capacity limiter Slewing range type MAXbase à If the Standard slewing range type has been entered; p. 11 - 53. Display of the slewing ranges The RCL display represents the four enabled slewing ranges in a diagram with four regions.
Page 644 Crane operation 11.4 Operation of the rated capacity limiter To enable the slewing movement, you must reduce the working radius correspondingly, for example, to 16 m (52.5 ft) for slewing into slewing range – When telescoping or derricking The diagram remains at the current posi- tion.
Page 645: Rcl Early Warning
Crane operation 11.4 Operation of the rated capacity limiter 11.4.7 RCL early warning If about 90% of the maximum permissible load is exceeded, an RCL early warning will be issued. – An intermittent buzzer tone will sound. After five seconds, you can switch off the buzzer tone using button (3) or (4).
Page 646 Crane operation 11.4 Operation of the rated capacity limiter – All crane movements which increase the load moment will be switched off. – A continuous buzzer tone will sound. After five seconds, you can switch off the buzzer tone using button (6) or (7). –...
Page 647: Displaying The Lifting Capacity Tables
Crane operation 11.4 Operation of the rated capacity limiter 11.4.9 Displaying the lifting capacity tables Open menu • Open the lifting capacity table menu (1) on the CCS control unit. Exiting the menu • Press the button (1) or press the button (2) on the CCS control unit once – the Start menu opens.
Page 648 Crane operation 11.4 Operation of the rated capacity limiter Limitation due to reeving If the maximum load is limited due to the con- firmed reeving then the disabled range is marked. I Display for main hoist, for example, maximum load 12 t II Display for main hoist, for example, maximum load 18 t Slewing range display...
Page 649 Crane operation 11.4 Operation of the rated capacity limiter à Slewing range If the Standard slewing range type has been entered; p. 11 - 59. type MAXbase Permissible working range display The displays apply to the confirmed rigging mode. 1 Slewing range display – four slewing ranges, marked in colour 2 Display of permissible working ranges –...
Page 650 Crane operation 11.4 Operation of the rated capacity limiter Slewing range display The display is same in all four slewing ranges. 1 Coloured: Enabled slewing range, for example, blue 2 Yellow/red: Shutdown range for maximum working radius 3 White: Shutdown range for minimum working radius – display only when the lifting capacity table specifies a limitation When slewing The symbol (1) for the superstructure always...
Page 651 Crane operation 11.4 Operation of the rated capacity limiter 11.4.10 RCL override – version A This section applies only when the supplied lifting capacity table contains the entry EN 13000 in the header (1). à RCL override – version B , p. 11 - 67. In the case of other entries;...
Page 652 Crane operation 11.4 Operation of the rated capacity limiter When rigging For rigging work, you can: à – override the lifting limit switch; p. 11 - 83 – override the RCL and thus enable a degree of utilisation of up to 110%. Risk of accidents if the RCL is overridden! It is not permitted to work with an overridden RCL! Use this type of override only for rigging.
Page 653 Crane operation 11.4 Operation of the rated capacity limiter To raise the boom You can release the raise boom function for derricking again within the per- mitted working range. This function is only active if the current degree of utilisation lies above 100% and the crane movements are switched off.
Page 654 Crane operation 11.4 Operation of the rated capacity limiter In emergencies During this type of override, the complete shutdown of the RCL is cancelled and no monitoring takes place. Risk of accidents due to overridden or faulty RCL It is not permitted to work with an overridden or faulty RCL. Set down the load immediately and stop operating the crane if the RCL is faulty.
Page 655: Rcl Override - Version B
Crane operation 11.4 Operation of the rated capacity limiter 11.4.11 RCL override – version B This section applies only when the supplied lifting capacity tables contain an entry other than EN 13000 in the header (1), for example, the entry ASME . à...
Page 656: Datalogger
Crane operation 11.4 Operation of the rated capacity limiter 11.4.12 Datalogger You can export data from the CCS crane control system to a USB stick and display this on a PC using the CraneEvaluation program supplied. • Open the Datalogger (1) menu. Export data You require a USB Stick (USB 2.0 / FAT32 file system / approx.
Page 657 Crane operation 11.4 Operation of the rated capacity limiter Display the data You need the CraneEvaluation program in order to display the exported data. The installation program is located in the CraneEvaluation folder on the Owner's USB stick supplied. Import data •...
Page 658 Crane operation 11.4 Operation of the rated capacity limiter Displaying the graphic • Select the desired period (7) and desired graphic. 1 Crane use (offers the greatest variety of information) 2 Lifting duration per utilisation area 3 Number of lifts per day 4 Number of lifts per reeving 5 Number of lifts per utilisation area 6 Wind speed for each day...
Page 659 Crane operation 11.4 Operation of the rated capacity limiter Displaying tables • Select the symbol (1) – a table is displayed. 2 List with all lifts 3 List with all events 4 List with all actuated switches When the Crane use graphic is also open, an element is displayed and marked in the respective other window when clicked.
Page 660 Crane operation 11.4 Operation of the rated capacity limiter Blank page 11 - 72 3 302 690 en Operating manual GMK4100L-1...
Page 661: Crane Operation With Main Boom
Crane operation 11.5 Crane operation with main boom 11.5 Crane operation with main boom 11.5.1 Checks during crane operation Horizontal During crane operation, the truck crane may tilt if the ground gives way due alignment to varying loads. Risk of accidents if the truck crane is not level The RCL calculates the working radius from the length and angle of the main boom.
Page 662 Crane operation 11.5 Crane operation with main boom Checking the Strong winds can result in the truck crane becoming overloaded. wind speed • Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed. The display (1) shows the current wind speed.
Page 663: Main Hoist
Crane operation 11.5 Crane operation with main boom 11.5.2 Main hoist You can reeve the hoist rope of the main hoist on the main boom or on the lattice extension. Risk of accidents from accidentally operating a hoist Always switch off the hoist that is not in use. Never operate the hoist if the hook block is unreeled and the hoist rope is completely wound onto the drum.
Page 664 Crane operation 11.5 Crane operation with main boom Switching on After the ignition is switched on, all of the power units will be switched off the main hoist and the lamps in the corresponding buttons will light up only dimly. •...
Page 665 Crane operation 11.5 Crane operation with main boom Raising: Pull the control lever to the rear – symbol (3) is displayed. Lowering: Pull the control lever to the front – symbol (2) is displayed. When the hoist drum is turning, you will notice a pulse on the slewing indicator (1).
Page 666 Crane operation 11.5 Crane operation with main boom Switching off the If you no longer require the main hoist, you should switch it off to avoid main hoist unintentional use. • Press the button (1) once. – The lamp in the button (1) will light up dimly. –...
Page 667: Auxiliary Hoist
Crane operation 11.5 Crane operation with main boom 11.5.3 Auxiliary hoist Risk of accidents when operating the auxiliary hoist Read and observe all of the safety instructions in the section titled Main hoist , p. 11 - 75 before operating the auxiliary hoist. All safety instructions for the operation of the main hoist also apply to the auxiliary hoist, along with the information in this section.
Page 668 Crane operation 11.5 Crane operation with main boom • Check whether the current reeving of the auxiliary hoist is displayed, à for example, 6. Correct the reeving if necessary; p. 11 - 39. Lifting and You can adjust the sensitivity of the control levers to suit the operating à...
Page 669 Crane operation 11.5 Crane operation with main boom You can set the desired engine speed (idling speed) with button (1); à p. 10 - 9. Maximum permis- The maximum permissible hoist rope speed is limited automatically sible hoist rope depending on the degree of utilisation of the lifting capacity and reeving. speed The scale of the limitation is specified in the supplied lifting capacity table .
Page 670: Lifting Limit Switch And Lowering Limit Switch
Crane operation 11.5 Crane operation with main boom 11.5.4 Lifting limit switch and lowering limit switch à Lifting limit switch To install/remove the lifting limit switch; p. 12 - 120. The lifting limit switch (1) prevents the hook block being lifted up to the main boom head and damaging it.
Page 671 Crane operation 11.5 Crane operation with main boom Lifting limit switch override When overriding, the shutdown of the lifting limit switch is cancelled and the crane operation is no longer completely monitored. Risk of accidents if the lifting limit switch is overridden You may override the lifting limit switch only if this is specified in the oper- ating instructions for carrying out maintenance or rigging work.
Page 672 Crane operation 11.5 Crane operation with main boom Lowering limit switch The lowering limit switch (1) prevents the hoist rope being reeled com- pletely off the drum. The lowering limit switch works only if the switch-off point is set correctly à...
Page 673: Derricking Gear
Crane operation 11.5 Crane operation with main boom 11.5.5 Derricking gear You can raise and lower the main boom. Depending on the size of the load and the rigging mode, the RCL will switch off the lowering process of the boom as soon as leaving the working area specified in the Lifting capacity table .
Page 674 Crane operation 11.5 Crane operation with main boom Raising and You can adjust the sensitivity of the control levers to suit the operating con- à Setting the characteristic curves for the control levers , p. 11 - 129. lowering ditions; Risk of accident due to unexpected crane movements! If assigned more than one function, check whether the Derricking control lever function is switched on before you move the control lever for...
Page 675 Crane operation 11.5 Crane operation with main boom You can set the desired engine speed (idling speed) with button (1); à p. 10 - 9. Maximum The maximum permissible derricking speed is limited automatically derricking speed depending on the system length. The scale of the limitation is specified in the supplied lifting capacity table.
Page 676 Crane operation 11.5 Crane operation with main boom Switching off the If the derricking gear is not required, it should be switched off to avoid derricking gear unintentional use. • Press the button (1) once. – The lamp in the button (1) will light up dimly. –...
Page 677: Telescoping Mechanism
Crane operation 11.5 Crane operation with main boom 11.5.6 Telescoping mechanism A telescoping process requires locking and unlocking processes in the main boom. You can telescope the main boom in different ways. – Manual telescoping For manual telescoping, you must initiate all locking and unlocking proc- esses at the right time.
Page 678 Crane operation 11.5 Crane operation with main boom Blank page 11 - 90 3 302 690 en Operating manual GMK4100L-1...
Page 679 Crane operation 11.5 Crane operation with main boom Overview This illustration shows the completely retracted main boom with the basic section (9) and the first three telescopic sections I to III (1) to (3). Each telescopic section is equipped with two locking pins (7) which are extended by spring force.
Page 680 Crane operation 11.5 Crane operation with main boom Telescoping This state should be the starting point for a telescoping process. A telescop- process ing processes consist of 4 steps: 1. Unlocking the telescoping cylinder The locking pins (5) retract – the telescoping cylinder is unlocked.
Page 681 Crane operation 11.5 Crane operation with main boom 3. Unlocking 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. 4.
Page 682 Crane operation 11.5 Crane operation with main boom Assignment for The CCS display shows a sectional view of the main boom in the menus. display The following elements are displayed: 0 Basic section 1 Telescopic section I 2 Telescopic section II 3 Telescopic section III 4 Locking pin on the telescopic section 5 Locking pins on the telescoping cylinder...
Page 683 Crane operation 11.5 Crane operation with main boom Fixed length, There are lifting capacity tables for main boom fixed lengths, main boom intermediate intermediate lengths and main boom telescoping lengths. length, telescop- The lengths are automatically detected by the RCL, and the corresponding lifting capacities according to the lifting capacity table are enabled and dis- ing length played automatically.
Page 684 Crane operation 11.5 Crane operation with main boom Telescoping The position of the telescopic sections, i.e. which telescopic section is extended to what extent, is referred to as telescoping. The CCS display shows main boom fixed lengths and main boom interme- diate/telescoping lengths in different ways.
Page 685 Crane operation 11.5 Crane operation with main boom Inspections prior When the ignition is turned on, CCS registers the displayed telescoping sta- to starting tus from the current status of the telescoping mechanism and the previ- operations ously saved locking and unlocking procedures. Normally, CCS detects differences between the current and the displayed à...
Page 686 Crane operation 11.5 Crane operation with main boom Switching on After the ignition is switched on, all of the power units will be switched off the telescoping and the lamps in the corresponding buttons will light up only dimly. mechanism •...
Page 687 Crane operation 11.5 Crane operation with main boom The distance between the hook block and the boom head changes during telescoping. Ensure that the hook block does not trigger the lifting limit switch or touch the ground. • Additionally carry out the following movements –...
Page 688 Crane operation 11.5 Crane operation with main boom à You can switch on high-speed mode for a higher speed; p. 11 - 113. You can set the desired engine speed (idling speed) with button (1); à p. 4 - 17. You can limit the maximum telescoping speed in the Power unit speeds menu;...
Page 689 Crane operation 11.5 Crane operation with main boom Manual To telescope manually, you must initiate all locking and unlocking proc- telescoping esses. The locking and unlocking processes are carried out automatically. The following sections describe the operating procedures: – Checking the initial position à...
Page 690 Crane operation 11.5 Crane operation with main boom Current telescoping The display (1) shows how far the telescoping cylinder is extended, for example, 98%. The display (2) shows the current main boom length. The display (3) shows the corresponding telescopic section, for example, telescopic section 3 .
Page 691 Crane operation 11.5 Crane operation with main boom Position of the locking pins The current positions of the locking pins are: 1 On the telescopic section 2 On the telescoping cylinder The area (3) shows an enlarged cut-out. The current settings are shown in different colours.
Page 692 Crane operation 11.5 Crane operation with main boom Unlocking • Select the symbol (1). Confirm the selection – the locking pins (2) will retract. – Yellow: Intermediate position – Red: Unlocked 11 - 104 3 302 690 en Operating manual GMK4100L-1...
Page 693 Crane operation 11.5 Crane operation with main boom Extending/retract- ing the telescop- ing cylinder Prerequisites – Telescoping mechanism on – symbol (3) green – Telescopic section locked – symbol (1) green – Telescoping cylinder unlocked – symbol (2) Extending/retracting • Move the control lever in the corresponding telescoping direction: –...
Page 694 Crane operation 11.5 Crane operation with main boom 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. If removing the load does not cause the lock to be released, you must lock à...
Page 695 Crane operation 11.5 Crane operation with main boom Unlocking the Unlocking a telescopic section is required for the telescopic section to be telescopic section telescoped. The telescoping cylinder and the telescopic section cannot be unlocked simultaneously. Prerequisites – Telescoping mechanism on – symbol (3) green –...
Page 696 Crane operation 11.5 Crane operation with main boom 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. If removing the load does not cause unlocking, you must lock the telescopic à...
Page 697 Crane operation 11.5 Crane operation with main boom Locking the tele- Every telescopic section can be locked at the fixed lengths – fixed lengths; à scopic section p. 11 - 95. Prerequisites – Telescoping mechanism on – symbol (3) green –...
Page 698 Crane operation 11.5 Crane operation with main boom Locking the tele- Once you have retracted the main boom for on-road driving, you must by all means lock the telescoping cylinder in telescopic section I so that the axle scopic section for à...
Page 699 Crane operation 11.5 Crane operation with main boom Confirming the entry • Select and confirm the symbol (1). Telescoping • Move the control lever for the displayed telescoping direction. 2 Extension 3 Retraction of the telescoping 4 Display in the case of return runs (without a telescopic section) End telescoping semi-automation The teleautomation will stop when the entered...
Page 700 Crane operation 11.5 Crane operation with main boom Telescoping with No additional telescoping menu needs to be opened for this type of tele- scoping operation. All displays are shown in the Monitoring RCL menu. Pre- pre-selection selection of the telescope status has already been performed when entering à...
Page 701: High-Speed Mode
Crane operation 11.5 Crane operation with main boom 11.5.7 High-speed mode The slewing gear cannot be operated in high-speed mode. You can switch on the high-speed mode for a higher speed. Risk of accidents due to the suddenly accelerating movements Reduce the engine speed before starting high-speed mode.
Page 702 Crane operation 11.5 Crane operation with main boom Risk of accidents due to overloading! Make sure the lifted load is no more than 50% of the maximum load accord- ing to the Lifting capacity table (maximum degree of utilisation of 50%) before operating the hoists in high-speed mode.
Page 703: Slewing Gear
Crane operation 11.5 Crane operation with main boom 11.5.8 Slewing gear 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). à...
Page 704 Crane operation 11.5 Crane operation with main boom Switching on the After the ignition is switched on, all of the power units will be switched off slewing gear and the lamps in the corresponding buttons will light up only dimly. •...
Page 705 Crane operation 11.5 Crane operation with main boom Releasing locked You can unlock the slewing gear if it has been locked. slewing gear • Press and hold the button (1) – the slewing gear is unlocked. The speed is reduced to 10%. Slewing The following requirements must be fulfilled before slewing: à...
Page 706 Crane operation 11.5 Crane operation with main boom With the brake pedal function switched on, slewing movements are not braked automatically. If you let go of the control lever or move it to initial à Braking the slew- position, the slewing movement will slowly run down; ing movement , p.
Page 707 Crane operation 11.5 Crane operation with main boom Braking the slew- You may only brake the slewing movement with the slewing gear brake. ing movement Risk of the main boom buckling. On no account switch the slewing gear off to brake it; only switch the slewing gear off when the superstructure has stopped rotating.
Page 708 Crane operation 11.5 Crane operation with main boom Switching off the If the slewing gear is not required, it should be switched off to avoid unin- slewing gear tentional use. Risk of damage to the main boom Brake the slewing movement down to a standstill before you switch off the slewing gear.
Page 709: Switching The Reduction Of Slewing Speed On And Off
Crane operation 11.5 Crane operation with main boom 11.5.9 Switching the reduction of slewing speed on and off When the ignition is switched on the reduction of slewing speed is switched on and depending on the degree of utilisation and the working radius, the slewing speeds are automatically reduced to the maximum permissible lev- els listed in the lifting capacity table under the comments on slewing speed.
Page 710: Possible Movement Combinations
Crane operation 11.5 Crane operation with main boom Switching reduction on • Select and confirm the symbol (2). – Symbol (1) – grey displayed. – The warning message (3) disappears. The slewing speed is reduced automatically. The reduction is automatically switched on when you enter the slewing range type MAXbase .
Page 711: Settings And Displays For Crane Operation
Crane operation 11.6 Settings and displays for crane operation 11.6 Settings and displays for crane operation This section only describes settings and displays needed during crane oper- ation. Operating elements that can be assigned to other procedures are described with the corresponding procedures. 11.6.1 Inclining the crane cab With the appropriate equipment, you can incline the crane cab to the rear in...
Page 712: Setting The Idling Speed
Crane operation 11.6 Settings and displays for crane operation 11.6.2 Setting the idling speed à Setting the idling speed , p. 10 - 9 11.6.3 Adjusting the wiper stroke interval of the windscreen wiper You can set a value between 3 and 30 seconds for the front and roof window wiper stroke interval.
Page 713: Limiting The Power Unit Speeds
Crane operation 11.6 Settings and displays for crane operation 11.6.4 Limiting the power unit speeds You can enter what percentage of the maximum speed should be enabled for each power unit. • Open the Power unit speeds (1). The values below the symbols (1) to (6) indi- cate the currently set power unit speeds.
Page 714: Economy Mode
Crane operation 11.6 Settings and displays for crane operation 11.6.5 Economy mode You can also switch economy mode on/off. If you do not move the control lever when Economy mode is switched on, then the engine speed is automat- ically reduced in two steps. If the crane truck is also equipped with APS (Auxiliary Power Supply), there is a further third step in which the engine is shut down and an external generator started.
Page 715 Crane operation 11.6 Settings and displays for crane operation Economy steps The economy steps 1 to 3: Step 1: The engine speed is reduced Step 2: The superstructure drive is shut down Step 3: The engine is switched off – APS started automatically Additional equipment The time interval between step 2 and step 3 is...
Page 716: Switching Units Of Measure
Crane operation 11.6 Settings and displays for crane operation Ending/ switching off Ending To end Economy Mode you can either: – press the accelerator pedal, – move a control lever, – switch on a power unit. Switching off • Select and confirm the symbol (2) – symbol (1) is displayed.
Page 717: Setting The Characteristic Curves For The Control Levers
Crane operation 11.6 Settings and displays for crane operation 11.6.7 Setting the characteristic curves for the control levers The control lever characteristic curve determines how high the power unit speed should be for a particular control lever movement. You can assign different control lever characteristic curves to the power units.
Page 718: Using The Slewable Spotlights
Crane operation 11.6 Settings and displays for crane operation 11.6.8 Using the slewable spotlights With the relevant equipment, the slewable spotlights (1) are located on the main boom. They are controlled from the crane cab. Risk of damage to the slewable spotlights! Make allowances for the position of the slewable spotlights before setting down the main boom.
Page 719 Crane operation 11.6 Settings and displays for crane operation Manually swinging Turn upwards • Press the button (1) in at the top. Turn downwards • Push the button (1) down. The direction of the spotlights will be adjusted until you let go of the button or they reach their end position.
Page 720: Overriding Torque Reduction
Crane operation 11.6 Settings and displays for crane operation 11.6.9 Overriding torque reduction If the engine torque has been reduced then the symbol (2) is shown in the start menu. You can override the torque reduction function for a limited time while working with the crane.
Page 721: Displaying The Operating Hours
Crane operation 11.6 Settings and displays for crane operation 11.6.10 Displaying the operating hours You can view the total operating hours for all power units in the Operating hours menu. You can also delete the recorded operating hours. The total operating hours cannot be deleted. •...
Page 722 Crane operation 11.6 Settings and displays for crane operation Blank page 11 - 134 3 302 690 en Operating manual GMK4100L-1...
Page 723: Working Range Limiter
Crane operation 11.7 Working range limiter 11.7 Working range limiter You can set and monitor three different limits in the working range limiter menus: – a maximum overall height, – a maximum working radius, – a maximum slewing angle, – a limited rope travel. The monitoring of the programmed limits can be switched on and off separately.
Page 724: Viewing Current Settings
Crane operation 11.7 Working range limiter 11.7.1 Viewing current settings On the RCL The displays show monitoring and speed limitations that are switched on. display Working range limiter displays The corresponding symbol is shown when a monitoring system is switched on. 1 Hoist rope travel limitation monitoring 2 Overall height monitoring 3 Slewing angle monitoring...
Page 725: Opening The Working Range Limiter Menu
Crane operation 11.7 Working range limiter In the CCS Start The RCL shows the limited working range for the slewing angle and working menu radius monitoring systems. Display examples for switched-on slewing angle and working radius monitoring systems. 1 Permissible working range according to the lifting capacity table –...
Page 726 Crane operation 11.7 Working range limiter The working range limiter values are displayed graphically and numerically. Limit values/current values for height The symbols show values for: 1 Current overall height 2 permissible overall height Limit values/current values for working radius The symbols show values for 1 current working radius 2 permissible working radius...
Page 727 Crane operation 11.7 Working range limiter Limit values/current values for slewing angle The symbols show values for 1 current slewing angle A 2 permissible slewing angle A 3 current slewing angle B 4 permissible slewing angle B The following applies to the slewing angle display: 0°...
Page 728: Entering Limit Values
Crane operation 11.7 Working range limiter 11.7.3 Entering limit values This section describes how to enter unknown limit values by moving to the shutdown points. à Entering limit values manually , You can enter known limit values directly; p. 11 - 144. Risk of accidents due to limits set too low When entering the limits, bear in mind that, even after switching off the engine, movements can still occur that would bring the load into the shut-...
Page 729 Crane operation 11.7 Working range limiter Working radius • Move the main boom head to just before the shutdown point without a load, for example, up to 10.0 m – value (1). • Press the button (3) or (4) once. –...
Page 730 Crane operation 11.7 Working range limiter Entering the permissible slewing range You must enter the slewing angles A and B separately. – Slewing angle A • Slew the main boom to the shutdown point from the right, for example, value (1).
Page 731 Crane operation 11.7 Working range limiter Limiting lifting • Lift the load to the necessary height. Select the symbol (1). • Press the button (6) or (7) once. The current numerical value (5) is set at the symbol (2) as the upper limit value, symbol (1) confirms the entry.
Page 732: Entering Limit Values Manually
Crane operation 11.7 Working range limiter 11.7.4 Entering limit values manually When entering the values: à Switching The monitoring must be switched off – symbol (1) is red; monitoring functions on/off , p. 11 - 146. Limit values The limit values for the overall height, the working radius, and the slewing angle are entered in the same way.
Page 733 Crane operation 11.7 Working range limiter – For slewing angles • Set the respective limit value and confirm with button (3) or (4). The value is adopted. – The symbol (1) for the slewing angle A – symbol is red, –...
Page 734: Switching Monitoring Functions On/Off
Crane operation 11.7 Working range limiter 11.7.5 Switching monitoring functions on/off After turning on the ignition, all monitoring functions are switched on that were on before the ignition was turned off. When monitoring is switched on, the movement towards the shutdown limit is continually reduced until reaching a standstill.
Page 735: Shutdown By Working Range Limiter
Crane operation 11.7 Working range limiter 11.7.6 Shutdown by working range limiter If a limit value is reached, RCL shutdown will occur. All movements that would go closer to the limit value will be disabled. Shutdown will remain active even if you switch off the monitoring function. The RCL display also shows an information symbol.
Page 736 Crane operation 11.7 Working range limiter Blank page 11 - 148 3 302 690 en Operating manual GMK4100L-1...
Page 737: Work Break
Crane operation 11.8 Work break 11.8 Work break 11.8.1 In case of short work breaks Risk of accident by suspended loads Never switch off the engine whilst a load is suspended. You must have the control levers at hand in order to intervene at any time. Always set down the load before you leave the crane cab.
Page 738: In Case Of Work Breaks Of More Than 8 Hours
Crane operation 11.8 Work break 11.8.2 In case of work breaks of more than 8 hours • Retract all telescopic sections. • Lower the main boom. • Switch off the slewing gear. – The lamp in the button (1) must be dimly lit. –...
Page 739: Heating And Air-Conditioning System
Crane operation 11.9 Heating and air-conditioning system 11.9 Heating and air-conditioning system • Do not cover the grille (1). Air is sucked in through the grille. 11.9.1 Standard heating system • Switching on Start the engine. The heating output is only provided when the engine is running.
Page 740 Crane operation 11.9 Heating and air-conditioning system Air distribution You can direct the air to flow out of various air vents. • Select the corresponding symbol (1) for the desired air vents. A Top only B Top and bottom C Bottom only Adjusting the air vents 1 –...
Page 741: Air-Conditioning System
Crane operation 11.9 Heating and air-conditioning system 11.9.2 Air-conditioning system You can use the air-conditioning system to cool and dry the air in the crane cab. Information Do not cool the air in the crane cab too much. The difference between the outside temperature and the inside temperature should be at the most 10 °C to 14 °C (50 °F to 57.2 °F).
Page 742 Crane operation 11.9 Heating and air-conditioning system Cooling, The illustration shows only a sample setting. Always adjust the setting to automatic the current conditions. • Select and confirm the symbol (1) – symbol is red. • Set the desired temperature – symbol (2). •...
Page 743: Auxiliary Heater
Crane operation 11.9 Heating and air-conditioning system 11.9.3 Auxiliary heater You can use the auxiliary air heater to preheat the crane cab. The batteries will be drained if you operate the auxiliary heater with the engine switched off. You must recharge the batteries at shorter intervals if you use the auxiliary heater frequently.
Page 744 Crane operation 11.9 Heating and air-conditioning system Setting the temperature • Select the symbol (1). • Set the desired temperature – symbol (2). • Change and confirm the respective values using the controls (3) or (4). Setting the heating start/ heating duration •...
Page 745 Crane operation 11.9 Heating and air-conditioning system Switching heat- ing start on/off Switching on • Select a storage location (for example, #1) – symbol (1) red. You can also selected other storage locations. The auxiliary heating now starts at the times stored in the corresponding column.
Page 746: Cranestar System
Crane operation 11.10 CraneSTAR system 11.10 CraneSTAR system 11.10.1 Overview Your truck crane is equipped with the CraneSTAR system. The CraneSTAR system is used to transmit crane data via mobile phone, thus allowing remote diagnostics and localisation of the truck crane. The CraneSTAR system works automatically, no controls must be operated.
Page 747: Rigging Work
Rigging work 12.1 Rigging work checklists for crane operation with the main boom Rigging work If the truck crane on the site has already been rigged, proceed according to the CHECKLIST: Checks before operating the crane , p. 11 - 1. 12.1 Rigging work checklists for crane operation with the main boom...
Page 748 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 4. For the free on wheels working position à – Check that the tyre pressure is correctly set; p. 1 - 16. – Check that the ground can support the maximum axle loads; à...
Page 749 Rigging work 12.1 Rigging work checklists for crane operation with the main boom The following points only apply when rigging the truck crane on outriggers. To continue rigging in the Free on wheels working position, continue the checklist at point 12. 8.
Page 750 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 12. Switch off the engine à Earthing the truck crane , p. 12 - 15. 13. Earth the truck crane, if necessary; 14. Inspect the truck crane, while looking out in particular for any leaking fluids (oil, fuel or water).
Page 751 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 17. Extend the step if necessary; p. 12 - 137. 18. Pick up the hook block and re-reeve the hoist rope, if necessary; à Hook block on a separate vehicle , p. 12 - 101, à...
Page 752 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 21. Install the camera on main boom if required; Cameras for crane operation , p. 12 - 132. à 22. Fold out and adjust all mirrors for crane operation; p.
Page 753: Checklist: Unrigging
Rigging work 12.1 Rigging work checklists for crane operation with the main boom 12.1.2 CHECKLIST: Unrigging This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1.
Page 754 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 7. For on-road driving with a dolly: – Set down the superstructure on a dolly with the RCL adjusted accord- à ingly and switch on the boom floating position; p.
Page 755 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 12. Retract the step; p. 12 - 137. à CHECKLIST: Retracting the outriggers , 13. Retract the outriggers; p. 12 - 41. 14. Switch on suspension (release locking) – symbol green (suspension à...
Page 756 Rigging work 12.1 Rigging work checklists for crane operation with the main boom Blank page 12 - 10 3 302 690 en Operating manual GMK4100L-1...
Page 757: Choice Of A Suitable Positioning Site
Rigging work 12.2 Choice of a suitable positioning site 12.2 Choice of a suitable positioning site Choose the position of your truck crane at the site with care. Observe the following aspects: – Check that the ground has sufficient load bearing capacity. You may need à...
Page 758 Rigging work 12.2 Choice of a suitable positioning site Load bearing capacity of the ground • Find the load bearing capacity of the ground using the table. Load bearing APPROXIMATE VALUES FOR THE LOAD BEARING capacity CAPACITY OF THE GROUND (t/m (lbs/ft Backfilled, not artificially compacted ground:...
Page 759 Rigging work 12.2 Choice of a suitable positioning site Load-bearing area • Now calculate the required load-bearing area. à • Check that the surface of the outrigger pad ( p. 1 - 17) is larger than the calculated load-bearing area. If the surface of the outrigger pad is smaller, you will need to enlarge the load-bearing area.
Page 760: Safe Distance From Slopes And Pits
Rigging work 12.2 Choice of a suitable positioning site 12.2.2 Safe distance from slopes and pits Erect the crane at a safe distance from slopes and pits. The distance also depends on the type of ground if the slopes and pits are not supported. Rule of thumb: If you are working on non-cohesive or filled-in ground, the safety distance (a) must be twice...
Page 761: Earthing The Truck Crane
Rigging work 12.2 Choice of a suitable positioning site 12.2.3 Earthing the truck crane The truck crane may become charged with static electricity. This may occur especially when using outrigger pads made of plastic or when the outrigger pads are packed with insulating material (e.g. wooden planks). Risk of accident due to electric shock Earth the truck crane before you start to work with it –...
Page 762: Safe Distance From Overhead Power Lines
Rigging work 12.2 Choice of a suitable positioning site 12.2.4 Safe distance from overhead power lines Always observe the regulations in the country in which you are working when working in the vicinity of overhead power lines. Risk of accident due to electric shock The truck crane is not insulated.
Page 763 Rigging work 12.2 Choice of a suitable positioning site For example, according to DIN VDE 0105 Voltage Safe distance (A) Up to 1,000 V 1 m (3.3 ft) over 1,000 V to 110,000 V 3 m (9.8 ft) over 110,000 V up to 220,000 V 4 m (13.1 ft) over 220,000 V up to 380,000 V 5 m (16.4 ft)
Page 764 Rigging work 12.2 Choice of a suitable positioning site Blank page 12 - 18 3 302 690 en Operating manual GMK4100L-1...
Page 765: Rigging Work After Driving With A Dolly
Rigging work 12.3 Rigging work after driving with a dolly 12.3 Rigging work after driving with a dolly If the main boom is resting on a dolly whilst the truck crane is being driven, you must perform the following before working with the crane: à...
Page 766: Switching Off The Slewing Gear Freewheel
Rigging work 12.3 Rigging work after driving with a dolly 12.3.2 Switching off the slewing gear freewheel If the slewing gear freewheel is switched on, switch it off prior to working with the crane. Risk of accidents with the slewing gear freewheel switched on Switch off the slewing gear freewheel before working with the crane.
Page 767: Switching Off Boom Pre-Tensioning
Rigging work 12.3 Rigging work after driving with a dolly 12.3.3 Switching off boom pre-tensioning You must switch off the boom pre-tensioning before you raise the main boom off the dolly. To switch off boom pre-tensioning, you must bring the valves I to IV into the required positions, which will empty the pressure accumulator.
Page 768 Rigging work 12.3 Rigging work after driving with a dolly Blank page 12 - 22 3 302 690 en Operating manual GMK4100L-1...
Page 769: Connecting/Disconnecting The Hand-Held Control
Rigging work 12.4 Connecting/disconnecting the hand-held control 12.4 Connecting/disconnecting the hand-held control For operation • Remove the hand-held control (1) from the clamp (2). For transport • Hang the hand-held control (1) in the clamp (2). • Close the covering (3). Operating manual 3 302 690 en 12 - 23...
Page 770 Rigging work 12.4 Connecting/disconnecting the hand-held control Functionality of the sockets The hand-held control is only active when it is connected to the sockets (1) or (2). Socket Enabled operations – Emergency operation for crane movements (except for telescoping mechanism) –...
Page 771 Rigging work 12.4 Connecting/disconnecting the hand-held control Connect the hand-held control • Open the cap (2) and remove the bridging plug (3) from the socket (1). • Insert the plug (5) into the socket (1) and secure it with the cap (2). •...
Page 772 Rigging work 12.4 Connecting/disconnecting the hand-held control Blank page 12 - 26 3 302 690 en Operating manual GMK4100L-1...
Page 773: Starting The Engine For Rigging
Rigging work 12.5 Starting the engine for rigging 12.5 Starting the engine for rigging For rigging work, you can also start the engine from the outrigger control units. You can generally start the engine only if a bridging plug is inserted in all sockets not required.
Page 774 Rigging work 12.5 Starting the engine for rigging Blank page 12 - 28 3 302 690 en Operating manual GMK4100L-1...
Page 775: Slewing Range - Only With The Standard Slewing Range Type
Rigging work 12.6 Slewing range – only with the Standard slewing range type 12.6 Slewing range – only with the Standard slewing range type The information in this section applies only to the Standard slewing range type. If you wish to operate the truck crane using the MAXbase slewing à...
Page 776: Enabled Outrigger Spans
Rigging work 12.6 Slewing range – only with the Standard slewing range type 12.6.2 Enabled outrigger spans Risk of overturning when slewing the superstructure With some outrigger spans, slewing is only permissible with certain à counterweight combinations and boom positions; Slewing with rigged counterweight , p.
Page 777: Outriggers - Overview - Maxbase Slewing Range Type
Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type 12.7 Outriggers – Overview – MAXbase slewing range type The information in this section applies to the MAXbase slewing range type. If you wish to operate the truck crane using the Standard slewing range type; à...
Page 778 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Representation of the outrigger spans – Outrigger length The outrigger length ( I ) has a fixed value of 8.660 m (28.4 ft) and never changes. – Outrigger width All possible outrigger spans (1) to (5) are always shown for all outrigger beams.
Page 779: Representation In The Lifting Capacity Tables
Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type 12.7.2 Representation in the lifting capacity tables The outrigger span is always specified in this form Outrigger length xxxx – outrigger width yyyyy – The value xxxx is always 8.660 m (28.4 ft). –...
Page 780: Enabled Outrigger Spans
Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Three / One The outrigger width is the same for three out- rigger beams and one outrigger beam is fully retracted. The overall width is entered once and an indi- vidual width is entered once.
Page 781 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Right / Left – Right greater than left The outrigger width is the same at the left and the same at the right. The table shows the permissible combinations. FR / RR FL / RL 3.600 m (11.8 ft)
Page 782 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Front / rear – Front greater than rear The front outrigger beams are extended fur- ther than the rear outrigger beams. The table shows the permissible combinations. FR / FL RR / RL 3.600 m (11.8 ft) 3.125 m (10.3 ft)
Page 783 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Three / One – One outrigger beam retracted – left Three outrigger beams are extended the same distance and one outrigger beam at the left side is retracted. The table shows the released combinations.
Page 784 Rigging work 12.7 Outriggers – Overview – MAXbase slewing range type Blank page 12 - 38 3 302 690 en Operating manual GMK4100L-1...
Page 785: Outrigger Operation
Rigging work 12.8 Outrigger operation 12.8 Outrigger operation Danger of crushing by extending outrigger beams. You may only activate the outriggers if you yourself or a banksman with whom you are in visual contact have an unobstructed view of their movements.
Page 786 Rigging work 12.8 Outrigger operation 5. Move the outrigger pads into the operating position and secure them; à p. 12 - 51. 6. Enlarge the load-bearing area if necessary; à Determining the required load-bearing area , p. 12 - 11, à...
Page 787: Checklist: Retracting The Outriggers
Rigging work 12.8 Outrigger operation 12.8.2 CHECKLIST: Retracting the outriggers This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! à 1. Retract the outrigger cylinders as far as possible; p.
Page 788: Preparing The Truck Crane
Rigging work 12.8 Outrigger operation 6. Switch off the engine; à – After operating it from the control units; p. 4 - 18. – After operating it from the crane cab or using the hand-held control; à p. 10 - 11. 12.8.3 Preparing the truck crane Driver's cab...
Page 789 Rigging work 12.8 Outrigger operation Switching the outrigger control units on/off You can switch the Outriggers control units on and off from the crane cab. The current status is displayed, either the symbol (1) or (2) grey. Switch the control units on: •...
Page 790: Setting The Outrigger Spans
Risk of accidents from incorrect or missing markings Replace missing and illegible markings. First query Manitowoc Crane Care for the correct position. This way you prevent the truck crane overturning due to an incorrect outrigger span.
Page 791 Rigging work 12.8 Outrigger operation Outrigger span (80%) Overall width 8.660 x 6.250 m (28.4 x 20.5 ft) Individual width 8.660 x 3.125 m (28.4 x 10.3 ft) (A) – Prerequisites Pins (1) and (2) must be pulled out (B) – Setting and securing •...
Page 792 Rigging work 12.8 Outrigger operation Outrigger span (40%) Overall width 8.660 x 3.800 m (28.4 x 12.4 ft) Individual width 8.660 x 1.90 m (28.4 x 6.2 ft) (A) – Prerequisites – Pin (1) must be removed – Pin (2) must be inserted (B) –...
Page 793: Extending/Retracting Outrigger Beams
Rigging work 12.8 Outrigger operation • For on-road Create the outrigger span 8.660 x 2.340 m (28.4 x 7.6 ft) for all outrigger driving beams and secure all the outrigger beams. à • Bring all the outrigger pads into driving position; p.
Page 794 Rigging work 12.8 Outrigger operation From the control units Starting the engine à • Start the engine from the driver's cab; p. 4 - 13. à You can also start the engine from the control units; p. 12 - 27. Switching on the lighting Only the lamp (1) lights up after opening the door.
Page 795 Rigging work 12.8 Outrigger operation From the The following operating elements are found in the Outrigger menu. crane cab The parking brake is engaged. Starting the engine à • Start the engine from the crane cab; p. 10 - 3. à...
Page 796 Rigging work 12.8 Outrigger operation Retracting • Press the button for the desired outrigger beam. 1 Front left 2 Front right 3 Rear left 4 Rear right • Press the button (5) in at the bottom – the selected outrigger beam retracts. 12 - 50 3 302 690 en Operating manual...
Page 797: Moving The Outrigger Pads Into Operating/Driving Position
Rigging work 12.8 Outrigger operation 12.8.6 Moving the outrigger pads into operating/driving position Moving them into working position • (A) – Pull out the pin (1). • (B) – Pull the outrigger pad outwards by the handle (2). • Secure the outrigger pad with the pin (1). •...
Page 798 Rigging work 12.8 Outrigger operation Blank page 12 - 52 3 302 690 en Operating manual GMK4100L-1...
Page 799: Enlarging The Load-Bearing Area
Rigging work 12.8 Outrigger operation 12.8.7 Enlarging the load-bearing area If the surface of the outrigger pads is too small, you must enlarge the à Determining the load-bearing area by packing the outrigger pads; required load-bearing area , p. 12 - 11. For packing, use only suitable materials that will withstand the outrigger pressure, e.g.
Page 800: Extending/Retracting Supporting Cylinders
Rigging work 12.8 Outrigger operation 12.8.8 Extending/retracting supporting cylinders Danger of overturning due to insufficient load bearing capacity of the ground Enlarge the load-bearing area if the ground cannot withstand the resulting outrigger pressure. This prevents the ground under the outrigger pad giving way and causing the truck crane to tilt and overturn.
Page 801 Rigging work 12.8 Outrigger operation From the control units Starting the engine • Start the engine, either à – from the driver's cab; p. 4 - 13 à – from the control units; p. 12 - 27. Moving the supporting cylinders Assignment of buttons: 1 Supporting cylinder 1.1 2 Supporting cylinder 2.1...
Page 802 Rigging work 12.8 Outrigger operation From the The following operating elements are found in the Outrigger menu. crane cab Starting the engine à • Start the engine from the crane cab; p. 10 - 3. • Switch off the slewing gear. Open menu •...
Page 803 Rigging work 12.8 Outrigger operation Retracting • Press the button for the desired outrigger cylinder. 1 Front left 2 Front right 3 Rear left 4 Rear right • Press the button (5) in at the bottom – the selected supporting cylinder retracts. Operating manual 3 302 690 en 12 - 57...
Page 804: Levelling The Truck Crane On Outriggers Horizontally
Rigging work 12.8 Outrigger operation 12.8.9 Levelling the truck crane on outriggers horizontally You must level the truck crane before crane operation horizontally and possibly correct its horizontal alignment during crane operation. Inclination After switching on the ignition, various inclination indicators display the indicators current alignment.
Page 805 Rigging work 12.8 Outrigger operation – Outrigger control units The assignment to the carrier corresponds to the top view. Due to the position of the control units, the displays on both sides differ. In this example, the carrier would be stand- ing higher to the rear on the right hand side.
Page 806 Rigging work 12.8 Outrigger operation à • Manual alignment Check that the prerequisites are met; p. 12 - 59. • Extend all supporting cylinders until none of the wheels is touching the ground. • Level the truck crane with the supporting cylinders until the lamp (1) is the à...
Page 807 Rigging work 12.8 Outrigger operation • 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 control units •...
Page 808: Levelling The Free-Standing Truck Crane
Rigging work 12.8 Outrigger operation 12.8.10 Levelling the free-standing truck crane This section describes the levelling with the outrigger. You can level the à truck crane using the axle raising; p. 12 - 64. The suspension is deactivated (locked) if the truck crane is in the Free on wheels working position.
Page 809 Rigging work 12.8 Outrigger operation Switching on the suspension • Select and confirm the symbol (1) once. The symbol (2) is green if the suspension is switched on. Now all wheels are lowered to the ground and are in the right position for the horizontal alignment.
Page 810: Operating The Axle Raising System
Rigging work 12.8 Outrigger operation 12.8.11 Operating the axle raising system The axle raising system has two functions. – Lifting/lowering wheels When the truck crane is supported on outriggers, you can raise the wheels (e.g. levelling horizontally) or lower the wheels (e.g. for driving with a rigged mobile crane).
Page 811 Rigging work 12.8 Outrigger operation • Press the button for the desired movement. Lifting/lowering wheels 1 Lifting wheels 2 Lowering wheels Aligning the truck crane 1 Lowering the truck crane 2 Lifting the truck crane Operating manual 3 302 690 en 12 - 65 GMK4100L-1...
Page 812: Outrigger Pressure Display
Rigging work 12.8 Outrigger operation 12.8.12 Outrigger pressure display Especially with asymmetrical outrigger spans, the outrigger pressure dis- plays do not provide useful information on correct alignment. Horizontal alignment is the decisive factor for correctly supporting the truck crane; à p.
Page 813 Rigging work 12.8 Outrigger operation On the outrigger control units The assignment of the displays to the carrier corresponds to the top view. 1 Display for the supporting cylinder 1.1 2 Display for the supporting cylinder 2.1 3 Display for the supporting cylinder 3.1 4 Display for the supporting cylinder 4.1 Operating manual 3 302 690 en...
Page 814 Rigging work 12.8 Outrigger operation Blank page 12 - 68 3 302 690 en Operating manual GMK4100L-1...
Page 815: Rigging/Unrigging The Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9 Rigging/unrigging the counterweight For driving the counterweight must either be stored on the rear / front Counterweight à à display rigged counterweight platform, or taken off; p. 6 - 1, p. 12 - 69. •...
Page 816 Rigging work 12.9 Rigging/unrigging the counterweight As the crane operator • Use only the Raise/lower hoist or Raise/lower derricking gear movements for setting down the counterweight. Execute the movement as slowly as possible. Notify the rigging personnel if the superstructure need to be slewed for positioning the counterweight.
Page 817: Counterweight Sections
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.2 Counterweight sections Depending on the version, the GMK4100L-1 can be equipped with a counterweight mass of 4.5 t (9,920 lbs) or 26.2 t (57,761 lbs). There are various counterweight sections, depending on the rigging of the truck crane.
Page 818 Rigging work 12.9 Rigging/unrigging the counterweight Blank page 12 - 72 3 302 690 en Operating manual GMK4100L-1...
Page 819: Identification
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.3 Identification The truck crane and its corresponding counterweight sections are labelled with the same serial number. Danger if counterweight sections are interchanged Operate the truck crane only with the counterweight sections that belong to it.
Page 820: Slinging Points On The Counterweight Sections
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.4 Slinging points on the counterweight sections Risk of accident if used improperly Attach the lifting gear to various counterweight section only at the appro- priate slinging points. Ensure the lifting gear has sufficient load bearing capacity.
Page 821 Rigging work 12.9 Rigging/unrigging the counterweight Multiple sections You can lift the assembled counterweight mass (max. 17 t) as a single item. The 2.1 t section (1) must be at the bottom. • Attach the lifting gear as shown in the diagram.
Page 822: Checklist: Rigging The Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.5 CHECKLIST: Rigging the counterweight This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 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).
Page 823 Rigging work 12.9 Rigging/unrigging the counterweight 6. Slew the superstructure into the 180° to the forwards position and lock it; à Braking the slewing movement , p. 11 - 119 à Locking/unlocking the superstructure , p. 11 - 15. 7. – Open Counterweight menu à...
Page 824: Checklist: Unrigging The Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.6 CHECKLIST: Unrigging the counterweight This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! Danger of overturning when slewing with a rigged counterweight Before slewing with the rigged counterweight, check whether slewing is permissible with the rigged outrigger span or with the truck free on wheels;...
Page 825 Rigging work 12.9 Rigging/unrigging the counterweight 5. Enter the current rigging mode with the currently rigged counterweight à combination; p. 11 - 32. 6. Depending on the driving mode, lift the necessary counterweight sections – on to the front counterweight platform; à...
Page 826: Assembling Counterweight Combination
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.7 Assembling counterweight combination Danger of overturning when slewing with a rigged counterweight You may only slew the superstructure with a rigged counterweight if an outrigger span of sufficient size is rigged. You can find the required outrig- ger span in the table in the section titled Slewing with rigged counterweight , p.
Page 827 Rigging work 12.9 Rigging/unrigging the counterweight Setting down the 2.7 t base plate Only the 2.7 t base plate may be set down directly on the rear counterweight platform. • Position the 2.7 t base plate in such a way that the holders (1) grip into the recesses (2).
Page 828 Rigging work 12.9 Rigging/unrigging the counterweight The illustration and the table show all counterweight sections and all counterweight combinations which can be rigged. • The table specifies which counterweight sections are needed for the respective counterweight combination. à • Slinging points on Lift the counterweight sections onto the base plate;...
Page 829 Rigging work 12.9 Rigging/unrigging the counterweight Counterweight sections in t (lbs) Counter- weight (5,950) (2,204) (4,630) (15,650) (3,307) (4,850) (8,818) (5,291) (1,764) combination in t (lbs) ● – – – – – – – – (1,764) ● ● ● – –...
Page 830 Rigging work 12.9 Rigging/unrigging the counterweight Blank page 12 - 84 3 302 690 en Operating manual GMK4100L-1...
Page 831: Counterweight Hoist Unit
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.8 Counterweight hoist unit The lifting cylinders (1) can be extended and retracted. To lift and lower the counterweight, the lifting cylinders are screwed into the 2.7 t base plate (2). Risk of crushing when lifting and lowering the counterweight! Make sure nobody is on the counterweight platform while the counterweight is being lifted or lowered.
Page 832 Lock the rear counterweight à platform; p. 12 - 95. 3 Contact Manitowoc Crane Care 4 If the pre-tensioning pressure continues to drop, the message (1). Extending/ This section describes how to operate the lifting cylinders manually, retracting the –...
Page 833 Rigging work 12.9 Rigging/unrigging the counterweight Correct the rigging mode • You can use the automatic mode only if the current rigging mode is displayed. A Counterweight rigged B Counterweight unrigged If necessary, correct the displayed rigging mode as follows: •...
Page 834 Rigging work 12.9 Rigging/unrigging the counterweight Pre-tensioning When the symbol (5) is red, you must pre-ten- sion the counterweight. Slewing is blocked – symbol display (2). • Select and confirm the symbol (3) until the symbol (4) becomes green. The slewing is released –...
Page 835 Rigging work 12.9 Rigging/unrigging the counterweight Switch on automatic mode • Select and confirm the symbol (3). Execute the automatic mode. • Move the slewing control lever in the dis- played direction (1) or (2) – the automatic mode starts. –...
Page 836 Rigging work 12.9 Rigging/unrigging the counterweight Automatic mode While the automatic mode is being executed, you can always à unrigging – Cancel the automatic mode; Cancel automatic mode , p. 12 - 91. – Interrupt the automatic mode by letting go of the control lever. After moving the lever in the displayed direction once more, the automatic mode is continued.
Page 837 Rigging work 12.9 Rigging/unrigging the counterweight • Move the slewing control lever in the dis- played direction (1) or (2) – the automatic mode continues. – The superstructure turns into position (C). – The lifting cylinders are retracted (D). • Release the control lever.
Page 838: Setting Down Counterweight For Driving
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.9 Setting down counterweight for driving The list of counterweight sections that can be carried on the rear counterweight platform (1) and on the front counterweight platform (2) whilst driving depends on the driving mode of à...
Page 839 Rigging work 12.9 Rigging/unrigging the counterweight For driving with axle loads up to 12 t Only the 2.7 t base plate may be set down directly on the rear counterweight platform. Risk of accidents due to the counterweight slipping or tipping over! Place only the 2.7 t base plate directly on to the rear counterweight platform and lock it.
Page 840 Rigging work 12.9 Rigging/unrigging the counterweight Front counter- For driving with axle loads greater than 12 t weight platform Depending on the driving mode, in addition to the counterweight on the rear counterweight platform, the 2.1 t plate and the 7.1 t plate can be placed on the front counterweight platform.
Page 841: Unlocking/Locking The Rear Counterweight Platform
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.10 Unlocking/locking the rear counterweight platform The information in this section applies only to the version (A). The lock is absent on version (B). You must unlock the rear counterweight platform Unlocking – before you lift the counterweight combination on to the turntable, –...
Page 842 Rigging work 12.9 Rigging/unrigging the counterweight Locking You must lock the rear counterweight platform after the counterweight has been set down for transport. • Remove the pins (1) from the clamps (2) and insert them into the connecting points (3). •...
Page 843: Slewing With Rigged Counterweight
Rigging work 12.9 Rigging/unrigging the counterweight 12.9.11 Slewing with rigged counterweight Slewing with a rigged counterweight is only permissible when: – The necessary outrigger span is rigged – The current rigging mode is shown on the RCL display – The permissible working radius according to Lifting capacity table is maintained.
Page 844 Rigging work 12.9 Rigging/unrigging the counterweight Blank page 12 - 98 3 302 690 en Operating manual GMK4100L-1...
Page 845: Rigging Work On The Main Boom
Rigging work 12.10 Rigging work on the main boom 12.10 Rigging work on the main boom 12.10.1 Hook block on the bumper à When the hook block is transported on a separate vehicle; p. 12 - 101. Picking up the Depending on the driving mode, you must pick up the hook block from the à...
Page 846 Rigging work 12.10 Rigging work on the main boom Attaching the Depending on the driving mode, you can attach the hook block to the front à Driving modes , p. 6 - 1. hook block bumper; Risk of accidents if the view is obstructed The reeved rope lines obstruct the view of the runway.
Page 847: Hook Block On A Separate Vehicle
Rigging work 12.10 Rigging work on the main boom 12.10.2 Hook block on a separate vehicle Risk of overturning while slewing. Always check before slewing whether slewing is permitted in the truck crane's current rigging mode. Correct the rigging mode if necessary; à...
Page 848 Rigging work 12.10 Rigging work on the main boom Picking up the Depending on the driving mode, the hook block can be placed on a separate à Driving modes , p. 6 - 1. hook block vehicle; • If the respective setting has been made in the RCL, slew the superstructure and lower the main boom until the boom head is directly above the hook block (1).
Page 849 Rigging work 12.10 Rigging work on the main boom • Detach the lifting limit switch weight (2) à from the hoist rope; p. 12 - 123. à • Unreeve the hoist rope; p. 12 - 113. • Secure the hook block (1) for transport. •...
Page 850: Hook Block, Separable
Rigging work 12.10 Rigging work on the main boom 12.10.3 Hook block, separable The hook block can be separated for on-road driving. The block hook remains reeved and can be attached to the bumper. The hook can be transported separately, e.g. on a separate vehicle. Rigging for on-road driving •...
Page 851 Rigging work 12.10 Rigging work on the main boom Rigging for crane operation • Slacken the hoist rope and raise the main boom simultaneously. • Raise the main boom until the boom head is in a vertical position above the block hook (1).
Page 852: Hook Block With Ballast Plates
Rigging work 12.10 Rigging work on the main boom 12.10.4 Hook block with ballast plates There are 1 and 3-sheave hook blocks for both versions A and B. By removing and installing ballast plates, you can adapt the hook block weight to the weight required according to the Lifting capacity table .
Page 853 Rigging work 12.10 Rigging work on the main boom Installing Risk of accident due to falling ballast plates. Always secure the ballast plates with the pins and the securing plugs. Always check the completeness and condition of the securing plugs before operating the crane.
Page 854: Reeving And Unreeving The Hoist Rope
Rigging work 12.10 Rigging work on the main boom 12.10.5 Reeving and unreeving the hoist rope You must reeve a certain number of rope lines, depending on the required load bearing capacity. Four reeved rope lines correspond, for example, à Possible reevings on the main boom , p.
Page 855 Rigging work 12.10 Rigging work on the main boom Risk of damage to the hoist rope! Always install the pocket lock as it is described in the following paragraph. This will prevent the hoist rope rubbing against the locknut and being damaged.
Page 856 Rigging work 12.10 Rigging work on the main boom Opening the hook block • Pull out the rods (2). • Fold down the plates (3). Positioning the hoist rope • Pull out the rods (1) and (4). • Feed the main hoist rope (2) under the rope grab (1).
Page 857 Rigging work 12.10 Rigging work on the main boom Reeving the hoist rope A For the main hoist rope B For the auxiliary hoist rope • Guide the hoist rope over the upper head sheave (1) to the lower head sheave (2). •...
Page 858 Rigging work 12.10 Rigging work on the main boom – Rope end fitting • Fasten the rope end fitting (3) using the pin (2). (A) – If there is an even number of lines to a fixed point (1) of the main boom head. (B) –...
Page 859 Rigging work 12.10 Rigging work on the main boom Unreeving hoist rope • Pull out the rods (5) and (3). • Fold down the plates (1). • Remove the rope end fitting from the fixed point (2) or (4). • Unreeve the hoist rope.
Page 860: Possible Reevings On The Main Boom
Rigging work 12.10 Rigging work on the main boom 12.10.6 Possible reevings on the main boom Possible reevings on lattice extensions and the auxiliary single-sheave à Lattice extension operating manual. boom top; The maximum lifting capacity is specified in the supplied lifting capacity table . à...
Page 861 Rigging work 12.10 Rigging work on the main boom 3-sheave hook block – On version with centre fixed point Reeving 7-fall 6-fall 5-fall 4-fall 3-sheave hook block – On version without centre fixed point Reeving 7-fall 6-fall 5-fall 4-fall Operating manual 3 302 690 en 12 - 115 GMK4100L-1...
Page 862 Rigging work 12.10 Rigging work on the main boom 1-sheave hook block Reeving 3-fall 2-fall 1-fall Hook tackle Reeving 1-fall 12 - 116 3 302 690 en Operating manual GMK4100L-1...
Page 863 Rigging work 12.10 Rigging work on the main boom à With 6 head If 5 head sheaves are provided; p. 12 - 114. sheaves 7-sheave hook block Reeving 12-fall 5-sheave hook block Reeving 11-fall 10-fall 9-fall 8-fall Operating manual 3 302 690 en 12 - 117 GMK4100L-1...
Page 864 Rigging work 12.10 Rigging work on the main boom 3-sheave hook block Reeving 7-fall 6-fall 5-fall 4-fall 1-sheave hook block Reeving 3-fall 2-fall 1-fall 12 - 118 3 302 690 en Operating manual GMK4100L-1...
Page 865 Rigging work 12.10 Rigging work on the main boom Hook tackle Reeving 3-fall With 7 head The 7th head sheave of the auxiliary single-sheave boom top is used for sheaves this version. 7-sheave hook block Reeving 14-falls 13-fall Additional equipment; à...
Page 866: Installing/Removing The Lifting Limit Switch
Rigging work 12.10 Rigging work on the main boom 12.10.7 Installing/removing the lifting limit switch à Function of the lifting limit switch; p. 11 - 82. For every reeved hoist rope, you must install a lifting limit switch, attach a lifting limit switch weight and place it around the hoist rope.
Page 867 Rigging work 12.10 Rigging work on the main boom If only one lifting limit switch has been installed • Cover the unused socket with the protective cap (2). • Check whether the lock on the used lifting limit switch, e.g. (1), is released; à...
Page 868 Rigging work 12.10 Rigging work on the main boom Attaching the lifting limit switch weight • Attach the lifting limit switch weight (1). These lifting limit switches must not be à Removing the lock , p. 12 - 125. blocked; If two hoist ropes are reeved, you must attach a lifting limit switch weight to each of the two lifting limit switches.
Page 869 Rigging work 12.10 Rigging work on the main boom Removing the lift- This section describes complete removal. ing limit switch If the hook block is to be attached to the bumper at a later point, you will need to detach the lifting limit switch weight from the hoist rope, so that you can unreeve or reeve when unrigging the hoist rope.
Page 870 Rigging work 12.10 Rigging work on the main boom Removing the right lifting limit switch • Pull out the plug and close the socket with the protective cap (1). • Remove the lifting limit switch (4) from the bracket (2) •...
Page 871: Locking/Unlocking The Lifting Limit Switch
Rigging work 12.10 Rigging work on the main boom 12.10.8 Locking/unlocking the lifting limit switch Locking If two lifting limit switches are installed, you must lock the lifting limit switch not used in order to enable all crane operations. Risk of damage if the lifting limit switch is locked If the lifting limit switch on which the lifting limit switch weight hangs is locked, release the lock.
Page 872: Anemometer And Air Traffic Control Light
Rigging work 12.10 Rigging work on the main boom 12.10.9 Anemometer and air traffic control light Risk of damage during on-road driving Always remove the anemometer and air traffic control light before on-road driving. This prevents the specified overall height from being exceeded at on-road level, and the anemometer from being damaged due to unfavourable air currents.
Page 873 Rigging work 12.10 Rigging work on the main boom Depending on the additional equipment, the truck crane can be equipped with a switchable air traffic control light. This air traffic control light (1) has flashing light and constant light lighting modes. •...
Page 874 Rigging work 12.10 Rigging work on the main boom For transport • Place the rod (1) in the holder (2). • Secure the rod (1) using the retaining pins. 12 - 128 3 302 690 en Operating manual GMK4100L-1...
Page 875: Other Rigging Work
Rigging work 12.11 Other rigging work 12.11 Other rigging work 12.11.1 Railings on the turntable The turntable is equipped with fixed handrails or extendable/retractable handrails, depending on the version. Risk of accidents if railings are not pushed out! The railings provide protection from falling. Always fold out the railings before stepping on to the turntable.
Page 876: Folding The Mirrors In And Out, And Adjusting Them
Rigging work 12.11 Other rigging work 12.11.2 Folding the mirrors in and out, and adjusting them The mirror must be folded in for driving. You must fold the mirror out and adjust it for crane operation or driving from the superstructure. Risk of accidents due to exceeding the permissible dimensions! Fold the mirror in for driving.
Page 877: Slinging Points For Personal Protective Equipment
Rigging work 12.11 Other rigging work 12.11.3 Slinging points for personal protective equipment The approved slinging points for personal safety equipment are marked with special labels (2). • Always secure yourself using your personal protective equipment for rigging work – e. g. on the main boom at the slinging points (1).
Page 878: Cameras For Crane Operation
Rigging work 12.11 Other rigging work 12.11.4 Cameras for crane operation Camera on For crane operation you have to install the camera and switch it on. main boom For on-road driving, you have to switch the camera off again and remove it. The transmitter (1) and the associated receiver (2) are matched to each other and are identified by the same number on the...
Page 879 Rigging work 12.11 Other rigging work You will need the respective connecting cable to connect the camera to a lat- tice extension. This means certain pre-conditions are applicable to installa- tion and removal. Risk of accidents due to falling camera Always use a retaining pin to hold the camera in the clamp.
Page 880 Rigging work 12.11 Other rigging work Removing – Only the camera • Withdraw the plug (4) from the socket (3) and close it with the cap. • Remove the camera (2) from the clamp (1) and put the retaining pin in the holder (1). •...
Page 881 Rigging work 12.11 Other rigging work Camera on This section describes the CCS display as the monitor. Depending on the the hoists version, a separate monitor may also be present. Risk of accidents due to exceeding the permissible dimensions! Always retract the camera before driving. When the camera is extended, the overall height specified for on-road driving is exceeded.
Page 882 Rigging work 12.11 Other rigging work Operating the Depending on the version, the image is shown on the CCS display or on a camera separate monitor. Switching on • Switch on the ignition. • (A) – Select and confirm the symbol (1) •...
Page 883: Step At The Crane Cab
Rigging work 12.11 Other rigging work 12.11.5 Step at the crane cab You can operate the access ladder in the Crane cab menu or on the outrigger control unit. Risk of accidents by exceeding the permissible overall width! Always retract the step for on-road driving. When the step is extended, the overall width specified for on-road driving is exceeded.
Page 884 Rigging work 12.11 Other rigging work Blank page 12 - 138 3 302 690 en Operating manual GMK4100L-1...
Page 885: Driving With A Rigged Truck Crane
Driving with a rigged truck crane 13.1 Route Driving with a rigged truck crane This section describes driving the truck crane with the counterweight à Lattice extension operating man- rigged. If a lattice extension is also rigged; ual . Risk of accidents due to partially obstructed view of the truck crane! When driving the truck crane, always stay in visual or radio contact with a banksman who can observe the parts you are unable to see, e.g.
Page 886: Permissible Rigging Modes And Axle Loads
Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2 Permissible rigging modes and axle loads Depending on the counterweight rigged, you must bring the superstructure and the main boom into certain positions so that the permissible axle loads are not exceeded.
Page 887 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Counter- Telescope status Main boom Superstruc- Maximum weight angle ture Axle load I/II/III/IV/V/VI in t in ° position in t (x 1,000 lbs) (lbs) front rear 15.0 14.5 0 - 0 - 0 - 0 - 0 - 0 5 - 70...
Page 888 Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads Counter- Telescope status Main boom Superstruc- Maximum weight angle ture Axle load I/II/III/IV/V/VI in t in ° position in t (x 1,000 lbs) (lbs) front rear 15.0 20.0 50 - 0 - 0 - 0 - 0 - 0 5 - 45...
Page 889: To Drive Without A Load
Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2.1 To drive without a load • Bring the main boom to an inclination permitted within the working range. • Tie down the hook block so that it cannot swing around. 13.2.2 To drive with a load When the truck crane is being driven with a lifted load, it may be driven only...
Page 890: Axle Loads
Driving with a rigged truck crane 13.2 Permissible rigging modes and axle loads 13.2.3 Axle loads The axle loads do not exceed 25.0 t (55,116 lbs) if the main boom is within the permissible working range in a permissible Lifting capacity table Free-on-wheels working position .
Page 891: Before Driving The Rigged Truck Crane
Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 13.3 Before driving the rigged truck crane 13.3.1 Check the tyre pressures and wind speed à • Tyres , Ensure that all the tyres are at the prescribed pressure levels; p.
Page 892: Putting The Truck Crane On The Wheels - With Raise Axle Function
Driving with a rigged truck crane 13.3 Before driving the rigged truck crane • Switch off the slewing gear – The lamp in the button (1) must be dimly lit. – Then symbol (2) turns red – slewing gear switched off. –...
Page 893 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane Aligning the truck crane • Retract the support cylinders until they do not make contact with the ground during alignment. • Level the truck crane with the Raise axle function.
Page 894: Putting The Truck Crane On The Wheels - With The Outriggers
Driving with a rigged truck crane 13.3 Before driving the rigged truck crane 13.3.4 Putting the truck crane on the wheels – with the outriggers You can also use the raise axle function to put the truck crane on the wheels; à...
Page 895 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane Levelling the truck crane • Retract the supporting cylinders evenly. Lower the truck crane only to the extent that the suspension struts still have enough play for alignment. •...
Page 896 Driving with a rigged truck crane 13.3 Before driving the rigged truck crane Blank page 13 - 12 3 302 690 en Operating manual GMK4100L-1...
Page 897: Driving From The Driver's Cab
Driving with a rigged truck crane 13.4 Driving from the driver's cab 13.4 Driving from the driver's cab Risk of accidents when driving the truck crane from the driver's cab with a lifted load! With a lifted load, drive the truck crane only from the crane cab. You must be able to carry out crane movements in an emergency at all times.
Page 898: Whilst Driving
Driving with a rigged truck crane 13.4 Driving from the driver's cab 13.4.2 Whilst driving • Only drive slowly, do not change up. • The turning radius should be as great as possible when driving around corners. • Steer the truck crane when it is moving, and avoid sudden changes to the steering.
Page 899: After Driving
Driving with a rigged truck crane 13.4 Driving from the driver's cab 13.4.3 After driving à • Switch separate steering off after driving; p. 5 - 63. • Engage the parking brake. Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise until none of the wheels touches the ground.
Page 900 Driving with a rigged truck crane 13.4 Driving from the driver's cab Blank page 13 - 16 3 302 690 en Operating manual GMK4100L-1...
Page 901: Driving From The Crane Cab
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5 Driving from the crane cab Risk of accidents when driving with a lifted load! The truck crane may be driven with a lifted load only when it is in the Free on wheels working position and the current rigging mode has been entered on the RCL.
Page 902: Preparing To Drive
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.1 Preparing to drive • Make sure that the rigging mode for driving with a load or without a load à is set correctly; p. 13 - 2. In the driver's cab –...
Page 903 Driving with a rigged truck crane 13.5 Driving from the crane cab If the symbol (1) is red, bring the ignition key in the driver's cab to position 1 – the symbol turns grey. • Select and confirm the symbol (2). The transmission is in the neutral position –...
Page 904 Driving with a rigged truck crane 13.5 Driving from the crane cab Closing Push the button below – apply the parking brake. • Select and confirm the symbol (1). • Press button (2) or (3). – The carrier ignition is switched off. –...
Page 905: Steering
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.3 Steering Switching on Opening the menu (1) switches on normal steering mode. Steering direction The steering direction is adjusted automatically to suit. – Turned to the front The buttons' direction of movement corresponds to the steering direction of the truck crane if the superstructure is in the 180°...
Page 906 Driving with a rigged truck crane 13.5 Driving from the crane cab Displays when The current steering angle of the wheels is displayed. steering The symbols show the current steering angle: 1 Straight ahead – position 2 Driving around corners 3 Crab travel mode Separate steering Always switch off the separate steering when driving a rigged truck crane.
Page 907 If the symbols (5) are yellow: Steer using the buttons (1) or (2) until the symbols (5) turn red. à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care Operating manual 3 302 690 en 13 - 23 GMK4100L-1...
Page 908 Driving with a rigged truck crane 13.5 Driving from the crane cab Automatic separate steering Symbol (1) or (2) is displayed • Steer the 1st and 2nd axle lines with the button (3). • – To turn to the left: Press the button (3) left.
Page 909 Driving with a rigged truck crane 13.5 Driving from the crane cab Steering with manual separate steering Symbol (1) is displayed • Steer the 1st and 2nd axle lines with the button (2). • Steer the 3rd and 4th axle lines with the button (3). •...
Page 910 Depending on the steering mode, steer using the buttons (3) or (5) until the symbols (1) turn green. à If the error symbol is displayed, contact p. 8 - 24. Manitowoc Crane Care 13 - 26 3 302 690 en Operating manual GMK4100L-1...
Page 911: Operating The Transmission
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.4 Operating the transmission After automatic opening, the symbols N, DM and RM are active. The transmission is in the neutral position – letter N (1) is white. Selecting the Which transmission mode you can select and how the transmission shifts transmission...
Page 912: Whilst Driving
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.5 Whilst driving DM and RM trans- The speed is limited to approx. 8 km/h (5 mph) (1st or 2nd gear only). mission mode Risk of accidents when driving with a lifted load! The maximum permissible speed for driving with a lifted load is 1.5 km/h (1 mph).
Page 913: Possible Connections
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.6 Possible connections Risk of damage to the differential locks Leave the transverse differential locks switched on only for as long as nec- essary. Always switch off the transverse differential locks before driving on a firm surface You can make the following connections, one after the other:...
Page 914 – first symbol (2) – yellow followed by symbol (3) – green, differential off. If symbol (3) is not green then drive back and forth slowly. If the error symbol is displayed, contact Manitowoc Crane Care 13 - 30 3 302 690 en Operating manual GMK4100L-1...
Page 915: After Driving
Driving with a rigged truck crane 13.5 Driving from the crane cab 13.5.7 After driving • Bring the truck crane to a halt with the brake pedal (1). • Restore the original condition: – Switch the transmission to neutral position (1) –...
Page 916 Driving with a rigged truck crane 13.5 Driving from the crane cab Blank page 13 - 32 3 302 690 en Operating manual GMK4100L-1...
Page 917: Malfunctions During Crane Operation
Malfunctions during crane operation 14.1 Emergency stop switch Malfunctions during crane operation 14.1 Emergency stop switch Risk of overloading if used improperly Press the emergency stop switch only if it is no longer possible to stop the crane movements with the normal operating elements. The emergency stop switch stops the crane movements suddenly.
Page 918: What To Do When Malfunctions Occur During Crane Operation
• Inform your supervisor. • Try to eliminate the malfunction. Inform if you Manitowoc Crane Care cannot correct the malfunction. • Load cannot Secure the danger area using cordons and warning signs. be set down •...
Page 919: Warning And Error Messages
• Program version Always note down the number of the program version and the serial number after a malfunction occurs before notifying Manitowoc Crane Care • Open the Program version menu (1). 1 Serial number display 2 Program version display 14.3.1...
Page 920 CAN bus malfunction • Switch off the ignition and wait about 15 seconds, then switch it on again. If the malfunction is still present, contact Manitowoc Crane Care Engine oil pressure • Switch off the engine as quickly as possible.
Page 921 Malfunctions during crane operation 14.3 Warning and error messages Refuelling The fuel tank is filled only to a level of about 5%. à • Refuel before the fuel is used up; p. 4 - 5. If the fuel tank is almost empty, air will be sucked in and you will have to à...
Page 922 Malfunctions during crane operation 14.3 Warning and error messages Pre-tension counterweight (early warning) The pre-tensioning pressure is at the lower limit – if the pre-tensioning pres- sure continues to drop, the slewing is disabled. à • Pre-tension the counterweight; p. 12 - 88. Pre-tension the counterweight The pre-tensioning pressure is too low.
Page 923: Error Messages On The Ccs Display
Malfunctions during crane operation 14.3 Warning and error messages 14.3.2 Error messages on the CCS display Risk of accidents Immediately stop operating the crane if an error message is displayed. The crane control may only be repaired by qualified personnel. •...
Page 924 • Select and confirm symbol (1) to acknowl- edge the error. If the error cannot be acknowledged, consult Manitowoc Crane Care. Error message display For each error the display shows: – the error code (5) – the symbols for...
Page 925: Warning Messages On The Rcl Display
Malfunctions during crane operation 14.3 Warning and error messages 14.3.3 Warning messages on the RCL display The buzzer tone sounds once when the RCL detects a malfunction. Lamps (2) and (3) light up. A symbol is displayed, e.g. the symbol (1). If several warning messages exist, all of the cor- responding symbols are displayed one after the other in consecutive order.
Page 926 Malfunctions during crane operation 14.3 Warning and error messages – Lattice extension angle too small à Raise the lattice extension; Lattice extension operating manual . – Lattice extension angle too large à Lower the lattice extension; Lattice extension operating manual . –...
Page 927 Malfunctions during crane operation 14.3 Warning and error messages – RCL override (switch 3) not actuated – RCL override (switch 3) actuated – RCL override, all switches actuated – Learn-in phase Displayed only during maintenance by service personnel – Data acquisition Displayed only during maintenance by service personnel –...
Page 928 Malfunctions during crane operation 14.3 Warning and error messages – Active working range limiter, maximum permissible slewing angle reached – Active working range limiter, maximum permissible working radius reached – Hoist rope travel limitation, upper or lower limit reached – Hoist rope travel limitation, working radius or telescope status changed If the described measures do not solve the problem, try to remedy the error by switching off the ignition and switching it on again after about 15 seconds.
Page 929: Troubleshooting
Control unit faulty, error mes- Acknowledge error mes- à sage is displayed sage once; p. 14 - 7 – if error persists, notify Manitowoc Crane Care Only the lifting function Lowering limit switch Leave the shutdown works approached range and raise the hoist.
Page 930 If required, acknowledge speed mode function not error message once and working briefly turn off the ignition – it if occurs again, notify Manitowoc Crane Care No lift function Control unit fuse blown Replace the blown fuse; à p. 14 - 73...
Page 931: Malfunctions In The Hoist Cameras
Check fuses and replace as à Manufacturer necessary; operating instructions . Connection between camera Check cable connection and and monitor is disconnected. notify Manitowoc Crane Care necessary. Extendable tripod not Fuse F7/5 blown Replace blown fuse; à working p. 14 - 73. 14.4.4...
Page 932: Malfunctions On The Derricking Gear
Acknowledge error mes- à sage is displayed sage once; p. 14 - 7 – if error persists, notify Manitowoc Crane Care Lowering function not Lifting limit switch Leave the shutdown working approached, lamp lights up range and lower the auxil-...
Page 933: Malfunctions In The Telescoping Mechanism
Control unit faulty, error Acknowledge error mes- à message is displayed sage once; p. 14 - 7 – if error persists, notify Manitowoc Crane Care Extending function not Control unit fuse blown Replace the blown fuse; à working p. 14 - 73...
Page 934: Malfunctions On The Slewing Gear
Acknowledge error mes- à message is displayed sage once; p. 14 - 7 – if error persists, notify Manitowoc Crane Care Enter RCL code for 0° to the Enter RCL code for a slew- rear position ing range Slewing function not Enter RCL code for 0°...
Page 935 Malfunctions during crane operation 14.4 Troubleshooting Malfunction Cause Solution Slewing only possible in Shutdown angle of a limited Enter the RCL code for a one direction slewing range reached (addi- slewing range of 360° ( Standard ) or reduce the tional equipment).
Page 936: Malfunctions On The Counterweight Hoist Unit
Electronic system has briefly turn off the ignition detected an electrical or – it if occurs again, notify logical error Manitowoc Crane Care à Extend lifting cylinder Superstructure unlocked Lock the superstructure , not working p. 11 - 16 14.4.9...
Page 937: Malfunctions When Operating With The Hand-Held Control
Pre-selected function Another function has been Pre-select the desired cannot be performed pre-selected function Operation not possible Malfunction in the control Inform Manitowoc Crane system Care 14.4.12 Malfunctions when inclining the crane cab Malfunction Cause Solution Crane cab inclination function Control unit fuse blown Replace the blown fuse;...
Page 938: Malfunctions Of The Outriggers
à bridging plug not inserted plug; p. 12 - 25 None of the specified Solenoid valves are not Inform Manitowoc Crane causes apply switching electrically Care 14.4.15 Malfunctions on the turntable lock Malfunction Cause Solution...
Page 939: Malfunctions On The Ccs/Rcl Control Units
– it if occurs again, notify Manitowoc Crane Care If this table does not help to remedy the malfunction; à Malfunctions in the transmission , p. 8 - 23, à...
Page 940: Malfunctions On The Cranestar System
Malfunctions during crane operation 14.4 Troubleshooting 14.4.18 Malfunctions on the CraneSTAR system If an error is present, then check the fuses and the electronic connections. Risk of damage if procedure is incorrect Observe the following notes to avoid malfunctions and damage. –...
Page 941 Malfunctions during crane operation 14.4 Troubleshooting • Check the fuses (1) and replace them if necessary. Designation Amperage F3401 F3402 • Check whether the plugs (2) are plugged in: After checking • Fold the plate (3) up and secure it with the screws (4).
Page 942 Malfunctions during crane operation 14.4 Troubleshooting Blank page 14 - 26 3 302 690 en Operating manual GMK4100L-1...
Page 943: Emergency Operations And Programs
Malfunctions during crane operation 14.5 Emergency operations and programs 14.5 Emergency operations and programs This section contains all the information about possible emergency opera- tions and emergency programs. The following are available: – Mechanical emergency activation for retracting, – The Telescoping emergency program menu, –...
Page 944: Mechanical Emergency Activation For Retracting
The best suitable retracting procedures in your particular case depend on the conditions on site and on the crane functions that are still available. Select the procedure best suited to your particular case and consult Manitowoc Crane Care 14 - 28 3 302 690 en...
Page 945 Malfunctions during crane operation 14.5 Emergency operations and programs Mechanical The following requirements must be met before unlocking manually: emergency – The main boom must be lowered to the horizontal position so that the activation telescopic section cannot retract by itself. –...
Page 946 Malfunctions during crane operation 14.5 Emergency operations and programs Releasing the lock • (A) – Extend about 35 mm (0.11 ft), so that the cutout (4) is accessible. • (B) – Screw a bolt into the bore (1). The lock- ing pins (2) must retract behind the tele- scopic section (3).
Page 947: Telescoping Emergency Program
Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.2 Telescoping emergency program The emergency program is intended only for retracting the telescoping when operation with the teleautomation menus is no longer possible due to a malfunction. The emergency program is enabled only when the current locking status can still be detected by the crane control.
Page 948 Malfunctions during crane operation 14.5 Emergency operations and programs • Telescoping emer- If possible, set down the load before starting the emergency program; à What to do when malfunctions occur during crane operation , p. 14 - 2. gency program menu •...
Page 949 Malfunctions during crane operation 14.5 Emergency operations and programs Notes on the These operating instructions describe only the displays required for opera- displays tion of the emergency program. The displays shown in (1) are required for expanded emergency operation and are mainly intended for service personnel.
Page 950 You have no way of determining the locking point of a telescopic section. In this case, consult Manitowoc Crane Care Risk of damage to the telescoping mechanism Never telescope the main boom without any length indicator display.
Page 951 If the required symbol (1) is displayed, you can operate the emergency à Retracting with emergency program , p. 14 - 38. program; If the symbol (2) is still displayed, the emergency program will be disabled. Contact Manitowoc Crane Care Operating manual 3 302 690 en 14 - 35 GMK4100L-1...
Page 952 If the symbol (3) is still displayed, the emer- gency program will be disabled. Contact Manitowoc Crane Care Status 3 – Telescoping cylinder on return run (without telescopic section) In this status, you should first check the functioning of the display for Shortly after the locking point and then check the functioning of the emergency program.
Page 953 If the symbol (5) is displayed, you can operate à the emergency program; p. 14 - 38. If the symbol (3) is still displayed, the emer- gency program will be disabled. Contact Manitowoc Crane Care Operating manual 3 302 690 en 14 - 37 GMK4100L-1...
Page 954 Malfunctions during crane operation 14.5 Emergency operations and programs Retracting This section describes a telescoping process for retracting in four steps. The starting position is a telescopic section locked at a fixed length and the telescoping with emergency cylinder locked in the telescopic section , which results in the sequence of steps program given here.
Page 955 Malfunctions during crane operation 14.5 Emergency operations and programs 3. Unlock the telescoping cylinder • Select and confirm the symbol (1). The telescoping cylinder is unlocked – display symbol (2). 4. Extend and lock the telescoping cylinder • During the first return run, check the display Shortly after the locking point and observe the specifications in the corresponding section;...
Page 956 Malfunctions during crane operation 14.5 Emergency operations and programs Tables for The extent to which the telescoping cylinder has to be extended in order to approaching the reach a locking point depends on whether you want to lock: locking points –...
Page 957 Malfunctions during crane operation 14.5 Emergency operations and programs Locking points for the telescopic sections The telescopic section must not be set down for locking or unlocking it. The cutout (1) must be clear. That is why you have to extend the telescoping cylinder about 25 mm further than for a return run.
Page 958 Malfunctions during crane operation 14.5 Emergency operations and programs Blank page 14 - 42 3 302 690 en Operating manual GMK4100L-1...
Page 959: Entering The Current Telescoping
Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.3 Entering the current telescoping CCS no longer displays the current telescoping – if you telescoped in emergency mode, or – if the power supply was interrupted in the course of saving data. In these cases, you must enter the current telescoping, e.g.
Page 960 Malfunctions during crane operation 14.5 Emergency operations and programs You can cancel the entry at any time using the (1) or (2) buttons. Risk of damage due to incorrect input Before working with the crane, check whether CCS indicates the current telescoping and correct if this is not the case.
Page 961: Emergency Operation With The Hand-Held Control
Malfunctions during crane operation 14.5 Emergency operations and programs 14.5.4 Emergency operation with the hand-held control If the power units no longer respond to the operating elements in the crane cab, you can operate the power units with the hand-held control. Operating them with the hand-held control is intended for emergencies only and for bringing the truck crane into a safe state or to shut it down.
Page 962 Malfunctions during crane operation 14.5 Emergency operations and programs To pre-select a The preselection is the same for all power units except the telescoping power unit mechanism. • Press the corresponding button once, e.g. button (1) for the main hoist. The lamp in the button illuminates –...
Page 963 Malfunctions during crane operation 14.5 Emergency operations and programs Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoist mechanism gear gear extension combination Lock None Lower Lowering Lower turntable Unlock Retract Raise Lifting Raise turntable None None Slew to right None None None...
Page 964: Notes On Slewing In Emergency Operation
Check the table to see if slewing is permitted. Adhere to the enabled work- ing range specified in the lifting capacity table and observe the restrictions described. If you have any doubts, contact Manitowoc Crane Care 14 - 48 3 302 690 en Operating manual...
Page 965 Malfunctions during crane operation 14.5 Emergency operations and programs Rigged outrigger span 8.660 x (28.4 x) 100% 2.340 m 3.800 m 5.300 m 6.250 m 7.200 m Free on (7.6 ft) (12.4 ft) (17.4 ft) (20.5 ft) 23.6 ft) wheels 0.8 t (1,764 lbs) 4.5 t...
Page 966 If you have any doubts, contact Manitowoc Crane Care When slewing with the hand-held control is unavoidable • Refer to the lifting capacity table (provided in digital form only) for the slewing ranges applicable to the current rigging mode.
Page 967: Hydraulic Emergency Operation With The Hand Pump
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6 Hydraulic emergency operation with the hand pump This section only applies to the standard hydraulic emergency operation. If the truck crane is equipped with an hydraulic emergency operation à...
Page 968: Establishing The Hydraulic Circuits Required
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6.3 Establishing the hydraulic circuits required You must switch over the necessary valves to establish a hydraulic circuit. The valves 1 to 3 are secured against unintentional switching over. Releasing/ Releasing/securing is described for a valve.
Page 969 Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump Switching over The valves 1 to 3 are labelled with their respective numbers. valves For crane operation • Switch the valves (1), (2) and (3) downwards. • Secure the valves in this position; à...
Page 970 Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump For lowering You must additionally switch a valve to continuous operation for lowering. Switching on continuous operation • Remove the cap (2) from valve Y1104 – Lowering (1). •...
Page 971: Performing Emergency Activation
Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump 14.6.4 Performing emergency activation If the required hydraulic circuit has been established, you can make the corresponding crane movement using the hand pump (1). • Insert the pump lever (2) provided into the holder at the hand pump lever.
Page 972 Malfunctions during crane operation 14.6 Hydraulic emergency operation with the hand pump • Remove the lever from the hand pump. Additionally after the lowering à • Switch off continuous operation on the valve Y1104; p. 14 - 54. 14 - 56 3 302 690 en Operating manual GMK4100L-1...
Page 973: Applications And Function
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7 Hydraulic emergency operation as per BGR 159 With this additional equipment, the truck crane is equipped with an hydrau- lic emergency bleed valve in accordance with BGR 159 (4.2.8). This allows small loads to be transported in case of emergency, e.g.
Page 974 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 Emergency supply You can supply another crane that also has an hydraulic emergency operation BGR159. In the event of emergency supply, the connec- tions (1) feed a transformer (2) which is con- nected to the hydraulic system of the other crane.
Page 975: Checklist: Emergency Operation
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.2 CHECKLIST: Emergency operation This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1.
Page 976: Checklist: After Emergency Operation
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.3 CHECKLIST: After emergency operation This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified here! 1.
Page 977: Connecting/Removing Transformer - For Self-Sufficiency
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.4 Connecting/removing transformer – for self-sufficiency • Switch the engine off. Risk of damage to the hoses Lay the hoses in such a manner that they can be moved freely, so as to pre- vent them being crushed or torn or becoming caught during subsequent crane movements.
Page 978 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 Removing After the emergency operation, you must disconnect the hoses and the transformer. On the superstructure • Remove the hoses (2) from the connec- tions (1). • Close off the hoses and connections with the caps.
Page 979: Switching Emergency Operation On/Off
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.5 Switching emergency operation on/off Switching on • Start the engine. • Select and confirm the symbol (1) – Symbol (2) is displayed. Emergency operation is switched on. Switching off •...
Page 980: Connecting/Removing Transformer - For External Energy Source
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.6 Connecting/removing transformer – for external energy source The external energy source can be provided by a vehicle with hydraulic emergency operation according to BGR 159 or by an external, hydraulic energy source that meets the requirements of hydraulic emergency opera- tion according to BGR 159.
Page 981: Establishing The Required Hydraulic Circuits
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.7 Establishing the required hydraulic circuits You must switch over the necessary valves to establish a hydraulic circuit. Switching The valves 1 to 5 are labelled with their respective numbers. over valves For crane operation •...
Page 982 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 For emergency operation • If necessary, remove the cover over the valves 1 to 5. • Switch the valves 1 to 5 to the positions for the desired crane movement – as shown in the following table.
Page 983 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 For lifting/ After establishing hydraulic circuits, switch one additional valve to continu- lowering ous operation. Switching on continuous operation Always switch only one valve to continuous operation. 1 Valve Y1104 – Lowering or 2 Valve Y1105 –...
Page 984 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 For slewing After switching over the valves behind the crane cab, you must also close a valve. (A) – Emergency operation position • Close the valve 6 – lever (1) at right angles to the line.
Page 985: Performing Emergency Operation
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.8 Performing emergency operation If the required hydraulic circuit has been established, you can make the corresponding crane movement. You can control the speed of all power units with the control lever. Slewing It is not possible to control the slewing movements with the control lever for emergency operation with the same degree of sensitivity as with the control...
Page 986 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 • Derricking Determine the maximum permissible working radius for the current rigging mode according to the Lifting capacity table . 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.
Page 987: Emergency Supply Of Another Crane
Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 14.7.9 Emergency supply of another crane For emergency The hoses are assigned according to the various diameters. supply – On the crane to be supplied • Attach the transformer (3). à...
Page 988 Malfunctions during crane operation 14.7 Hydraulic emergency operation as per BGR 159 Blank page 14 - 72 3 302 690 en Operating manual GMK4100L-1...
Page 989: Fuses In The Crane Cab
Notify if a fuse with the same amperage blows again Manitowoc Crane Care when the ignition is switched on. Risk of fire Never repair a blown fuse with other electrically conductive materials.
Page 990 Malfunctions during crane operation 14.8 Fuses in the crane cab • Loosen the bolts (2) and remove the cover (1). The fuse groups F1 to F8 consist of eight fuses each. The following tables show the designations of the individual fuses, including their amperage and functions.
Page 991 Malfunctions during crane operation 14.8 Fuses in the crane cab Designation Amperage (A) Function F2/1 Control unit UB 1 IOL 30 F2/2 Control unit UB 2 IOL 30 F2/3 Control unit UB 2 IOL 30 F2/4 Control unit UB 1 IOL 34 F2/5 Control unit UB 2 IOL 34 F2/6...
Page 992 Malfunctions during crane operation 14.8 Fuses in the crane cab Designation Amperage (A) Function F4/1 Control unit UE IOL 30, CCM 10, UE SCM F4/2 Reserve F4/3 CraneSTAR system F4/4 Radio F4/5 – Unassigned F4/6 – Unassigned F4/7 – Unassigned F4/8 –...
Page 993 Malfunctions during crane operation 14.8 Fuses in the crane cab Designation Amperage (A) Function F6/1 Windscreen washing system F6/2 Sockets 12 V F6/3 Crane cab spotlight F6/4 Main boom spotlight F6/5 House Lock F6/6 CraneSTAR system F6/7 Radio control F6/8 Camera system Designation Amperage (A)
Page 994 Malfunctions during crane operation 14.8 Fuses in the crane cab Blank page 14 - 78 3 302 690 en Operating manual GMK4100L-1...
Page 995 Index Index To avoid making the index unnecessarily long and unclear, we have not included every single element from the instrument panel. Those elements, such as switches and buttons, lamps and displays are described and named in detail in the overviews of Chapter 3 and Chapter 9 Truck Crane Description .
Page 996 Index Blank page 15 - 2 3 302 690 en Operating manual GMK4100L-1...
Page 997 Index AdBlue system operating elements in the crane cab ....... . 11 - 92 operating elements in the driver's cab .
Page 998 Index operating elements in the driver's cab ....... . 5 - 58 Parking brake .
Page 999 Index in the date/time menu ......... . 5 - 30 in the display brightness menu .
Page 1000 Index slewing with rigged counterweight ....... . . 14 - 97 unrigging automatic mode .

Manitowoc Grove GMK4100L-1 Operating Manual

Overview

Accidents

Branch Offices

Warranty Specifications

Terms Used

Technical Data

Documentation Supplied

Notes on the Operating Manual

Conversion Table for US Measuring Units

Training - Information

Identification

EC Declaration of Conformity

6.1 Driving Modes

Quick Links

Troubleshooting

Related Manuals for Manitowoc Grove GMK4100L-1

Summary of Contents for Manitowoc Grove GMK4100L-1