Page 1 Operating manual Part 1 – Driving 3 112 993 en 12.07.2013...
Page 2 Important note Any kind of duplication or excerpt from this document, even in electronic form, is not subject to updating by Manitowoc Crane Group Germany GmbH. © Copyright reserved by Manitowoc Crane Group Germany GmbH Industriegelände West D-26389 Wilhelmshaven, Germany...
Page 3 Correction sheet Possible reeving methods on the main boom Contrary to the information specified in the operating manual, there are corrected hoist rope reevings on the main boom for the GMK6400 truck crane. Only reeve the hoist rope as described/illustrated in this correction sheet. It is important that you still observe all notes and safety instructions regarding rigging work on the main boom in the operating manual supplied.
Page 4 5 sheave hook block Reeving 3 sheave hook block Reeving 3 302 804 en Correction sheet GMK6400...
Page 5 1 sheave hook block Reeving Hook tackle Reeving Correction sheet GMK6400 3 302 804 en...
Page 6 With 10 head sheaves 11 sheave hook block Reeving 9 sheave hook block Reeving 3 302 804 en Correction sheet GMK6400...
Page 7 7 sheave hook block Reeving 5 sheave hook block Reeving Correction sheet GMK6400 3 302 804 en...
Page 8 3 sheave hook block Reeving 1 sheave hook block Reeving 3 302 804 en Correction sheet GMK6400...
Page 9 Hook tackle Reeving Correction sheet GMK6400 3 302 804 en...
Page 10 Blank page 3 302 804 en Correction sheet GMK6400...
Page 11 Technical data Contrary to the information given in the operating instructions supplied, the technical data have changed in part. Operating speeds The specified operating speeds only apply to an engine speed of about 1300 rpm without load. Main hoist: Rope speed when lifting and lowering Normal speed: maximum 50 m/min (164 ft/min) High-speed mode: maximum 120 m/min (394 ft/min)
Page 12 Blank page 3 113 115 en Correction sheet GMK6400...
Page 13 Safety harness on the main boom This truck crane is equipped with a safety har- ness (1) on the main boom. The safety harness is fixed securely to the main boom. The safety harness consists of two ropes with spacers and wear pads. Always secure yourself with the safety har- ness and your personal protective equipment when you have to step on the main boom,...
Page 14 The weight of the person to be secured must not exceed 140 kg (309 lbs). If you are unsure about which type of fall prevention safety system is required, please contact Manitowoc Crane Care 3 113 060 en Additional page GMK6400...
Page 15 Attaching/detaching fall prevention safety system to/from safety harness Attachment All points designed for fastening a fall prevention safety system are marked with a symbol. When stepping, observe the following procedure so that you are always secured. Risk of accidents due to incomplete safety system Make sure you always attach one line of the fall prevention safety system with the safety harness before stepping onto the main boom.
Page 16 Detachment Risk of accidents due to incomplete safety system Only detach the second line of the catch belt once you have reached a secure position on a ladder or access ladder. This will prevent falling due to an incomplete safety system. When stepping, observe the following procedure so that you are always secured.
Page 17 Make sure damaged, worn, or deformed fastening or connecting parts are immediately replaced by or an authorised GROVE Manitowoc Crane Care dealer or your repair crew. The safety harness must always be replaced completely following stress caused by a fall, even if no damage can be detected.
Page 18 Blank page 3 113 060 en Additional page GMK6400...
Page 19 Anemometer and air traffic control light Transport The storage compartment (1) for anemome- ters and air traffic control lights described in the accompanying operating manual is only available for certain versions of truck crane. In this case the rod (2) is fastened to the main boom head for transport and the anemometer (3) and air traffic control lights are transported in the crane cab.
Page 20 For transport à • Operating Dismount the anemometer; manual . • (A) – Remove the anemometer (1) and the air traffic control lights – if available – from the rod (3). • Fasten the linchpin (2) to the rod (3). •...
Page 21 Use of additional head sheaves These additional pages only apply for GMK 6400 that – are equipped with a second head sheave (2) – (A) – are equipped with 7 head sheaves (1) – (B) – are equipped with 7 head sheaves (1) and an additional head sheave (3).
Page 22 Risk of accident due to a damaged hoist rope Always use the second head sheave together with the additional head sheave located underneath it or with the auxiliary single-sheave boom top. This prevents the hoist rope from becoming overloaded, snapping during operation and letting the load fall.
Page 23 Instructions for operation with a trailer For operation with a trailer there are support points (2), locking points (3) and lashing eye- lets (1) on each side of the main boom. • Always set the main boom down on a trailer so that the support points (2) and locking points (3) are in contact with the corre- sponding counter bearings of the trailer...
Page 24 Maximum The lashing eyelets, support points and locking points are designed for the permitted load maximum forces listed below. Lashing eyelets The maximum forces permitted for the lashing eyelets (1) are F1 and F2 in the direction indi- cated. – Horizontally: F1 = max. 45 kN (10 115 lbf) –...
Page 25 This operating manual is divided into two parts: Part 1 – Driving Part 2 – Crane operation Contents overview of part 1: 1 Overview 2 Basic safety instructions 3 Operating elements for driving 4 Starting/turning off the engine for driving 5 Driving 6 Driving modes and rigging for on-road driving 7 Malfunctions in driving mode...
Page 26 Blank page 3 112 993 en Operating manual GMK 6400...
Page 27: Table Of Contents
Manitowoc Crane Care ........
Page 28 3 112 993 en Operating manual GMK 6400...
Page 29: Overview
1.1 Accidents Overview Accidents In the case of an accident, contact the relevant branch office of Manitowoc in the country in which you are working and specify your crane Crane Care 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 30: 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/MCG_CARE/Contact_Us/EN/ContactUs.asp 1.2.2 Dealer list Visit the following address for a global list of dealers: http://www.manitowoccranegroup.com/DealerLocator/locator.asp...
Page 31 Overview 1.3 Warranty specifications Blank page Operating manual GMK 6400 3 112 993 en 1 - 3...
Page 32: Terms Used
Overview 1.4 Terms used Terms used 1 - 4 3 112 993 en Operating manual GMK 6400...
Page 33 Overview 1.4 Terms used (A) – Carrier 1 Driver's cab 2 Boom rests 3 Counterweight platform 4 Axle lines 5 Outrigger beams 6 Supporting cylinders 7 Outrigger pads (B) – Superstructure 8 Slewing gear 9 Crane cab 10 Main boom with telescoping mechanism 11 Telescopic sections 12 Hook block 13 Derricking cylinder, derricking gear...
Page 34 Overview 1.4 Terms used Blank page 1 - 6 3 112 993 en Operating manual GMK 6400...
Page 35: Technical Data
Overview 1.5 Technical data Technical data GROVE crane GMK 6400 Permissible temperature range: –25°C to +40°C (–13°F to +104°F) Crane designation: Truck crane in accordance with DIN 15 001, part 1 Crane application: Service crane in accordance with DIN 15 001, part 2 Crane classification: Hoist class H1 in accordance with DIN 15 018, part 1...
Page 36: Dimensions And Weights Of The Truck Crane, Axle Loads
Overview 1.5 Technical data 1.5.2 Dimensions and weights of the truck crane, axle loads All dimensions in the illustration are in mm. 1 - 8 3 112 993 en Operating manual GMK 6400...
Page 37 Overview 1.5 Technical data à Driving modes , p. 6 - 1. Dimensions All dimensions relate to on-road mode; Length without auxiliary 17.58 m (57.7 ft) hoist: Height: At on-road level: – 385/95 R25 3.95 m (13 ft) – 445/95 R25; 525/80 R25 4.00 m (13.1 ft) Max.
Page 38: Dimensions And Weights Of Removable Parts
Overview 1.5 Technical data 1.5.3 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 Designation in m (ft)
Page 39 Overview 1.5 Technical data Main boom Designation Length x width x Weight in kg (lbs) height in m (ft) Complete main boom 16.0 x 2.0 x 2.0 27 500 (52.5 x 6.6 x 6.6) (60 630) Hook blocks and hook tackle Length x width x height Weight...
Page 40 Overview 1.5 Technical data Counterweight- sections version A Length x width x Weight Designation height in m (ft) in kg (lbs) 15 t base plate 5.48 x 2.50 x 1.71 15 000 (17.98 x 8.20 x 5.61) (33 070) each 10 t plate 1.95 x 2.45 x 0.38 10 000 (6.40 x 8.04 x 1.25)
Page 41: Carrier
Overview 1.5 Technical data 1.5.4 Carrier Engine Mercedes-Benz: OM 502 LA Engine emission: EUROMOT 3A \ EPA \ EUROMOT 3B \ EPA \ CARB (off road) CARB (off road) Power: 450 kW (612 HP) at 405 kW (550 HP) at 1800 rpm 1800 rpm (80/1269 - 89/491 EEC –...
Page 42 Overview 1.5 Technical data Tyres 12 x 385/95 R 25 on disc wheels 9.50-25/1.7 12 x 445/95 R 25 on disc wheels 11.00-25/1.7 12 x 525/80 R 25 on disc wheels 17.00-25/1.7 Additional equipment Torque for wheel nuts: 650 Nm (480 lbf ft). Tyre pressure with cold tyres for axle loads up to max.
Page 43 Overview 1.5 Technical data Outriggers Design: 4-point telescoping outrigger system Control system: Can be controlled from both sides on the car- rier and individually from the crane cab Outrigger spans: 8.70 x 8.50 m (28.5 x 27.9 ft) 8.70 x 7.40 m (28.5 x 24.3 ft) 8.70 x 6.30 m (28.5 x 20.4 ft) 8.70 x 5.00 m (28.5 x 16.4 ft) 8.70 x 2.71 m (28.5 x 8.9 ft)
Page 44 Overview 1.5 Technical data Turning radii All dimensions in the illustration are in mm. = values for normal steering mode = values for all-wheel steering 1 - 16 3 112 993 en Operating manual GMK 6400...
Page 45: Superstructure
Overview 1.5 Technical data 1.5.5 Superstructure Main hoist Drum diameter: 464 mm (18.27 in) (rope centre to rope centre) Rope diameter: 24 mm (0.95 in) Rope length: 380 m (1 246 ft) Rope pull: 110 kN/line (24 730 lbf) Power unit group: M 3 (in accordance with ISO 4301 - 2) Load spectrum: Factor of the load...
Page 46 Overview 1.5 Technical data Derricking gear Cylinder: Differential cylinder Adjusting angle –1.5° to + 83° from horizontal position (main boom): Power unit group: M2 (in accordance with ISO 4301 - 2) Main boom Main boom lengths: 15.4 m to 60.0 m (50.5 ft to 196.9 ft) Main boom head: 7 sheaves 10 sheaves...
Page 47: 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 48: Questions On Documentation
Dealer list , p. 1 - 2. You can find your responsible dealer here: You can also send questions in either German or English directly to: E-mail: whv-techpublications@manitowoc.com In case of repeat orders for documentation, please contact our EMEA service.
Page 49: Notes On The Operating Instructions
Overview 1.7 Notes on the operating instructions Notes on the operating instructions These operating instructions are not a training manual for prospective crane operators. All descriptions have been written explicitly for crane operators who have been trained to operate truck cranes. These operating instructions are designed as a reference manual.
Page 50 Overview 1.7 Notes on the operating instructions 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 51: How Are The Operating Instructions Structured
Overview 1.7 Notes on the operating instructions 1.7.2 How are the operating instructions structured? Division The operating instructions are divided into two parts. – Part 1 with chapters 1 to 8 contains a description of how to drive the truck crane.
Page 52 Overview 1.7 Notes on the operating instructions Structure of the Each page of the operating instructions is divided into a wide text column pages and a narrow column. The narrow column contains various pieces of information: – Chapter and section numbers –...
Page 53: How Do I Find The Information I Need
Overview 1.7 Notes on the operating instructions 1.7.3 How do I find the information I need? The operating instructions contain the following guides for orientation. – The Contents at the front in sections 1 and 2 list all the chapters in the sec- tion.
Page 54 Overview 1.7 Notes on the operating instructions Cross-references The illustrations and texts in this section are only an example and may differ example from the conditions on your truck crane. 1 - 26 3 112 993 en Operating manual GMK 6400...
Page 55 Overview 1.7 Notes on the operating instructions The parking brake is used as an example to show how the cross-references guide you through the operating instructions. A In this example, the general overview is shown on page 4 - 2. The driver's cab is labelled as number 1.
Page 56: What Information Is Available For Operations Planning
Overview 1.7 Notes on the operating instructions 1.7.4 What information is available for operations planning? Extensive information is required for operations planning in order to guar- antee safe, smooth and efficient operation of the truck crane: The operating instructions contain à...
Page 57: 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 when the truck crane is used in countries that use US units of measurement and vice versa.
Page 58 Overview 1.8 Conversion table for US measuring units Blank page 1 - 30 3 112 993 en Operating manual GMK 6400...
Page 59: Training - Information
Overview 1.9 Training – Information Training – Information For the EMEA (Europe, Middle East, Africa) area, Manitowoc Crane Group offers comprehensive training for crane types GMK Germany GmbH and GTK. Our training centre is located in a maritime environment, on Germany's North Sea coast in Wilhelmshaven.
Page 60: Identification
Overview 1.10 Identification 1.10 Identification 1 - 32 3 112 993 en Operating manual GMK 6400...
Page 61 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, only with truck cranes that are delivered in member countries of the EU. 3 The serial number of the driver's cab 4 The chassis number and crane type 5 The chassis number in front of the first axle line in the frame.
Page 62: 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 Con- formity as a supplement to the delivery protocol. An illustration of the Dec- laration of Conformity is shown below. This Declaration of Conformity is only valid if the rated capacity limiter of the truck crane is programmed in accordance with the stand-...
Page 63 Basic safety instructions Intended use ............2 - 2.1.1 Improper use .
Page 64 3 112 993 en Operating manual GMK 6400...
Page 65: Basic Safety Instructions
Nevertheless, the operator or third parties can still be endangered and the crane or other property put at risk while using it. The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
Page 66: Improper Use
Basic safety instructions 2.1 Intended use 2.1.1 Improper use Manitowoc Crane Group Germany GmbH is not liable for damage resulting from improper or unauthorized use of the GMK 6400 truck crane. The user alone bears the risk. Improper use includes: –...
Page 67: Organisational Measures
Basic safety instructions 2.2 Organisational measures Organisational measures The operating instructions 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 these operating instructions and comply with them when working.
Page 68 To avoid damage, especially to electronic parts, there are certain measures you must take before doing any welding work. You should therefore always consult Manitowoc Crane Care before any welding work. Make sure that the prescribed intervals and the intervals specified in the operation and maintenance manual for periodic inspections, tests and maintenance work are adhered to.
Page 69: Qualifications Of The Staff
Only trained personnel with special knowledge and experience in the fields of hydraulics, pneumatics and electrical equipment and electronics may carry out maintenance work on the truck crane. Manitowoc Crane Group Germany GmbH conducts general and type-spe- cific crane operator courses and technical courses. Operating manual GMK 6400...
Page 70: Safety Instructions For Driving The Truck Crane
Basic safety instructions 2.4 Safety instructions for driving the truck crane 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 instructions.
Page 71 Basic safety instructions 2.5 Safety instructions for crane operation Keep all handles, steps, step treads and ladders free of dirt, snow and ice. Keep all electric and hydraulic connections free from dirt. Check the con- necting points for dust, foreign bodies and moisture before installation. This also applies to protective caps and bridging plugs.
Page 72: Notes On Transporting Persons
Basic safety instructions 2.6 Notes on transporting persons Notes 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 73 Basic safety instructions 2.6 Notes on transporting persons Operation Operations planning for transporting persons must be carried out with spe- cial care. If official registration is required in the country in which you are working, this must be done with the relevant authorities in good time. The truck crane must be equipped as prescribed and be level.
Page 74 Basic safety instructions 2.6 Notes on transporting persons Truck crane The truck crane must be equipped such (e.g. with hydraulic emergency operation) that the equipment for lifting persons can be set down and that persons transported can safely leave it even if there is a failure of the drive or crane control.
Page 75 Operating elements for driving Overview of the operating elements ........3 - 3.1.1 On the outside of the truck crane .
Page 76 3 112 993 en Operating manual GMK 6400...
Page 77: 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. If the receptacle (1) is present, then the truck crane is equipped with the additional equip- ment DEF system The DEF system is only present on truck cranes that comply with the exhaust emissions in...
Page 78: 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 3 112 993 en Operating manual GMK 6400...
Page 79 Operating elements for driving 3.1 Overview of the operating elements à 1 Front flap p. 3 - 64 à 2 Driver's cab p. 3 - 4 à 3 Valves on hydraulic tank p. 4 - 11 4 Hydraulic oil cooler, second cooler à...
Page 80: Driver's Cab
Operating elements for driving 3.1 Overview of the operating elements 3.1.2 Driver's cab Overview 3 - 4 3 112 993 en Operating manual GMK 6400...
Page 81: Instrument Panel
Operating elements for driving 3.1 Overview of the operating elements à 1 Passenger's seat p. 5 - 12 2 Storage space or 2nd passenger seat à 3 Instrument panel p. 3 - 7 à 4 Parking brake p. 3 - 49 à...
Page 82 Operating elements for driving 3.1 Overview of the operating elements Behind the cover à 1 Fuses p. 7 - 19 In the rear of the driver's cab 1 Spare key, spare selector handle for battery master switch, radio equipment 3 - 6 3 112 993 en Operating manual GMK 6400...
Page 83 Operating elements for driving 3.1 Overview of the operating elements 3.1.3 Instrument panel Left/right à 1 Lighting on/off p. 3 - 56 à 2 Heating/Air-conditioning system p. 3 - 26 à 3 Spotlights on the rear of the carrier p. 3 - 57 à...
Page 84 Operating elements for driving 3.1 Overview of the operating elements Middle 3 - 8 3 112 993 en Operating manual GMK 6400...
Page 85 Operating elements for driving 3.1 Overview of the operating elements à 1 CAN BUS system malfunction p. 5 - 50 à 2 Torque reduction indicator lamp p. 5 - 52 à 3 Fog light indicator lamp p. 3 - 55 à...
Page 86 Operating elements for driving 3.1 Overview of the operating elements Middle 3 - 10 3 112 993 en Operating manual GMK 6400...
Page 87: 27 Display, Driving Mode
Operating elements for driving 3.1 Overview of the operating elements à 18 Steering circuit warning lamp p. 3 - 50 à 19 Parking brake indicator lamp p. 3 - 49 20 Air filter indicator lamp à 21 Superstructure ignition indicator lamp p.
Page 88 Operating elements for driving 3.1 Overview of the operating elements 3.1.4 Display, driving mode à 1 Tempomat display p. 5 - 22 à 2 Display for gearbox malfunctions p. 7 - 30 à 3 Transmission display p. 3 - 43 à...
Page 89: Steering Column/Steering Wheel
Operating elements for driving 3.1 Overview of the operating elements 3.1.5 Steering column/steering wheel à 1 Horn/headlight flasher/headlight – full beam p. 3 - 55 à Turn signal indicator/wiper-washing system p. 3 - 55 à 2 – Set idling speed p.
Page 90: Transmission Operating Elements
Operating elements for driving 3.1 Overview of the operating elements 3.1.6 Transmission operating elements à 1 Switch lever p. 3 - 45 à 2 Selecting the transmission mode p. 3 - 42 à Reverse camera on p. 3 - 46 3 without function 3 - 14 3 112 993 en...
Page 91: Tachograph
Operating elements for driving 3.1 Overview of the operating elements 3.1.7 Tachograph Tachograph à 1 Display p. 5 - 19 à 2 Time correction –: p. 3 - 60 à 3 Time correction +: p. 3 - 60 à 4 Opening the drawer p.
Page 92: Ecos Control Unit
Operating elements for driving 3.1 Overview of the operating elements 3.1.8 ECOS control unit 3 - 16 3 112 993 en Operating manual GMK 6400...
Page 93 Operating elements for driving 3.1 Overview of the operating elements à 1 ECOS display p. 3 - 41 à Main menu overview p. 3 - 18 à Reverse camera display p. 3 - 46 à 2 Sensor for brightness p. 3 - 41 à...
Page 94: Ecos Display - Main Menu
Operating elements for driving 3.1 Overview of the operating elements 3.1.9 ECOS display – Main menu 3 - 18 3 112 993 en Operating manual GMK 6400...
Page 95 Operating elements for driving 3.1 Overview of the operating elements à 1 Displaying vehicle height p. 5 - 8 à 2 Suspension display p. 3 - 53 à 3 Level adjustment system submenu p. 3 - 20 à 4 Monitoring submenu p.
Page 96: Ecos Display - Submenus
Operating elements for driving 3.1 Overview of the operating elements 3.1.10 ECOS display – Submenus Level adjustment system submenu 3 - 20 3 112 993 en Operating manual GMK 6400...
Page 97 Operating elements for driving 3.1 Overview of the operating elements à 1 Switch between measuring ranges p. 3 - 60 à 2 Display of current inclination p. 3 - 59 à 3 Overall level pre-selection p. 3 - 58 à 4 Front level pre-selection p.
Page 98 Operating elements for driving 3.1 Overview of the operating elements Settings submenu à 1 Setting the speed, transmission mode DM and RM p. 5 - 34 à 2 Lamp test p. 4 - 13 à 3 Operating hours submenu p. 3 - 24 à...
Page 99 Operating elements for driving 3.1 Overview of the operating elements Submenu Checking à 1 Hydraulic oil temperature display p. 4 - 23 à 2 DEF supply display p. 4 - 23 à 3 Voltage monitoring display p. 4 - 23 à...
Page 100 Operating elements for driving 3.1 Overview of the operating elements à Displaying the operating hours , p. 5 - 21. Operating hours Description of the displays; submenu 1 ECOS – superstructure 2 Auxiliary drive gears 3 Telescoping mechanism 4 Hydraulic system drive in the superstruc- ture 5 Derricking gear 6 Locking system...
Page 101 Operating elements for driving 3.1 Overview of the operating elements Error submenu à 1 Displaying errors/total errors p. 7 - 36 à 2 Next error p. 7 - 36 à 3 Previous error p. 7 - 36 à 4 Error display p.
Page 102: Heating/Air-Conditioning System
Operating elements for driving 3.1 Overview of the operating elements 3.1.11 Heating/Air-conditioning system Standard heating system à 1 Setting the blower/fresh air/recirculated air p. 5 - 70 à 2 Air distribution p. 5 - 71 à 3 Setting the temperature p.
Page 103 Operating elements for driving 3.1 Overview of the operating elements Auxiliary water heating system à 1 Heating display p. 5 - 78 à 2 Setting the time and weekday p. 5 - 78 à 3 – Saving the automatic heating start p.
Page 104: Sockets For Hand-Held Control
Operating elements for driving 3.1 Overview of the operating elements 3.1.12 Sockets for hand-held control There are sockets (4) on the carrier and sockets (1) to (3) on the superstruc- ture for the hand-held controls supplied. The hand-held controls contain the operating elements for the outrigger, the inclination indicator, for rigging work and for driving the power units in case of emergency.
Page 105: Outrigger Control Units
Operating elements for driving 3.1 Overview of the operating elements 3.1.13 Outrigger control units à Outrigger control units , Contain operating elements for crane operation; p. 9 - 52. Operating manual GMK 6400 3 112 993 en 3 - 29...
Page 106: Control Unit Of The Rear Outrigger Box
Operating elements for driving 3.1 Overview of the operating elements 3.1.14 Control unit of the rear outrigger box à 1 Left auxiliary support control p. 3 - 54 à 2 Right auxiliary support control p. 3 - 54 à 3 Extending/Retracting the pre-selection p.
Page 107: Short Description Of The Operating Elements
This section does not contain all the requirements that must be fulfilled for several operating elements to be active. If some operating elements do not work, first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care. 3.2.1...
Page 108: General Notes On The Operating Elements
Operating elements for driving 3.2 Short description of the operating elements Switches and For switches and buttons, the terms down and up are used. buttons Regardless of the fitting position (vertical, horizontal, diagonal, perpendicu- lar or turned), the following always applies: –...
Page 109: General Rules For Buttons And Symbols On The Display
Operating elements for driving 3.2 Short description of the operating elements 3.2.3 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 110: Engine
Operating elements for driving 3.2 Short description of the operating elements 3.2.4 Engine 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, daytime driving light on 3 Starting position à...
Page 111 Operating elements for driving 3.2 Short description of the operating elements Instrument panel Tachometer à Display, engine speed in rpm; p. 4 - 22 Flame start system monitoring – On: Engine not ready to start – is being warmed up –...
Page 112 Operating elements for driving 3.2 Short description of the operating elements Superstructure ignition indicator lamp – On: Ignition in the crane cab on, engine for driving cannot be started – Off: Ignition in the crane cab off, engine for driving can be started à...
Page 113: Def System
Operating elements for driving 3.2 Short description of the operating elements 3.2.5 DEF system If the GMK 6400 truck crane complies with TIER 4i and Euromot 3B exhaust gas emissions, there are additional display and operating elements in the driver's cab. Instrument panel DEF warning –...
Page 114 Operating elements for driving 3.2 Short description of the operating elements Display, driving Torque reduction display override mode The ignition is switched on or the engine is running. – Off: Torque reduction not overridden – On: Torque reduction overridden à p.
Page 115: Electrical System
Operating elements for driving 3.2 Short description of the operating elements 3.2.6 Electrical system Sockets 12 V/24 V 1 Socket 12 V 2 Socket 24 V Battery heater on/off – Down: Heating system on – Up: Heating system off à Separate operating manual .
Page 116 Operating elements for driving 3.2 Short description of the operating elements Error/warning message – Flashing: New warning message or error has occurred – On: Error acknowledged – but still present – Off: No warning message or error present à p. 11 - 114 Opening the Error submenu The lamp (1) lights up or flashes.
Page 117 Operating elements for driving 3.2 Short description of the operating elements Sensor for brightness Registers the brightness of the operating environment. The brightness of all displays is automatically adjusted. à Manual input; p. 4 - 15. ECOS display The main menu appears after switching on the ignition.
Page 118: Transmission
Operating elements for driving 3.2 Short description of the operating elements 3.2.8 Transmission à Operating the transmission , p. 5 - 23. Transmission control unit Selecting the transmission mode The engine is running. – Position N: Neutral position on – No gear engaged –...
Page 119 Operating elements for driving 3.2 Short description of the operating elements – Position RM: At a standstill – Hydraulic drive, reverse on For driving in reverse – Transmission in neutral posi- tion, clutch open For driving forwards – Neutral position on Display, driving mode Transmission display...
Page 120 Operating elements for driving 3.2 Short description of the operating elements Error messages display 1 Severe malfunction – stop the truck crane 2 Other malfunction 3 Error messages entry à Error messages ; p. 7 - 41 Hydraulic drive (MegaDrive) indicator lamp –...
Page 121 Operating elements for driving 3.2 Short description of the operating elements Switch lever The truck crane is stationary or driving. – 1 x to the left: Change over between automatic and manual oper- ating mode – without change of gear à...
Page 122: Reverse Camera
Operating elements for driving 3.2 Short description of the operating elements 3.2.9 Reverse camera The truck crane GMK 6400 is equipped with a reverse camera (1) or (2). The reverse camera displays the area behind the truck crane on the ECOS display in the driver's cab.
Page 123: Final Drive
Operating elements for driving 3.2 Short description of the operating elements 3.2.10 Final drive à Longitudinal and transverse differential locks , p. 5 - 58 Transverse differential locks on/off – Switching on: Press button 1 x – dot (1) green, maximum 20 km/h (12 mph) –...
Page 124: Brakes
Operating elements for driving 3.2 Short description of the operating elements 3.2.11 Brakes Service brake Display – 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 125 Operating elements for driving 3.2 Short description of the operating elements Switching the transmission retarder function on/off – Switching on: Press upper switch in – light (1) out – Switching off: Press lower switch in – light (1) on à p.
Page 126: Steering/Separate Steering
Operating elements for driving 3.2 Short description of the operating elements 3.2.12 Steering/separate steering à Separate steering , p. 5 - 66 Instrument panel Steering circuit 1 and 2 warning lamp – On: Engine off – ignition on Engine on – malfunction, stop – check oil loss –...
Page 127 Operating elements for driving 3.2 Short description of the operating elements Steering system warning – On: Steering system defective – stop immediately. Display symbol (1) – 5th and 6th axle cannot be steered; if it is possible, it can only be steered in straight running position –...
Page 128 Operating elements for driving 3.2 Short description of the operating elements Steering mode display The steering mode switched on is shown using different symbols: 1 Separate steering – driving around corners 2 Separate steering – crab travel mode 3 Separate steering – manual 4 Normal steering mode –...
Page 129: Suspension
Operating elements for driving 3.2 Short description of the operating elements 3.2.13 Suspension à Switching the suspension on/off , p. 5 - 14. Suspension on/off – Switching on: Press button 1 x – dot green – Switching off: Press button 1 x – dot black à...
Page 130: Control Unit Of The Rear Outrigger Box
Operating elements for driving 3.2 Short description of the operating elements 3.2.14 Control unit of the rear outrigger box à Installing/removing the supporting box , p. 6 - 53 Locking pin pre-selection – Press in to the left: Locking pin pre-selection à...
Page 131: Lighting/Windscreen Wipers/Horn
Operating elements for driving 3.2 Short description of the operating elements 3.2.15 Lighting/windscreen wipers/horn Steering column Multipurpose switch Horn/headlight flasher/headlight – full beam 1 Horn: Press the button 2 Headlight flasher: Upward The parking light/headlight is switched on: 3 Parking light/headlight: Middle position 4 Headlight –...
Page 132 Operating elements for driving 3.2 Short description of the operating elements Fog tail light indicator lamp – On: Fog tail light on – Off: Fog tail light off Indicator lamp for turn signal indicator 1 – Flashing: Turn signal indicator on –...
Page 133 Operating elements for driving 3.2 Short description of the operating elements Headlight indicator lamp – On: Headlight on – Off: Headlight off The headlight or parking light is switched on. 4 Fog light on 5 Fog tail light on 6 – on Rotating beacon on/off –...
Page 134: Level Adjustment System
Operating elements for driving 3.2 Short description of the operating elements Roof The lamps on the driver's and passenger's side are identical. Cab lighting 1 Permanently on 2 Permanently off 3 On/off via door contact Reading lamp 1 On 2 Off 3.2.16 Level adjustment system à...
Page 135 Operating elements for driving 3.2 Short description of the operating elements Lowering/raising the level Suspension struts are pre-selected. 1 To lower: Press button – suspension struts retract 2 To lift: Press button – suspension struts extend à p. 5 - 62 The movement stops after the button is released and when an end position is reached.
Page 136: Tachograph/Speedometer
Operating elements for driving 3.2 Short description of the operating elements Switch between measuring ranges – To switch over: Press button once – the current measuring range 1° or 5° is shown à p. 5 - 62 3.2.17 Tachograph/speedometer à Setting the tachograph , p.
Page 137: Diagnostics
2 Diagnostics submenu If there is a malfunction, press button (2) 1 x, read the values in the submenu and report to Manitowoc Crane Care. Operating manual GMK 6400 3 112 993 en 3 - 61...
Page 138: Windows, Doors, Keys
Operating elements for driving 3.2 Short description of the operating elements 3.2.19 Windows, doors, keys 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 139 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 (2) pressed in. Once closed in this manner, the door can only be opened again using the ignition key.
Page 140: Front Flap
Operating elements for driving 3.2 Short description of the operating elements 3.2.20 Front flap Opening • Move the front flap (1) up as far as it will go, holding it by the lower edge. The front flap is held in the open position. Closing •...
Page 141 Starting/turning off the engine for driving Starting the engine from the driver's cab ....... . 4 - 4.1.1 CHECKLIST: Starting the engine .
Page 142 3 112 993 en Operating manual GMK 6400...
Page 143: Starting/Turning Off The Engine For Driving
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab Starting/turning off the engine for driving Starting the engine from the driver's cab This section describes how to start the engine from within the driver's cab. You can also start the engine using the hand-held control, or from the crane à...
Page 144 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab à 4. Switch on the battery master switch; p. 4 - 12. 5. Check that – The bridging plugs are inserted in the sockets for hand-held control; à...
Page 145 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 10. Check the consumables level; à Refuelling , p. 4 - 8, – à DEF , p. 4 - 10. – à 11. Shift the transmission to the neutral position; p.
Page 146: Checklist: At Low Temperatures
Starting/turning off the engine for driving 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 at low outside temperatures: 1. The fuel and engine oil must be suited for use in the outside tempera- à...
Page 147 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab Ladders There are different ladders on the truck crane. Risk posed by ladders falling down. Always secure the ladders before driving. The prevents the ladders from falling down while driving and endangering other vehicles.
Page 148 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab A folding ladder is also mounted on the carrier. You can fold out the ladder (1) ). While driving • Push the ladder (1) into the holders (3) and (4) and secure it with the spring latch (2).
Page 149 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab Blank page Operating manual GMK 6400 3 112 993 en 4 - 7...
Page 150: Refuelling
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.4 Refuelling à Separate engine manufacturer’s operat- Use only permissible consumables; ing manual . Danger of fire due to inflammable gases. Switch off the engine, the heater and all additional heaters before refuel- ling.
Page 151 Starting/turning off the engine for driving 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 152 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab When additional equipment is in use, the sub- menu Inspection shows the fill level of the DEF tank (1). The display (2) indicates the current level as a percentage.
Page 153: Inspections Before Starting The Engine
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.5 Inspections before starting the engine On the hydraulic Before you start the engine, all valves on the hydraulic tank must be open. tank Risk of damage to the hydraulic pumps. You may only start the engine when all the valves on the hydraulic tank are open.
Page 154: Switch On The Ignition
Starting/turning off the engine for driving 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 switch • Switch on the battery master switch (1). The battery master switch is switched on if you are unable to pull off the selector handle.
Page 155: Lamp Test/Equalisation Of The Switching States
• Check that the lamps go on for about two seconds after switching on the ignition (1): Contact Manitowoc Crane Care if one or more lamps do not light up. If you could not check all the lamps in the specified time, you can conduct the lamp test again as follows.
Page 156 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab Conducting the lamp test • ö If necessary, open the main menu and press button (1) once. The Settings submenu opens. • Press the button (1). The lamps on the ECOS control unit remain lit until you let go of the but- ton again.
Page 157: Display - Setting The Brightness
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.8 Display – setting the brightness The brightness of the displays is regulated automatically by the ECOS , depending on the ambient brightness. You can set a minimum degree of brightness manually, which is always observed when the brightness is reg- ulated.
Page 158: Start The Engine
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.9 Start the engine This section describes only how to start the engine from the driver's cab. à You can also start the engine with the hand-held control; p.
Page 159 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab Without flame This section applies to starting a warm and a cold engine. start system 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 suction unit can ignite.
Page 160 Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab With flame start The flame start system warms the suction air of the engine. system This section applies to starting a warm and a cold engine. Danger of explosion when using starter fuel The engine may never be started with the aid of starter fuel.
Page 161: Inspections After Starting The Engine
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.10 Inspections after starting the engine Checking in the main menu Risk of damage to the engine. If symbol (1) lights up or the STOP lamp comes on and the warning buzzer sounds, switch the engine off immediately.
Page 162 The main menu shows a symbol. With the sym- The oil supply for the steering is still being built up. If bol (2): the symbol has not yet gone out, contact Manitowoc Crane Care With the sym- Service mode on.
Page 163 If the lamp (1) is lit, the symbol (2) is shown. The steering system has failed. You may not under any circumstances drive the truck crane. Contact Manitowoc Crane Care and arrange for the error to be rectified. Risk of accidents due to the fact that the truck crane cannot be steered.
Page 164: Monitoring Elements
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.11 Monitoring elements Instrument panel Tachometer 1 Green: Economic consumption 2 Yellow: Engine brake active 3 Red: Engine speed too high – danger; à Checks when driving downhill , p. 5 - 43 4 Lights up Engine speed is too high Fuel level display à...
Page 165: Monitoring Submenu
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.12 Monitoring submenu The Monitoring submenu provides an overview of the most important meas- ured values. • ö If necessary, open the main menu and press the button (1) once. The Monitoring submenu opens.
Page 166: Setting The Idling Speed
Starting/turning off the engine for driving 4.1 Starting the engine from the driver's cab 4.1.13 Setting the idling speed After the engine is started, the idling speed is regulated automatically. If necessary, you can adjust the idling speed manually using the multipurpose switch.
Page 167: Turning Off The Engine
Starting/turning off the engine for driving 4.2 Turning off the engine Turning off the engine 4.2.1 On the ignition lock/with hand-held control/on the outrigger control units Risk of accidents due to the fact that the truck crane cannot be steered. Only turn off the engine once the truck crane is at a standstill.
Page 168: Using The Emergency Stop Switches
Starting/turning off the engine for driving 4.2 Turning off the engine 4.2.2 Using the emergency stop switches Emergency stop switch Four emergency stop switches are provided for an emergency: 1 On the carrier 2 On the hand-held control 3 In the crane cab •...
Page 169: Air Intake Inhibitor
Starting/turning off the engine for driving 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. The air intake inhibitor is triggered, –...
Page 170 Starting/turning off the engine for driving 4.3 Air intake inhibitor Blank page 4 - 28 3 112 993 en Operating manual GMK 6400...
Page 171 Driving Before driving ............5 - 5.1.1 CHECKLIST: Checks before on-road driving.
Page 172 5.6.1 Standard heating system ......... . . 5 - 70 5.6.2 Air-conditioning system .
Page 173: 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 there. 1. If the boom is on the boom rest –...
Page 174 Driving 5.1 Before driving 3. On the outriggers – All outrigger beams are fully retracted and secured to prevent exten- à sion; p. 12 - 34. à – The outrigger pads are in the driving position; p. 12 - 43. à...
Page 175 Driving 5.1 Before driving 9. Inspect the truck crane, looking out in particular for any leaking fluids (oil, fuel or water). 10. The warning signs for marking the vehicle width are folded down (only for vehicle widths over 2.75 m [9.0 ft]); à...
Page 176 Driving 5.1 Before driving à 15. Switch on ignition; p. 4 - 12. à 16. Adjust the driver's seat; p. 5 - 11. à 17. Adjust the steering column; p. 5 - 13. à 18. Adjust the mirrors; p. 5 - 6. à...
Page 177 Driving 5.1 Before driving à ! D H k 21. Check the electrical system; p. 5 - 6. 22. Check the fluid supply; à – Refuelling , p. 4 - 8, à DEF , p. 4 - 10. – à 23.
Page 178: Checking The Condition Of The Truck Crane
Driving 5.1 Before driving 5.1.2 Checking 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 179 Driving 5.1 Before driving Electrical adjustment • Turn the button to position A Neutral position B Mirror on the driver's side C Mirror on the passenger side • Press the button (5) – the mirror moves: 1 Up 2 Right 3 Down 4 Left Mirror heating...
Page 180 Driving 5.1 Before driving Warning plates for Depending on the vehicle width, fold-up warning plates are fitted below the vehicle width driver's cab. The warning plates (1) must be folded down to indicate the vehicle width during on-road driv- ing. For off-road driving, the warning plates can be folded up and fastened with the spring latch (2).
Page 181 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 approx. 8 bar (116 psi). If the supply pressure is too low, such as after repairs, you can build it up as follows.
Page 182 Driving 5.1 Before driving Parking brake Check the function of the parking brake. • Apply the service brake. Risk of accident by truck crane moving unintentionally Always apply the service brake before releasing the parking brake. This prevents the truck crane from rolling in an uncontrolled manner when the parking brake is released.
Page 183: Adjusting The Seats And Steering Column
Driving 5.1 Before driving 5.1.3 Adjusting the seats and steering column Driver's seat The seat height and lumbar support are adjusted pneumatically. You can only make these adjustments when: – The (1) switch on the driver's seat is off (not pressed in), –...
Page 184 Driving 5.1 Before driving Settings for body shape 1 Lumbar area support 2 Seat cushion – longitudinal adjustment 3 Seat cushion – angle Passenger's seat The passenger's seat is adjusted mechanically. 1 Back rest – angle 2 Seat – longitudinal adjustment 3 Seat cushion –...
Page 185 Driving 5.1 Before driving Adjusting the The steering column is unlocked pneumatically. steering column Risk of accident by unlocked steering column Always stop the truck crane before you unlock the steering column. You can no longer steer safely after unlocking the steering column. The steering column is only unlocked when sufficient supply pressure is à...
Page 186: 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 (1) displays under the main menu and in the Suspension submenu.
Page 187 Driving 5.1 Before driving Switching on the The suspension cylinders are enabled when the suspension is switched on. suspension This state must be established for on-road driving. Danger of overturning when switching on the suspension Only switch on the suspension when the truck crane has been rigged for on-road driving and the main boom has been set down.
Page 188: Setting The Tachograph
Driving 5.1 Before driving 5.1.5 Setting the tachograph The diagram sheets (24-hour discs) can be inserted in the tachograph for two drivers simultaneously. As a crane operator, you are obligated to set each activity on the tacho- graph. This section only describes the basic operation of the tachograph (inserting diagram sheets, setting time groups, operating errors).
Page 189 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 (6) button once. First the symbol (5) and the running bar (4) appear, then the drawer (3) opens.
Page 190 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 191 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 192 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 193: Displaying The Operating Hours
Driving 5.1 Before driving 5.1.6 Displaying the operating hours You can view the operating hours for all power units in the Operating hours submenu. • ö If necessary, open the main menu and press the (1) button once. This opens the Settings submenu. •...
Page 194: Settings/Indications On The Driving Display
Driving 5.1 Before driving 5.1.7 Settings/indications on the driving display You can enter settings, e.g. the time and date, and have information dis- played, e.g. the outside temperature. The ignition is switched on. Kilometre counter 1 Daily kilometre counter – position after the decimal point: 1 = 100 m (33 ft) 2 Overall route in kilometres 3 Reset daily kilometre counter...
Page 195: 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 The transmission is in neutral position N if the ignition is switched off. •...
Page 196: Switching The Transmission To Neutral Position
Driving 5.2 Operating the transmission 5.2.2 Switching the transmission to neutral position You can switch the transmission to neutral position at any time. Risk of accident when switching on while driving If you switch the transmission to neutral position while driving, the drive line will be interrupted.
Page 197: 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 - 36 driving direction The following requirements must be met before selecting the driving direc- tion: –...
Page 198 Driving 5.2 Operating the transmission For reverse travel The reverse camera is switched on. The display (1) shows the area behind the truck crane. If you choose the gear position N, D or DM, the camera is switched off and the display (1) shows the ECOS menu.
Page 199: 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 when the vehicle is stationary or when driving.
Page 200: Starting
Driving 5.2 Operating the transmission 5.2.5 Starting Danger by unexpected rolling Also apply the parking brake before starting on sloping ground. The gear will only be engaged after you step on the accelerator. This can lead to the truck crane starting to move (also backwards) while you are moving your foot from the brake pedal to the accelerator.
Page 201 Driving 5.2 Operating the transmission In manoeuvring mode, the truck crane responds more sensitively to the accelerator. The gear positions DM and RM are provided for manoeuvring; à DM and RM transmission mode , p. 5 - 33. If a transmission malfunction is detected, the corresponding entries (1), (2) à...
Page 202: 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 driv- ing direction, e.g. in position D for forward travel. Risk of accident when changing while driving If you change over to a position while driving which deviates from the cur- rent driving direction, the transmission shifts to the neutral position.
Page 203 Driving 5.2 Operating the transmission In manual In this operating mode, the transmission only shifts when you actuate the operating mode switch lever. Manual upshifting To upshift, you must press the gearshift lever forwards briefly: – Upshifting one gear: Push forwards once –...
Page 204: 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 selected gear will be shown in the display.
Page 205: Dm And Rm Transmission Mode
Driving 5.2 Operating the transmission 5.2.9 DM and RM transmission mode The DM and RM transmission modes are intended for manoeuvring the vehicle without changing gears, e.g. for moving the truck crane while loaded. In these transmission modes, only the 4th and 5th axles are (hydraulically) driven.
Page 206 Driving 5.2 Operating the transmission • Switching off Release the accelerator. • Stop the truck crane just in case. • Wait until the engine runs at idle speed. • Shift to position N. • Shift to position D or R for the required direction –...
Page 207 Driving 5.2 Operating the transmission • Press the (3) button once. A red bar (2) appears below the display (1). • Set the required top speed with the switch (4). While making the setting, you can read the value setting from the display (1) (0 to 100%). The speed setting is only reached when you press the accelerator down fully.
Page 208: On The Roller Type Dynamometer
Driving 5.2 Operating the transmission 5.2.10 On the roller type dynamometer Danger of unexpectedly moving off rollers Always shift to the neutral position on the roller type dynamometer. In position D or R, a suitable gear is engaged for the speed. The engine braking power is applied against the rollers and the truck crane can drive out of them.
Page 209: Driving And Turning Off The Truck Crane
• Stop the vehicle as soon as possible. Briefly turn off the ignition and then on again. If the lamp is still lit, contact Manitowoc Crane Care. Operating manual GMK 6400 3 112 993 en...
Page 210 Drive at a speed of over approx. 10 km/h (6 mph). – If only one lamp is still lit, drive slowly to the next repair shop. The steering may be sluggish, – If two lamps are still lit, stop immediately. Refer to Manitowoc Crane Care à...
Page 211 Driving 5.3 Driving and turning off the truck crane • While driving Observe all warning messages. Risk of damage if warning messages are not observed After a warning message appears (on the ECOS display or combination instrument display), always promptly observe all information in the section titled Warning submenu , and take the appropriate corrective measures.
Page 212: Cruise Control
Driving 5.3 Driving and turning off the truck crane 5.3.2 Cruise control Cruise control enables you to drive at a constant speed without pressing the accelerator. Risk of accident due to carelessness Be ready to brake at all times when cruise control is switched on. Only switch cruise control on if the traffic situation permits a constant speed.
Page 213: Cruise Control
Driving 5.3 Driving and turning off the truck crane Switching off • Push the switch forwards once. Cruise control is switched off. The symbol (1) goes out in the Driving display. Cruise control is also switched off: – When the service brake or additional brake is applied. –...
Page 214: Driving Downhill
Driving 5.3 Driving and turning off the truck crane 5.3.4 Driving downhill Risk of accident when driving in neutral position Never switch into neutral position while driving. In neutral position, the truck crane may accelerate and the engine retarder is ineffective. Starting The engine must be running.
Page 215 Driving 5.3 Driving and turning off the truck crane Checks when While driving, the engine speed may not exceed 2300 min (rpm). The driving downhill engine speed is not automatically limited. Risk of damage due to excessive engine speed Shift to a higher gear or slow the truck crane down when the maximum per- missible engine speed has been reached.
Page 216 Driving 5.3 Driving and turning off the truck crane 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 900 min (rpm) and can be used up to a maximum speed of 2300 min (rpm).
Page 217 Driving 5.3 Driving and turning off the truck crane For long downhill drives, we recommend that you use level 2. When the eddy current retarder is switched on, you cannot regulate the speed with the accelerator. Switching on the additional brakes •...
Page 218: Driving Uphill
Driving 5.3 Driving and turning off the truck crane 5.3.5 Driving uphill Starting The engine must be running. Danger of the truck crane starting to roll in an unexpected direction Always hold the truck crane with the parking brake until the gears have engaged when starting to move forward.
Page 219: Warning Submenu
Driving 5.3 Driving and turning off the truck crane 5.3.6 Warning submenu ECOS differentiates between warning messages and error messages (error à Errors submenu , p. 5 - 53). A warning message indicates that messages; certain values do not correspond to a target value. Further warning messages can be displayed on the instrument panel;...
Page 220 Driving 5.3 Driving and turning off the truck crane Hydraulic oil too hot The hydraulic oil is hotter than 80°C (176°F). à Current temperature display; p. 4 - 22. à Possible cause and solution; p. 7 - 33. Danger of overheating There is a fault if the hydraulic oil temperature exceeds 80°C (176°F).
Page 221 Driving 5.3 Driving and turning off the truck crane Coolant level too low Immediately top up the coolant so that the engine does not overheat; à Maintenance manual . Pressure in the suspension struts or permissible lateral tilt exceeded • Immediately bring the truck crane to a halt and check the pressure in the à...
Page 222: Warning Or Malfunction Messages On The Instrument Panel
CAN BUS system interrupted If the lamp continues to light up, switch off the ignition and switch it back on after 15 seconds; notify Manitowoc Crane Care. Battery charge indicator warning The voltage in the carrier electrical system is too high or too low.
Page 223 Driving 5.3 Driving and turning off the truck crane Steering circuit 1 or 2 warning à Steering mal- Malfunction in steering circuit 1 or 2 – check for loss of oil; functions , p. 7 - 32. Steering circuit 3 warning (emergency steering pump) à...
Page 224: Overriding Torque Reduction
Driving 5.3 Driving and turning off the truck crane 5.3.8 Overriding torque reduction When the DEF supply is empty, the torque reduction is activated via the engine control system. You can override torque reduction up to 3 times. – If the DEF supply drops to the reserve level, the lamp (1) lights up. –...
Page 225: Errors Submenu
Driving 5.3 Driving and turning off the truck crane 5.3.9 Errors submenu ECOS differentiates between error messages and warning messages à Warning submenu , p. 5 - 47). (warning messages; In the event of an error message, the lamps (1) and (2) flash. à...
Page 226 Driving 5.3 Driving and turning off the truck crane Transport at the rear of the carrier • Push the chock (2) behind the bracket (3) and hang it on the holder (1). (A) – Folding out • Press the locking bar (4) through the bore (5).
Page 227 Driving 5.3 Driving and turning off the truck crane Securing the truck crane against unauthorised use • Secure the truck crane against unauthorised use by: – Stowing away the hand-held control in the crane cab or in the driver's cab. –...
Page 228: Folding Berth
Driving 5.3 Driving and turning off the truck crane 5.3.11 Folding berth The berth must always be folded up for driving. Risk of accident due to the berth folding down Check that the locking bar is engaged and put up the back rest of the seats before driving.
Page 229: 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 230: Longitudinal And Transverse Differential Locks
Start moving slowly – Display: – The symbol (3) first turns yellow – Then symbol (2) turns red, differential locks on If the error symbol is displayed, contact Manitowoc Crane Care. 5 - 58 3 112 993 en Operating manual GMK 6400...
Page 231 Driving 5.4 Off-road driving Switching off • Press button (1) once for: – Central differential locks (A) – Transverse differential locks (B) The dot turns black. Display: – The symbol (3) first turns yellow – Then symbol (2) turns green, differential locks off If symbol (2) is not displayed, then drive back and forth slowly.
Page 232: Operating The Level Adjustment System
– Set the on-road driving level, – Pre-select the suspension struts and change the vehicle level. If the symbol (1) is shown for an error during a level adjustment, refer to Manitowoc Crane Care. 5 - 60 3 112 993 en...
Page 233 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 234 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 accident by exceeding total permissible height Always bring the truck crane to on-road level before driving on roads after changing the level.
Page 235 Driving 5.4 Off-road driving (A) – When the truck crane is level, only the lamp (1) in the middle lights up. The other lamps show the sides of the truck crane which are higher. The assignment to the carrier is given by the directional indicator (2).
Page 236: Freeing Truck Crane Stuck In Terrain
Driving 5.4 Off-road driving 5.4.3 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 237 Driving 5.4 Off-road driving • Towing free Fasten a steel rope to the front towbar coupling. forward 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 238: Separate Steering
Driving 5.5 Separate steering Separate steering There are two types of steering with separate steering. – Driving around corners: When separate steering is switched on, the steering angle is larger than for normal steering mode – the turning radius is smaller. –...
Page 239 When separate steering is switched on, the speed is limited to approx. 20 km/h (12 mph). If the error symbol is displayed, contact Manitowoc Crane Care. • Manual Steer the 1st and 2nd axle lines with the steering wheel.
Page 240 Driving 5.5 Separate steering (A) – for driving around corners • Steer the 6th axle line opposite to the 1st and 2nd axle lines. The other axle lines are steered to suit the turning radius. (B) – for crab travel mode •...
Page 241 – Steer the 1st and 2nd axle lines with the steering wheel, – The 3rd and 4th axle lines remain facing forward, – Steer the 5th and 6th axle lines according to the turning radius. If the error symbol is displayed, contact Manitowoc Crane Care; à p. 7 - 32.
Page 242: 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 blower/fresh air/recirculated air You can regulate the air volume with the switch (1) for: A Recirculated air –...
Page 243 Driving 5.6 Heating and air-conditioning system Air distribution You can allow the air to flow out from 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 244 Driving 5.6 Heating and air-conditioning system Examples This section only contains sample settings. Always adjust the setting to the current conditions (warm, cold, damp). (A) – Ventilating – Turn the switch into the positions shown, – If necessary, open the air vents for the side and centre.
Page 245: 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 sys- tem. Notes 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 246 Driving 5.6 Heating and air-conditioning system Cooling The illustration only shows one 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 247: Auxiliary Water Heater
Driving 5.6 Heating and air-conditioning system 5.6.3 Auxiliary water heater The batteries will run down 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. You can use the auxiliary water heater to: –...
Page 248 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 (2) to Warm setting. • Switch (1) on the Recirculated air symbol, level 1.
Page 249 Driving 5.6 Heating and air-conditioning system • Switching on the Check whether the auxiliary heater is allowed to be operated at the cur- auxiliary heater rent site of the truck crane before switching it on. Find out whether there are any possible sources of danger that could result in an explosion Danger of explosion when operating the auxiliary heater The auxiliary heater is not allowed to be operated: –...
Page 250 Driving 5.6 Heating and air-conditioning system Switching off the This section only describes how to switch off the heater manually. The aux- auxiliary heater iliary heater is switched off again after a certain heating period if it was à Setting the switched on automatically.
Page 251 Driving 5.6 Heating and air-conditioning system Saving the Heating is started automatically on schedule only if the time and the day of à automatic heating the week have been correctly set; p. 5 - 78. start You can set three different automatic heating starts – up to seven days in advance.
Page 252 Driving 5.6 Heating and air-conditioning system Setting the After an automatic start, the auxiliary heater switches itself off as soon as heating period the set heating period has elapsed. The heating period applies to all saved heating starts. • Switch off the auxiliary heating using the (1) button. •...
Page 253 Driving 5.6 Heating and air-conditioning system Setting the If the ignition is turned off while the auxiliary heater is running, the auxiliary remaining time heater continues to run for the remaining time. • Switch on the auxiliary heating using the (1) button. •...
Page 254: Towing A Trailer
Driving 5.7 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 accident by trailer moving unintentionally Before coupling or uncoupling the trailer, it must be secured with the trailer parking brake as well as with chocks to prevent it from rolling away.
Page 255 Driving 5.7 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 coupling pin to move down with great force, seriously injuring your hand.
Page 256 Driving 5.7 Towing a trailer Risk of accident if the trailer is coupled improperly If the pin is protruding from the guide bushing, the trailer is not coupled properly and could become disengaged from the towbar coupling while driving. Connecting the supply lines •...
Page 257 Driving 5.7 Towing a trailer Removing supply lines Risk of accident due to trailer moving unintentionally Always first remove the hose from the supply line so that the trailer is braked. This prevents the trailer from moving when you remove the brake hose.
Page 258 Driving 5.7 Towing a trailer Risk of injury when manually closing the towbar coupling When closing, the lever moves down with great force in the direction of the coupling jaw. Start the closing process only by moving the lever briefly in the direction of the coupling jaw with the ball of your hand.
Page 259 Driving 5.7 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.
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Page 261 Driving modes and rigging for on-road driving Driving modes ............6 - 6.1.1 Information on how to use the tables .
Page 262 6.5.8 Installing the reverse camera........6 - 68 6.5.9 Crane movements during installation and removal .
Page 263: Driving Modes And Rigging For On-Road Driving
The GMK 6400 truck crane is designed for driving with maximum axle loads axle loads of 12 t (26 500 lbs). Manitowoc Crane Group Germany GmbH notes that 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 264: Information On How To Use The Tables
Driving modes and rigging for on-road driving 6.1 Driving modes 6.1.1 Information on how to use the tables The tables consist of two parts: – The driving mode of your truck crane is specified in the top part, next to Equipment.
Page 265: Tables For A Maximum Axle Load Of 12 T (26 500 Lbs)
Tables for a maximum axle load of 12 t (26 500 lbs) This section only shows some standard driving modes. For further informa- tion on additional or individual driving modes, please contact Manitowoc Crane Care. If you remove indicated parts from the truck crane in driving mode, then the total weight decreases but can be distributed in such a way that the front or rear axle loads are over 12 t (26 500 lbs).
Page 266 Driving modes and rigging for on-road driving 6.1 Driving modes With removable Driving mode supporting box 385/95 R 25 tyres 445/95 R25 tyres ✔ 525/80 R 25 tyres Steel rims ✔ aluminium rims ● Front outrigger beam removed ● Supporting box removed 6 - 4 3 112 993 en Operating manual GMK 6400...
Page 267: Maximum Permitted Speeds With An Axle Load Of Over 12 T (26 500 Lbs)
Driving modes and rigging for on-road driving 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 permit- ted speed given here.
Page 268: Rigging Work For Driving With A Trailer
Driving modes and rigging for on-road driving 6.2 Rigging work for driving with a trailer Rigging work for driving with a trailer 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 trailer (dolly) when driving.
Page 269: Switching On The Slewing Gear Freewheel
Driving modes and rigging for on-road driving 6.2 Rigging work for driving with a trailer 6.2.1 Switching on the slewing gear freewheel When the main boom is set down on a trailer, the superstructure must be able to slew when driving around corners. You must switch on the slewing gear freewheel for this purpose.
Page 270: Switching On Boom Floating Position
Driving modes and rigging for on-road driving 6.2 Rigging work for driving with a trailer 6.2.2 Switching on boom floating position If the main boom has been placed on a trailer, the boom floating position must be switched on so that the main boom can move up and down. Risk of accident from the boom floating position being switched off Always switch on the boom floating position when the main boom is on a trailer.
Page 271: Switching On Boom Pre-Tensioning
Driving modes and rigging for on-road driving 6.2 Rigging work for driving with a trailer 6.2.3 Switching on boom pre-tensioning If the main boom has been set down on a trailer, you can change the axle loads on the rear axle lines by switching on the boom pre-tensioning. •...
Page 272: Switching The Superstructure Driving Lights On/Off
Driving modes and rigging for on-road driving 6.2 Rigging work for driving with a trailer 6.2.4 Switching the superstructure driving lights on/off The lighting for the Superstructure includes lamps (2) and (3). With standard equipment, the lamps (2) and (3) are always switched on or off together with the parking light and the headlights.
Page 273: Removing/Installing Main Boom
Only remove or install the main boom if the truck crane is equipped with the factory-installed pulling devices and with the necessary accessories. Without this factory-installed pulling device, the main boom may only be removed by Manitowoc Crane Care. Additional equip- In addition to the pulling devices, you also need the following accessories: ment required –...
Page 274 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom Blank page 6 - 12 3 112 993 en Operating manual GMK 6400...
Page 275: Checklist: Removing The Main Boom
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.1 CHECKLIST: Removing the main boom This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there. Requirements –...
Page 276 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom à 4. Sling the main boom to an auxiliary crane; p. 6 - 18. 5. On the derricking cylinder head axle: – Take the load off of the head pin –...
Page 277: Checklist: Installing The Main Boom
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom à 10. Secure the derricking cylinder with a tightening belt; p. 6 - 31. 6.3.2 CHECKLIST: Installing the main boom This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references.
Page 278 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 4. Lift the main boom into the turntable and align the connecting points; à p. 6 - 31. 5. On the boom pivot pin: – Open the hydraulic circuit, –...
Page 279 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 9. Remove the derricking cylinder support from the counterweight plat- form. 10. Place the main boom on the boom rest. à 11. Carry out the checks with the main boom set down; p.
Page 280: Slinging The Main Boom
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.3 Slinging the main boom Slings are fitted to the main boom when rigging and it is lifted with an aux- à iliary crane. Note the equipment necessary for this; p.
Page 281 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom • Insert the bracket (3) into the slinging point (1). Pull the pin (2) • Insert the bracket into the lifting gear (4) • Secure the bracket with the pin (2) and the retaining pin •...
Page 282 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom Blank page 6 - 20 3 112 993 en Operating manual GMK 6400...
Page 283: Retracting/Fitting The Derricking Cylinder Head Pin
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.4 Retracting/fitting the derricking cylinder head pin The derricking cylinder head axle is retracted and fitted with a pulling device. Derricking Before retracting the head pin, the derricking cylinder support must be cylinder support erected.
Page 284 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom Retracting the After you have pulled the head pin, you can no longer derrick the main derricking cylinder boom. head axle (A) – Releasing the head pin • Loosen the bolt (3) and remove the disc (B) –...
Page 285 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom • Fitting the derrick- Check to see if the tightening belt of the derricking cylinder is taken off ing cylinder head axle Aligning the derricking cylinder • (A) – Remove the bolt (1) and remove the disc •...
Page 286: Retracting/Extending The Boom Pivot Pin
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.5 Retracting/extending the boom pivot pin The boom pivot pin is retracted and extended with a hydraulic pulling device. Before retracting Before retracting the boom pivot pin you must: –...
Page 287 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom After extending After extending the boom pivot pin you must: – Close the hydraulic circuit again, – secure the pulling device. Closing the hydraulic circuit Switch the valve (1) – Position B. Risk of accidents from falling main boom! Always secure the pulling device with the pins.
Page 288 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom Retracting/ extending the pivot pin Risk of damage to the main boom! Before retracting, the main boom must be slung and all other sling gear must be tightened. Before extending, the bearing points on the turntable must be aligned with the boom pivot pin.
Page 289: Disconnecting/Connecting Hydraulics/Electrical
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.6 Disconnecting/connecting hydraulics/electrical Disconnecting The number of hoses/cables depends on how the truck crane is equipped. – The main boom must be raised. Risk of malfunction in the superstructure electronics! Always turn off the ignition in the crane cab before you establish or separate the electrical connection.
Page 290 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom Establishing The number of hoses/cables depends on how the truck crane is equipped. – The main boom must be raised. Risk of malfunction in the superstructure electronics! Always turn off the ignition in the crane cab before you establish or separate the electrical connection.
Page 291: Lifting The Main Boom Off/On The Turntable
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.7 Lifting the main boom off/on the turntable à – The main boom is slung; p. 6 - 18. à – The hydraulic/electrical connections are disconnected; p. 6 - 27. à...
Page 292 Driving modes and rigging for on-road driving 6.3 Removing/installing main boom Lifting on to the turntable • Lift the main boom backwards and down- wards on to the turntable. Make sure that: – The connection lines (3) do not hang loose.
Page 293: Aligning The Connecting Points
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.8 Aligning the connecting points Risk of damage to the turntable and the connection lines Make sure that the connection lines are located within the turntable and that the main boom does not swing when you raise it for insertion into the turntable.
Page 294: Transporting The Main Boom
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.10 Transporting the main boom Transport the main boom only on a separate vehicle which is of sufficient size and has sufficient lifting capacity. à Transport dimensions and weight; Operating instructions .
Page 295: Inspections After Main Boom Mounting
Driving modes and rigging for on-road driving 6.3 Removing/installing main boom 6.3.11 Inspections after main boom mounting • Turn on the ignition. • Check if the RCL control unit (1) or ECOS (2) show an error message. • If an error message is displayed, check that all electrical connections are established;...
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Page 297: Installing/Removing Outrigger Beams
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams Installing/removing outrigger beams If the truck crane is fitted with a removable supporting box (ROB), you can only assemble/disassemble the front outrigger beams. à Installing/removing the supporting box , p. 6 - 53. To rig the outrigger beams, the outriggers must be fitted with hydraulic con- nections (1) which can be separated.
Page 298: Checklist: Removing The Outrigger Beams
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.1 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 there. 1.
Page 299 Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6. Sling the outrigger beam and pull it out of the outrigger box until it à reaches the centre of gravity; p. 6 - 47. 7. – Sling the outrigger beams in the centre of gravity and pull them out of the outrigger box.
Page 300: Checklist: Installing The Outrigger Beams
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.2 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 there. 1.
Page 301 Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams à 6. Screw in the spacers; p. 6 - 45. à 7. If necessary put outrigger pads into position; p. 6 - 41. 8. Mount all necessary outrigger beams in the same way in accordance with this checklist.
Page 302: Preparing The Truck Crane
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.3 Preparing the truck crane Requirements The following requirements must be met before mounting/removing the outrigger beams: – All rigging work which involves slewing the superstructure was com- pleted. –...
Page 303: Removing/Attaching Outrigger Pads
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.4 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 304 Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams Attaching After mounting the outrigger beam, you must attach the outrigger pad. outrigger pads • (A) – Remove the pin (1). • Extend the outrigger cylinder far enough so that the bearing surface (3) is below the guide (2).
Page 305: Disconnecting/Establishing The Hydraulic Connection
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.5 Disconnecting/establishing the 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. Disconnecting Always disconnect all connections (4).
Page 306: Establishing/Disconnecting The Electrical Connection
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.6 Establishing/disconnecting the electrical connection The electrical connection is only present on truck cranes with an outrigger pressure indicator. Risk of malfunctions in the electronic system Always turn off the ignition before you disconnect or establish the electrical connection.
Page 307: Unscrewing/Screwing In The Spacers
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.7 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 beams on the rear right hand side.
Page 308 Driving modes and rigging for on-road driving 6.4 Installing/removing 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 309: Disconnecting/Establishing The Connections To The Outrigger Box
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.8 Disconnecting/establishing the connections to the outrigger The illustrations show as an example the connecting points for the outrig- ger beam on the rear right hand side. (A) – To disconnect •...
Page 310 Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams • Using the auxiliary crane, sling the outrigger beam in the centre of gravity (2). • Remove the chain hoist and lifting gear. • Fasten a guide rope (1). •...
Page 311 Driving modes and rigging for on-road driving 6.4 Installing/removing 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.
Page 312 Driving modes and rigging for on-road driving 6.4 Installing/removing 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 313: Transporting The Outrigger Beams
Driving modes and rigging for on-road driving 6.4 Installing/removing outrigger beams 6.4.10 Transporting the outrigger beams • For transportation, only use a separate vehicle with sufficient lifting à capacity. Transport dimensions and weight; p. 1 - 10. • Load the separate vehicle in such a way that the weight is evenly distrib- uted.
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Page 315: Installing/Removing The Supporting Box
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box Installing/removing the supporting box The rear support mechanism comes from the rear supporting box. When using additional equipment, this can be completely removed with support- ing cylinders and outrigger beams for driving on roads. Risk of overturning when slewing the superstructure Support the truck crane with an outrigger span of 7.98 x 8.50/1.00 m (26.1 x 27.9/3.3 ft) and set the corresponding RCL code before slewing the...
Page 316: Checklist: Removing The Supporting Box
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.1 CHECKLIST: Removing the supporting box This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there. 1.
Page 317 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6. Release the locking pin between the outrigger box and carrier; à p. 6 - 71. à 7. – Remove the hydraulic connections; p. 6 - 64, à –...
Page 318 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 11. If the main boom is to be set down on a trailer: With the RCL set accordingly, slew the superstructure to the rear and lower the main boom; à...
Page 319: Checklist: Installing The Supporting Box
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.2 CHECKLIST: Installing the supporting box This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there. 1.
Page 320 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box à 5. – Establishing an hydraulic connection; p. 6 - 64, à – Establishing an electrical connection; p. 6 - 63. à 6. Pin the outrigger box to the carrier; p.
Page 321: Rigging The Outrigger Span 7.98 X 8.50/1.00 M (26.1 X 27.9/3.3 Ft)
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.3 Rigging the outrigger span 7.98 x 8.50/1.00 m (26.1 x 27.9/3.3 ft) With this outrigger span, the truck crane is sta- bilised at the front to an outrigger width (2) 8.50 m (26.1 ft).
Page 322 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box Front outrigger • At the front outrigger, set the span to 8.50 m à Setting the outrigger spans , (26.1 ft); p. 12 - 34. • Extend the support cylinders until they make contact with the ground.
Page 323 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box Retracting • (A) – Left auxiliary support – Press and hold down the button (1) below. • Press the button (3) on the right. • (B) – Right auxiliary support – Press and hold down the button (2) below.
Page 324: Establishing/Disconnecting The Pneumatic Connection
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.4 Establishing/disconnecting the pneumatic connection When additional equipment is in use, there is a pneumatic connection between the carrier and the supporting box. (A) – Making a connection •...
Page 325: Establishing/Disconnecting The Electrical Connection
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.5 Establishing/disconnecting the electrical connection Risk of malfunctions in the carrier electronics Always turn off the ignition before you establish or break the electrical con- nection. This prevents malfunctions and error messages in the carrier elec- tronics.
Page 326: Disconnecting/Establishing The Hydraulic Connection
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.6 Disconnecting/establishing the hydraulic connection The hydraulic connection between the supporting box and carrier consists of two hoses with couplings. Always close off hoses or connections you do not need with appropriate caps.
Page 327: Attaching/Raising The Supporting Box With The Truck Crane
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.7 Attaching/raising the supporting box with the truck crane Requirements – The RCL code for the outrigger span 7.98 x 8.50/1.00 m (26.1 x 27.9/3.3 ft) as stated in the Lifting capacity table , has been entered. –...
Page 328 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box • Lifting Raise the main boom until you are able lift the outrigger box upwards in an upright position. If the outrigger box is to be placed on a separate vehicle: •...
Page 329 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box Attaching The supporting box is within one of the radii permitted by the RCL. The supports must be retracted before hanging the box. • Sling the outrigger box. •...
Page 330: Installing The Reverse Camera
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.8 Installing the reverse camera Depending on the driving mode, you can install the reverse camera on the carrier or the outrigger box. (A) – On the supporting box (B) –...
Page 331: Crane Movements During Installation And Removal
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.9 Crane movements during installation and removal When the rear outrigger box is removed, the setting down and raising of the main boom and the slewing of the superstructure is monitored by RCL. There are RCL codes for different working positions for an outrigger span of 7.98 x 8.50/1.00 m (26.1 x 27.9/3.3 ft).
Page 332: Slinging Points On The Supporting Box
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.10 Slinging points on the supporting box Risk of accident if used improperly Attach the outrigger box only to the designated points and only use lifting gear of sufficient lifting capacity. Weight of the outrigger box; à...
Page 333: Fixing/Releasing The Outrigger Pins
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.11 Fixing/releasing the outrigger pins Risk of crushing when extending/retracting the pins The pins on both sides are always moved at the same time from the Sup- porting box control unit. Make sure that no-one is in the vicinity of the carrier retainers on the other side of the vehicle when you extend or retract the pins.
Page 334 Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box Releasing the locking pin • Sling the outrigger box before releasing the pins. • Pull the securing plugs (4) out of the two pins (3). • Press the button (2) on the left and the but- ton (1) on the right.
Page 335: Transporting The Supporting Box On The Separate Vehicle
Driving modes and rigging for on-road driving 6.5 Installing/removing the supporting box 6.5.12 Transporting the supporting box on the separate vehicle Risk of damage to add-on parts on the outrigger box and outrigger pads Always secure the supporting box against slipping and overturning. This will prevent damage.
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Page 337 Malfunctions in driving mode Emergency stop switch ..........7 - What to do when a malfunction occurs in road traffic .
Page 338 3 112 993 en Operating manual GMK 6400...
Page 339: Malfunctions In Driving Mode
Malfunctions in driving mode 7.1 Emergency stop switch Malfunctions in driving mode Emergency stop switch Four emergency stop switches are available in an emergency: 1 On the carrier 2 On the hand-held control 3 In the crane cab • Press an emergency stop switch (1), (2) or (3).
Page 340 Malfunctions in driving mode 7.1 Emergency stop switch Blank page 7 - 2 3 112 993 en Operating manual GMK 6400...
Page 341: What To Do When A Malfunction Occurs In Road Traffic
When in a danger area, only carry out the repair work required to leave the danger area. If you are unable to repair the damage yourself, notify Manitowoc Crane à Towing the truck crane , p. 7 - 5.
Page 342 Malfunctions in driving mode 7.2 What to do when a malfunction occurs in road traffic Blank page 7 - 4 3 112 993 en Operating manual GMK 6400...
Page 343: Towing The Truck Crane
– The wheels of the fifth and sixth axle lines must be in the forward position. If the wheels can no longer be steered into the forward position, notify Manitowoc Crane Care prior to towing. – If the engine, steering or service brake no longer function properly, the truck crane must be towed with a special breakdown truck.
Page 344: Towing After Engine/Transmission Damage
Tow the truck crane at a maximum speed of 10 km/h (6 mph) and a maxi- mum distance of 1 km (0.62 mi). Additional measures must be taken for longer distances, refer to Manitowoc Crane Care. Compressed-air When the engine fails, the truck crane must be supplied with compressed supply air by the towing vehicle so that the brake system is still operable.
Page 345 Malfunctions in driving mode 7.3 Towing the truck crane Electric power supply • Switch on the battery master switch. • Turn on the ignition. On the trans- mission • Switch the transmission to neutral position N. Switching on towing mode •...
Page 346 Manitowoc Crane Care. Risk of accident by faulty brakes If the service brake system has been damaged, you may only tow the truck crane from the immediate danger area after consulting with Manitowoc Crane Care. 7 - 8 3 112 993 en...
Page 347: Starting To Tow
Tow the truck crane at a maximum speed of 10 km/h (6 mph) and a maxi- mum distance of 1 km (0.62 mi). Additional measures must be taken for longer distances, refer to Manitowoc Crane Care. 7.3.2 Starting to tow It is not possible for the truck crane to start towing for transmission reasons.
Page 348 Malfunctions in driving mode 7.3 Towing the truck crane Blank page 7 - 10 3 112 993 en Operating manual GMK 6400...
Page 349: Other Emergency Operations
Malfunctions in driving mode 7.4 Other emergency operations Other emergency operations If the batteries on the carrier are discharged, you can: – Externally start the truck crane. – Charge the batteries with a battery charger. 7.4.1 Externally starting the truck crane •...
Page 350 Malfunctions in driving mode 7.4 Other emergency operations Blank page 7 - 12 3 112 993 en Operating manual GMK 6400...
Page 351: Wheels And Tyres
Malfunctions in driving mode 7.5 Wheels and tyres Wheels and tyres This section contains all the information about changing a wheel and about using the tyre inflator connection. 7.5.1 Wheel change • If a puncture occurs while driving, stop the truck crane, taking the follow- ing traffic into account, and secure the truck crane as outlined in the appli- cable legal stipulations of the country in which you are working.
Page 352 Malfunctions in driving mode 7.5 Wheels and tyres à • Removing Switch off the suspension; p. 5 - 15. a damaged wheel • Raise the truck crane with the outriggers until the wheel to be changed just barely leaves the ground. Risk of accident by falling wheel When unscrewing the final lug nuts, the wheel can slip off the hub and fall toward you.
Page 353 Malfunctions in driving mode 7.5 Wheels and tyres Removing a wheel • Undo the lug nuts (1). • Lift the spare wheel off the spare wheel holder. • Secure the spare wheel against falling over if you put it down temporarily. Mounting a wheel •...
Page 354 Malfunctions in driving mode 7.5 Wheels and tyres • Hand-tighten the lug nuts (1) and (2) to secure the wheel. • Tighten the remaining lug nuts. • Always tighten the lug nuts in the order (1) to (12). – First all lug nuts to 200 Nm (150 lbf ft). –...
Page 355: Inflating The Tyres Yourself
Malfunctions in driving mode 7.5 Wheels and tyres 7.5.2 Inflating the tyres yourself In emergencies you can inflate the tyres with the compressed air system of the truck crane if an appropriate filling hose is available. The tyres can be inflated up to a maximum pressure of about 8 bar (116 psi). This pressure might not correspond to the prescribed tyre pressure, à...
Page 356 Malfunctions in driving mode 7.5 Wheels and tyres Inflating the tyres The compressed air system's maximum operation pressure of 8 bar (116 psi) can only be reached with the engine running. à • Start the engine; p. 4 - 16. •...
Page 357: Fuses
Replace blown fuses only with new fuses of the same amperage. This pre- vent parts from being overloaded and damaged or the fuse from being immediately damaged again. Notify Manitowoc Crane Care if a fuse with the same amperage fails again once the ignition is switched on. Risk of fire Never repair a blown fuse with other electrically conductive materials.
Page 358: Fuses In The Driver's Cab
Malfunctions in driving mode 7.6 Fuses 7.6.1 Fuses in the driver's cab • Remove the covers (1) 2 Fuse groups F1 to F10 3 Reserve fuses The following sections show the designations of the individual fuses, including their amper- age and functions. Group F1 The fuses are labelled with the numbers.
Page 359 Malfunctions in driving mode 7.6 Fuses Group F2 Designation Amperage (A) Function F2/1 Tachograph, radio, control unit ESX 3 F2/2 Warm water auxiliary heater F2/3 Ignition lock F2/4 Heater fan Automatic parking light F2/5 Power supply F2/6 Retarder , air-conditioning system F2/7 ABS trailer F2/8...
Page 360 Malfunctions in driving mode 7.6 Fuses Group F4 Designation Amperage (A) Function Instrument lighting, trailer socket, engine F4/1 brake Battery heating F4/2 particulate filter F4/3 Central lubrication F4/4 Power supply F4/5 Tachograph Engine electronic system, ECOS control F4/6 unit F4/7 Diagnostics plug F4/8 TCM supply...
Page 361 Malfunctions in driving mode 7.6 Fuses Group F6 Designation Amperage (A) function Left-hand side marker lights and parking F6/1 light Right-hand side marker lights F6/2 parking light Left-hand marker light and tail lamps F6/3 Instrument lighting F6/4 Right-hand marker light and tail lamps F6/5 Left full-beam headlight Right-hand full beam headlight, indicator...
Page 362 Malfunctions in driving mode 7.6 Fuses Group F9 Designation Amperage (A) Function F9/1 MegaDrive control F9/2 MegaDrive control F9/3 MegaDrive control F9/4 MegaDrive control F9/5 MegaDrive control F9/6 MegaDrive control F9/7 MegaDrive control F9/8 Unassigned Group F10 Designation Amperage (A) Function F10/1 Radio...
Page 363: Fuses In The Battery Box
Malfunctions in driving mode 7.6 Fuses 7.6.2 Fuses in the battery box Fuses F7 to F10 are contained in the battery box. Danger from lead and lead compounds on battery Battery poles, battery terminals and parts of the battery itself contain lead and lead compounds.
Page 364 Malfunctions in driving mode 7.6 Fuses Blank page 7 - 26 3 112 993 en Operating manual GMK 6400...
Page 365: Troubleshooting
Malfunctions in driving mode 7.7 Troubleshooting Troubleshooting This section does not include all malfunctions. – If a warning is shown in the display (1); à p. 5 - 47. – If the lamp on the instrument panel (2) lights à p.
Page 366 – the performance in order to drive on to the next will increase again place where it is possible to stop Other malfunctions: Manitowoc Crane Care must be notified 7 - 28 3 112 993 en Operating manual GMK 6400...
Page 367: Malfunctions In The Def System
– Flashes DEF tank empty – DEF reservoir sensor faulty Have the exhaust system – Error in the DEF dosing unit checked by Manitowoc – Light up – DEF lines blocked Crane Care, an authorised – Temperature sensor faulty GROVE retailer or an –...
Page 368: Malfunctions In The Transmission
Remedy – Lights up – Loss of oil Checking the hydraulic lines – Solenoid valve faulty Manitowoc Crane Care must be notified – Malfunction in the elec- Switch off the ignition and tronics switch it back on again after around 15 seconds.
Page 369: Service Brake Malfunctions
Malfunctions in driving mode 7.7 Troubleshooting 7.7.5 Service brake malfunctions Malfunction Cause Remedy Lights up while The air pressure in one of the The vehicle can be driven driving or goes out two circuits has fallen below slowly to the next garage after the engine is 5.5 bar (80 psi) started...
Page 370: Steering Malfunctions
Separate steering not ECOS malfunction Read out error messages à working and the ECOS dis- p. 7 - 35) and notify play shows an error mes- Manitowoc Crane Care sage 7 - 32 3 112 993 en Operating manual GMK 6400...
Page 371: Differential Lock Malfunctions
à p. 5 - 58 Error symbol is displayed ECOS malfunction Read out error messages à p. 7 - 35) and notify Manitowoc Crane Care 7.7.8 Malfunctions in the hydraulic system/hydraulic oil cooler Malfunction Cause Remedy Hydraulic oil temperature Hydraulic system under Stop the truck crane while tak- above 80°C, fan in the hydrau-...
Page 372: Malfunctions On The Suspension
7 - 20 Error symbol is displayed ECOS malfunction Read out error messages à p. 7 - 35) and notify Manitowoc Crane Care 7.7.10 Malfunctions on the level adjustment system Malfunction Cause Remedy à Switching on the suspension ,...
Page 373: Malfunctions On The Ecos Carrier
Outrigger control units. ECOS program Always note the number of the programme version before referring to version Manitowoc Crane Care for malfunctions. • ö If required, open the main menu The display (1) shows the number of the current programme version.
Page 374 Malfunctions in driving mode 7.7 Troubleshooting Error messages If ECOS detects an error, an error message is indicated: – Lamp (1) flashes. – Lamp (2) flashes. Open the Errors submenu for more information. • Press the (2) button once. The button is only active when the lamp (1) flashes or lights up.
Page 375 4 The error type The error code (5) consists of four digits, e.g. 2332. • Always note the error code before contact- ing Manitowoc Crane Care You can exit the Errors submenu at any time. Exiting the submenu • Press the (1) button once.
Page 376 Malfunctions in driving mode 7.7 Troubleshooting Blank page 7 - 38 3 112 993 en Operating manual GMK 6400...
Page 377: Procedure During Malfunctions
Malfunctions in driving mode 7.8 Procedure during malfunctions Procedure during malfunctions 7.8.1 Switching on emergency operation in coolant circuit For cooling purposes, the fan wheel of the engine is switched on and off automatically. When this automatic system fails, you can switch on emer- gency operation so that the fan wheel always runs when the engine is switched on.
Page 378: Procedure During Engine Malfunctions
à • If necessary, note the error messages ( p. 7 - 36) and refer to Manitowoc Crane Care Severe engine malfunction The STOP warning lamp (3) lights up. In addition the following lamps light up: – Lamps (1) and (2) •...
Page 379: 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 380 CW entry Short error message – clutch wear. If CW is shown (approx. 10 seconds after switching on the ignition), then refer to Manitowoc Crane Care. Repairs will be necessary in the near future. AL entry The supply pressure is insufficient.
Page 381 Malfunctions in driving mode 7.8 Procedure during malfunctions Displaying error An error code is stored for each malfunction. Always note the error code codes before referring to Manitowoc Crane Care. • Engage the parking brake. • Shift to position N.
Page 382 Malfunctions in driving mode 7.8 Procedure during malfunctions Blank page 7 - 44 3 112 993 en Operating manual GMK 6400...
Page 383 Index Operating manual GMK 6400 3 112 993 en...
Page 384 3 112 993 en Operating manual GMK 6400...
Page 385 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 386 Index Blank page 8 - 2 3 112 993 en Operating manual GMK 6400...
Page 387 Index Access ladders on the carrier ......... . . 4 - 4 Adjusting the mirrors for driving .
Page 388 Index While towing ............7 - 8 CHECKLIST at low temperatures Driving .
Page 389 Index Inclining ............11 - 105 Operating elements Auxiliary air heater .
Page 390 Index Warning message ..........5 - 47 Documentation supplied .
Page 391 Index Adjusting the brightness of the display – in the driver’s cab ....4 - 15 Operating elements in the crane cab in submenu for outriggers ........9 - 24 in the errors submenu .
Page 392 Index Emergency stop devices Engine for crane operation ........10 - 18 for the engine .
Page 393 Index Final drive Operating elements in the driver's cab ....... 3 - 47 Front flap Opening and closing .
Page 394 Index Houselock Switching off ........... . 11 - 17 Switching on .
Page 395 Index Hazard warning system ..........3 - 56 Instruments .
Page 396 Index Hand-held control ..........14 - 20 Hoist cameras .
Page 397 Index Symbols used ........... . 1 - 21 Outrigger pressure display .
Page 398 Index Railings on the turntable ..........12 - 135 Raise axle Short description of the operating elements .
Page 399 Index Other rigging work Folding mirror in/out ......... 12 - 136 Folding the railings on the turntable in/out .
Page 400 Index Switching off ........... . 12 - 18 Switching on .
Page 401 Index Operating speeds ..........1 - 18 Superstructure .
Page 402 Index Stopping ........... . . 5 - 32 Switching on .
Page 403 Index Shutdown ........... . . 11 - 127 Switching monitoring function on/off .
Page 404 Index 8 - 20 3 112 993 en Operating manual GMK 6400...
Page 407 Operating manual Part 2 – Crane operation 3 112 993 en 12.07.2013...
Page 408 Important note Any kind of duplication or excerpt from this document, even in electronic form, is not subject to updating by Manitowoc Crane Group Germany GmbH. © Copyright reserved by Manitowoc Crane Group Germany GmbH Industriegelände West D-26389 Wilhelmshaven, Germany...
Page 409 Correction sheet Possible reeving methods on the main boom Contrary to the information specified in the operating manual, there are corrected hoist rope reevings on the main boom for the GMK6400 truck crane. Only reeve the hoist rope as described/illustrated in this correction sheet. It is important that you still observe all notes and safety instructions regarding rigging work on the main boom in the operating manual supplied.
Page 410 5 sheave hook block Reeving 3 sheave hook block Reeving 3 302 804 en Correction sheet GMK6400...
Page 411 1 sheave hook block Reeving Hook tackle Reeving Correction sheet GMK6400 3 302 804 en...
Page 412 With 10 head sheaves 11 sheave hook block Reeving 9 sheave hook block Reeving 3 302 804 en Correction sheet GMK6400...
Page 413 7 sheave hook block Reeving 5 sheave hook block Reeving Correction sheet GMK6400 3 302 804 en...
Page 414 3 sheave hook block Reeving 1 sheave hook block Reeving 3 302 804 en Correction sheet GMK6400...
Page 415 Hook tackle Reeving Correction sheet GMK6400 3 302 804 en...
Page 416 Blank page 3 302 804 en Correction sheet GMK6400...
Page 417 Technical data Contrary to the information given in the operating instructions supplied, the technical data have changed in part. Operating speeds The specified operating speeds only apply to an engine speed of about 1300 rpm without load. Main hoist: Rope speed when lifting and lowering Normal speed: maximum 50 m/min (164 ft/min) High-speed mode: maximum 120 m/min (394 ft/min)
Page 418 Blank page 3 113 115 en Correction sheet GMK6400...
Page 419 Safety harness on the main boom This truck crane is equipped with a safety har- ness (1) on the main boom. The safety harness is fixed securely to the main boom. The safety harness consists of two ropes with spacers and wear pads. Always secure yourself with the safety har- ness and your personal protective equipment when you have to step on the main boom,...
Page 420 The weight of the person to be secured must not exceed 140 kg (309 lbs). If you are unsure about which type of fall prevention safety system is required, please contact Manitowoc Crane Care 3 113 060 en Additional page GMK6400...
Page 421 Attaching/detaching fall prevention safety system to/from safety harness Attachment All points designed for fastening a fall prevention safety system are marked with a symbol. When stepping, observe the following procedure so that you are always secured. Risk of accidents due to incomplete safety system Make sure you always attach one line of the fall prevention safety system with the safety harness before stepping onto the main boom.
Page 422 Detachment Risk of accidents due to incomplete safety system Only detach the second line of the catch belt once you have reached a secure position on a ladder or access ladder. This will prevent falling due to an incomplete safety system. When stepping, observe the following procedure so that you are always secured.
Page 423 Make sure damaged, worn, or deformed fastening or connecting parts are immediately replaced by or an authorised GROVE Manitowoc Crane Care dealer or your repair crew. The safety harness must always be replaced completely following stress caused by a fall, even if no damage can be detected.
Page 424 Blank page 3 113 060 en Additional page GMK6400...
Page 425 Anemometer and air traffic control light Transport The storage compartment (1) for anemome- ters and air traffic control lights described in the accompanying operating manual is only available for certain versions of truck crane. In this case the rod (2) is fastened to the main boom head for transport and the anemometer (3) and air traffic control lights are transported in the crane cab.
Page 426 For transport à • Operating Dismount the anemometer; manual . • (A) – Remove the anemometer (1) and the air traffic control lights – if available – from the rod (3). • Fasten the linchpin (2) to the rod (3). •...
Page 427 Use of additional head sheaves These additional pages only apply for GMK 6400 that – are equipped with a second head sheave (2) – (A) – are equipped with 7 head sheaves (1) – (B) – are equipped with 7 head sheaves (1) and an additional head sheave (3).
Page 428 Risk of accident due to a damaged hoist rope Always use the second head sheave together with the additional head sheave located underneath it or with the auxiliary single-sheave boom top. This prevents the hoist rope from becoming overloaded, snapping during operation and letting the load fall.
Page 429 Instructions for operation with a trailer For operation with a trailer there are support points (2), locking points (3) and lashing eye- lets (1) on each side of the main boom. • Always set the main boom down on a trailer so that the support points (2) and locking points (3) are in contact with the corre- sponding counter bearings of the trailer...
Page 430 Maximum The lashing eyelets, support points and locking points are designed for the permitted load maximum forces listed below. Lashing eyelets The maximum forces permitted for the lashing eyelets (1) are F1 and F2 in the direction indi- cated. – Horizontally: F1 = max. 45 kN (10 115 lbf) –...
Page 431 This operating manual is divided into two parts: Part 1 – Driving Part 2 – Crane operation Content overview of Part 2: Operating elements for crane operation 10 Starting/turning off the engine – for crane operation 11 Crane operation 12 Rigging work 13 Driving with rigged truck crane 14 Malfunctions during crane operation 15 Index...
Page 432 Blank page 3 112 993 en Operating manual GMK 6400...
Page 433 Operating elements for crane operation Overview of the operating elements ........9 - 9.1.1 Exterior of the truck crane .
Page 434 3 112 993 en Operating manual GMK 6400...
Page 435: 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 436: 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 3 112 993 en Operating manual GMK 6400...
Page 437 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Lifting limit switch – function p. 11 - 62 à Lifting limit switch – rigging p. 12 - 126 à 2 Anemometer and air traffic control light p.
Page 438: Crane Cab
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.2 Crane cab 9 - 4 3 112 993 en Operating manual GMK 6400...
Page 439: Front Panel
Operating elements for crane operation 9.1 Overview of the operating elements à 1 Side panel p. 9 - 7 à 2 Front panel p. 9 - 6 à 3 Standard heating system p. 9 - 11 à 4 Control panels p.
Page 440 Operating elements for crane operation 9.1 Overview of the operating elements 9.1.3 Front panel à 1 Emergency stop switch p. 9 - 66 à 2 RCL control unit (Rated Capacity Limiter) p. 9 - 38 Depending on the version: à –...
Page 441: Side Panel
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.4 Side panel Below 1 Ashtray à 2 Standard heating system p. 9 - 11 à 3 Diagnostics (behind lid) p. 9 - 113 Operating manual GMK 6400 3 112 993 en 9 - 7...
Page 442 Operating elements for crane operation 9.1 Overview of the operating elements Above 9 - 8 3 112 993 en Operating manual GMK 6400...
Page 443 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Air vents p. 11 - 132 à 2 High speed indicator lamp for hoists p. 9 - 76 à 3 Windscreen wiper on/off p. 9 - 106 à...
Page 444 Operating elements for crane operation 9.1 Overview of the operating elements Console, rear 1 Configuration according to version à 1) 2) 2 Battery heater p. 9 - 62 3 Socket (12 V) 1) 2) 4 Key-operated switch Additional equipment à Separate operating manual 9 - 10 3 112 993 en...
Page 445 Operating elements for crane operation 9.1 Overview of the operating elements Standard heating system à 1 CraneSTAR systemAir-conditioning system p. 11 - 133 à 2 Setting fresh air/recirculated air/mixed air p. 11 - 131 à 3 Setting the fan p. 11 - 131 à...
Page 446 Operating elements for crane operation 9.1 Overview of the operating elements Auxiliary water heater à 1 Heating display p. 11 - 137 à 2 Setting the day and time p. 11 - 138 à 3 – Storing the heating start p.
Page 447 Operating elements for crane operation 9.1 Overview of the operating elements Auxiliary air heater à 1 Heating display p. 11 - 142 à 2 Temperature p. 11 - 143 à 3 Setting the time/day p. 11 - 143 à 4 – Storing the heating start p.
Page 448: Control Panels
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.5 Control panels Left à 1 Left control lever (configuration according to version) p. 9 - 16 à 2 Dead man's switch p. 9 - 63 3 Horn button à...
Page 449 Operating elements for crane operation 9.1 Overview of the operating elements Right à 1 Right control lever p. 9 - 16 (configuration according to version) à 2 Dead man's switch p. 9 - 63 3 Horn button à 4 Hoist high-speed mode on/off p.
Page 450: Control Lever Configuration
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.6 Control lever configuration 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 451 Operating elements for crane operation 9.1 Overview of the operating elements In version 2, the right control lever is configured with the Telescope function. Version 2 Left control lever Right control lever Slew to the left Raise/retract Slew to the right Lower/extend Lower the auxiliary hoist Lower the main hoist...
Page 452: Ecos Control Unit
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.7 ECOS control unit 9 - 18 3 112 993 en Operating manual GMK 6400...
Page 453 Operating elements for crane operation 9.1 Overview of the operating elements à 1 ECOS display p. 9 - 66 à Main menu overview p. 9 - 20 à 2 Brightness sensor p. 9 - 66 à 3 Error/warning message p. 9 - 64 à...
Page 454: Ecos Display - Main Menu
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.8 ECOS display – main menu The main menu displays symbols for further submenus and symbols for current displays. 9 - 20 3 112 993 en Operating manual GMK 6400...
Page 455 Operating elements for crane operation 9.1 Overview of the operating elements 1 Switch between measuring ranges à 2 Current inclination indicator p. 9 - 72 à 3 Anemometer display p. 9 - 75 à 4 Telescoping submenu p. 9 - 26 à...
Page 456 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 22 3 112 993 en Operating manual GMK 6400...
Page 457: Ecos Display - Submenus
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.9 ECOS display – submenus Superstructure lock submenu à 1 Superstructure locking status displays p. 9 - 89 à 2 Display slewing direction to 0°/180° p. 9 - 90 à...
Page 458 Operating elements for crane operation 9.1 Overview of the operating elements Outriggers submenu 9 - 24 3 112 993 en Operating manual GMK 6400...
Page 459 Operating elements for crane operation 9.1 Overview of the operating elements à 1 All supporting cylinders p. 9 - 69 à 2 Front right outriggers p. 9 - 69 à 2.1 Front right-hand outrigger pressure display p. 9 - 75 à...
Page 460 Operating elements for crane operation 9.1 Overview of the operating elements Telescoping submenu 9 - 26 3 112 993 en Operating manual GMK 6400...
Page 461 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Unlock telescopic section selection p. 9 - 84 à 2 Lock selection p. 9 - 84 à 3 Unlock telescoping cylinder selection p. 9 - 83 à 4 Locking status display p.
Page 462 Operating elements for crane operation 9.1 Overview of the operating elements Power unit speeds submenu à 1 Enter slewing gear speed p. 11 - 107 à 2 Enter telescoping mechanism speed p. 11 - 107 à 3 Enter main hoist speed p.
Page 463 Operating elements for crane operation 9.1 Overview of the operating elements Monitoring submenu à 1 Hydraulic oil temperature display p. 10 - 11 à 2 Fuel level display p. 10 - 11 à 3 Voltage monitoring display p. 10 - 11 à...
Page 464 Operating elements for crane operation 9.1 Overview of the operating elements Settings submenu 9 - 30 3 112 993 en Operating manual GMK 6400...
Page 465 Operating elements for crane operation 9.1 Overview of the operating elements 1 Auxiliary drive gears pressure display à 2 Slewing gear hydraulic circuit pressure display p. 9 - 88 à 3 Telescoping cylinder pressure display p. 9 - 88 à 4 Outrigger control units on/off p.
Page 466 Operating elements for crane operation 9.1 Overview of the operating elements à Displaying the operating hours , p. 11 - 110. Operating hours Description of the displays; submenu 1 ECOS – superstructure 2 Auxiliary drive gears 3 Telescoping mechanism 1), 2) 4 Mega Wing Lift 5 Derricking gear 6 Locking system...
Page 467 Operating elements for crane operation 9.1 Overview of the operating elements à Warning submenu , p. 11 - 111. Warning submenu Description of the displays; For the superstructure 1 Refuel 2 Air intake inhibitor triggered 3 Voltage monitoring 4 Replace air filter 5 Coolant level too low 6 Top up DEF 7 Engine malfunction...
Page 468 Operating elements for crane operation 9.1 Overview of the operating elements For the carrier 1 Refuel 2 Air intake inhibitor triggered 3 Voltage monitoring 4 Replace air filter 5 Coolant level too low 6 Top up DEF 7 Engine malfunction 8 Torque reduction 9 Torque reduction override button;...
Page 469 Operating elements for crane operation 9.1 Overview of the operating elements Errors submenu à 1 Current errors/total errors display p. 14 - 32 à 2 Next error p. 14 - 32 à 3 Previous error p. 14 - 32 à 4 Error display p.
Page 470 Operating elements for crane operation 9.1 Overview of the operating elements Working range limiter submenu à 1 Working range limiter display p. 11 - 126 à 2 Enter maximum overall height p. 11 - 118 à 2.1 Maximum overall height display p.
Page 471 Operating elements for crane operation 9.1 Overview of the operating elements Enter slewing angle submenu 1 Limited slewing angle display 2 Select slewing angle A 2.1 Maximum/current slewing angle A dis- play 3 Select slewing angle B 3.1 Maximum/current slewing angle B dis- play 4 Manual input on/off à...
Page 472: Rcl Control Unit
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.10 RCL control unit 9 - 38 3 112 993 en Operating manual GMK 6400...
Page 473 Operating elements for crane operation 9.1 Overview of the operating elements à 1 RCL display p. 9 - 93 à Main menu overview p. 9 - 4 à 2 Brightness sensor p. 9 - 92 à 3 Error/warning message p. 9 - 64 à...
Page 474: Rcl Display - Main Menu
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.11 RCL display – main menu The main menu shows symbols for further submenus and symbols for cur- rent displays. à 1 Date/time display p. 9 - 93 à 2 Enter rigging mode submenu p.
Page 475: Rcl Display - Submenus
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.12 RCL display – submenus Enter rigging mode submenu à 1 Entering counterweight p. 9 - 95 à 2 Selection p. 9 - 94 à 3 Entering outrigger span p.
Page 476 Operating elements for crane operation 9.1 Overview of the operating elements Monitoring submenu 9 - 42 3 112 993 en Operating manual GMK 6400...
Page 477 Operating elements for crane operation 9.1 Overview of the operating elements à 1 Current telescoping display p. 9 - 99 à 2 Lattice extension inclination display p. 9 - 100 à Lattice extension angle display p. 9 - 99 à 3 Error display p.
Page 478 Operating elements for crane operation 9.1 Overview of the operating elements Rigging mode monitoring submenu 1 Query – accept rigging mode? 2 Permissible lattice extension working range 3 RCL code 4 Length of lattice extension 5 Reeving 6 Permissible main boom working range 7 Hoists display 8 Counterweight 9 Permissible slewing range...
Page 479 Operating elements for crane operation 9.1 Overview of the operating elements Lifting capacity table submenu à 1 RCL code display p. 9 - 102 à 2 Reeving display p. 9 - 102 3 Selection à 4 Maximum load display p. 9 - 102 à...
Page 480 Operating elements for crane operation 9.1 Overview of the operating elements Working range submenu à 1 RCL code display p. 9 - 103 à 2 Reeving display p. 9 - 103 à 3 Maximum load display p. 9 - 103 à...
Page 481 Operating elements for crane operation 9.1 Overview of the operating elements Errors submenu à 1 Selection p. 14 - 25 à 2 Display error location p. 14 - 25 à 3 Display of current errors/total errors p. 14 - 25 à...
Page 482 Operating elements for crane operation 9.1 Overview of the operating elements Settings submenu à 1 Enter time/date p. 11 - 51 à 2 Enter time/date display p. 11 - 51 Buttons/displays (3) are only shown if a service device is connected. For this reason, these functions are not described in these operating instructions.
Page 483: Hand-Held Controls
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.13 Hand-held controls à 1 Engine control panel p. 9 - 108 à 2 Pre-select emergency operation p. 9 - 109 à 3 Function buttons p. 9 - 109 à...
Page 484 Operating elements for crane operation 9.1 Overview of the operating elements Outriggers con- trol panel à 1 Front left outriggers p. 9 - 67 à 2 Current inclination indicator p. 9 - 72 à 3 Front right outriggers p. 9 - 67 à...
Page 485 Operating elements for crane operation 9.1 Overview of the operating elements Rigging control panel à 1 Rigging counterweight p. 12 - 84 2 Locking status à 3 Rig auxiliary hoist p. 12 - 102 à 4 Boom pivot pin pulling device p.
Page 486: Outrigger Control Units
Operating elements for crane operation 9.1 Overview of the operating elements 9.1.14 Outrigger control units Button 9 - 52 3 112 993 en Operating manual GMK 6400...
Page 487 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-hand and right-hand mean: to the left or the right of the control unit. Outrigger button à...
Page 488 Operating elements for crane operation 9.1 Overview of the operating elements Inclination and outrigger pressure display à 1 Left-hand outrigger pressure display, opposite p. 9 - 75 à 2 Right-hand outrigger pressure display, opposite p. 9 - 75 à 3 Left-hand outrigger pressure display p.
Page 489 Operating elements for crane operation 9.1 Overview of the operating elements Raise axle display à 1 Axle line 1 p. 9 - 73 à 2 Axle line 2 p. 9 - 73 à 3 Axle line 3 p. 9 - 73 à...
Page 490 Operating elements for crane operation 9.1 Overview of the operating elements Blank page 9 - 56 3 112 993 en Operating manual GMK 6400...
Page 491: Short Description Of The Operating Elements
This section does not contain all the requirements that must be fulfilled for several operating elements to be active. If some operating elements do not work, first read the following chapters which are referred to at the respective places before contacting Manitowoc Crane Care 9.2.1 Definition of direction references...
Page 492: 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 493: Engine
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.3 Engine à Start the engine , p. 10 - 8. Side panel Ignition lock – 0 Ignition off, engine off, key can be removed – R, 1 Ignition on and power supply on for: instrument lighting, ECOS, engine control system, RCL –...
Page 494 Operating elements for crane operation 9.2 Short description of the operating elements Console, rear Battery heating system on/off – Up: Heating system on – Down: Heating system off à Separate operating manual . Further information on operation; ECOS display There is no short description of the displays in the submenus; à...
Page 495: Seat Contact Switch And Dead Man's Switch
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.4 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 496: Ecos Crane Control
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.5 ECOS crane control The truck crane GMK 6400 is equipped with the ECOS electronic crane con- trol (Electronic Crane Operating System). The ECOS includes a control unit in the crane cab, an operating unit in the driver's cab and several control units (ESX0, ESX1, ESX2 etc.) and I/O circuit boards (I/O 0, I/O 1 etc.) distrib- uted on the superstructure and carrier.
Page 497 Operating elements for crane operation 9.2 Short description of the operating elements Open Warning submenu The lamp (1) lights up or flashes. This opens the Warning submenu for the carrier – Press the button 1 x: à p. 11 - 111 Keycode entry The lamps next to all three buttons are lit.
Page 498 Operating elements for crane operation 9.2 Short description of the operating elements Brightness sensor Registers the brightness of the operating environment. The brightness of all displays is automatically adjusted. à Manual input; p. 10 - 5. Emergency stop switch May only be used in an emergency. –...
Page 499: Outriggers
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.6 Outriggers à Extending/retracting outrigger beams , p. 12 - 37 à Extending/retracting supporting cylinders , p. 12 - 45 à Hand-held control All directional information refers to the carrier; p.
Page 500 Operating elements for crane operation 9.2 Short description of the operating elements Function buttons There are four button combinations to execute the pre-selected functions. Engaged buttons are shown in black: Outrigger beams Only supports on the same side are pre- selected.
Page 501 Operating elements for crane operation 9.2 Short description of the operating elements Pre-selecting the outrigger All supporting cylinders – Pre-select: Press button 1 x – dot (1) turns green – pre-selection on After 10 seconds – dot (1) turns black – pre-selection off : / >...
Page 502 Operating elements for crane operation 9.2 Short description of the operating elements à On the outrigger All directional information refers to the carrier; p. 9 - 59. control units The display fields in the Settings submenu need to be switched on to operate in crane mode.
Page 503 Operating elements for crane operation 9.2 Short description of the operating elements Extending/retracting all supporting cylinders Button (3) or (4) is pressed. 1 To retract: Press button – all supporting cylinders retract 2 To extend: Press button – all support cylinders extend Movement stops after the button is released, and when an end position is à...
Page 504: Inclination Indicators
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.7 Inclination indicators à Inclination indicators , p. 12 - 50 Current inclination indicator A On the hand-held control B In the main menu In the Outriggers submenu C On the Outrigger control units 1 Measuring range display 2 Inclination indicator...
Page 505: Raise Axle
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.8 Raise axle When the suspension is switched off (blocked), the Raise axle function can be used to raise or lower axle lines or axle pairs, depending on the selection made.
Page 506 Operating elements for crane operation 9.2 Short description of the operating elements When you raise/lower the axles, the carrier's horn will sound once. Raising/lowering axles Raise: Press button (1) – the selected axles are raised and the truck crane is lowered Lower: Press button (2) –...
Page 507: Outrigger Pressure Displays
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.9 Outrigger pressure displays Outriggers submenu Outrigger pressure display – Unit of measurement: Displayed depending on setting – t – tons or – klbs – kilopounds – (1 kilopound = 1000 lbs) –...
Page 508: Main Hoist
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.11 Main hoist à Main hoist , p. 11 - 56. Main hoist on/off There is a lamp in the button. – Press 1 x: – Lamp bright – main hoist on –...
Page 509 Operating elements for crane operation 9.2 Short description of the operating elements Hoist high-speed mode on/off The parking brake must be engaged. – Left: High-speed mode on, off when released – 1 x to right: High-speed mode on – continuous operation –...
Page 510: Auxiliary Hoist
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.12 Auxiliary hoist à Auxiliary hoist , p. 11 - 59. Auxiliary hoist on/off There is a lamp in the button. – Press 1 x: – Lamp bright – auxiliary hoist on –...
Page 511: Slewing Gear
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.13 Slewing gear à Slewing gear , p. 11 - 98. Slewing gear on/off There is a lamp in the button. – Press 1 x: – Lamp bright – slewing gear on Slewing gear brake released –...
Page 512 Operating elements for crane operation 9.2 Short description of the operating elements Submenu Slewing gear/houselock submenu – To open: Press button 1 x – submenu opens Display slewing direction to 0°/180° Current position ± 20° in front of the 0° or 180° superstructure position. –...
Page 513: Derricking Gear
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.14 Derricking gear à Derricking gear , p. 11 - 64. Derricking gear on/off There is a lamp in the button. – Press 1 x: – Lamp bright – derricking gear on Power units with the same control lever configuration –...
Page 514 Operating elements for crane operation 9.2 Short description of the operating elements Raise button, shutdown bypassed – On: Shutdown bypassed – Off: Shutdown not bypassed à p. 11 - 44 9 - 80 3 112 993 en Operating manual GMK 6400...
Page 515: Telescoping Mechanism
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.15 Telescoping mechanism à Telescoping mechanism , p. 11 - 68. Control panels Telescoping mechanism on/off There is a lamp in the button. – Press 1 x: – Lamp bright – telescoping mechanism on, Power units with the same control lever configuration –...
Page 516 Operating elements for crane operation 9.2 Short description of the operating elements Submenu Telescoping submenu – To open: Press button 1 x – submenu opens Display for telescoping mechanism on/off – Green: Telescoping mechanism on – Red: Telescoping mechanism off à...
Page 517 Operating elements for crane operation 9.2 Short description of the operating elements Telescope diagram display Current relation between the telescopic sections – section of top view. Locking pin Display 1 and 2 1 On the telescopic section – Green: Locked 2 On the telescoping cylinder –...
Page 518 Operating elements for crane operation 9.2 Short description of the operating elements Unlock telescopic section selection – Display Yellow: Telescopic section unlocked Grey: Telescopic section locked Flashing: Unlock selected (yellow/grey) – To select: Press button 1 x – Telescoping cylinder locked: Unlock selected –...
Page 519 Operating elements for crane operation 9.2 Short description of the operating elements Locking point display – Direction of travel to the locking point 1 Extend telescoping cylinder 2 Retract telescoping cylinder – Distance to the locking point 3 Yellow: approx. 1 m (3.3 ft) 4 Yellow less than 1 m (3.3 ft) 5 Green:...
Page 520 Operating elements for crane operation 9.2 Short description of the operating elements Teleautomation direction display Start teleautomation with Extending 1 On: Start teleautomation with Retracting 2 On: Flashing = control lever movement incorrect à p. 11 - 91 Teleautomation on display/Manual telescoping on 1 Teleautomation on à...
Page 521 Operating elements for crane operation 9.2 Short description of the operating elements Current telescoping mechanism status dis- play The current status is shown using different symbols: 1 Normal 2 Waiting 3 Emergency programme access 4 Keycode input 5 Emergency programme 6 Telescope status divergence 7 Inactive à...
Page 522: Hydraulic System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.16 Hydraulic system Inclining the crane cab – Press down: Incline back – Press up: Incline forward à p. 11 - 105 In the Settings submenu Current pressure in bar for movements of the 1 Auxiliary drive gears: –...
Page 523: Superstructure Lock/Houselock Submenu
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.17 Superstructure lock/houselock submenu Superstructure lock submenu – To open: Press button 1 x – submenu opens Superstructure locking status displays The current status of the locking pin is shown by different symbols: 1 and 5 Green –...
Page 524 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 525: Rated Capacity Limiter (Rcl)
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.18 Rated capacity limiter (RCL) Control unit This section contains the operating elements that are the same for all menus opened. Buttons F1 to F14 The function of buttons F1 to F14 is shown on the symbol next to or above the button.
Page 526 Operating elements for crane operation 9.2 Short description of the operating elements Input confirmation The lamp (1) lights up. – In the Rigging mode sub- Press button 1 x – Rigging mode monitoring menu: submenu opens – In the Rigging mode moni- Press button 1 x –...
Page 527 Operating elements for crane operation 9.2 Short description of the operating elements Entering values The input mode for the RCL code is switched on. – To the right: Next greater value – To the left: Next smaller value Slowly turning – changes the value gradually Quickly turning –...
Page 528 Operating elements for crane operation 9.2 Short description of the operating elements à Entering the rigging mode , p. 11 - 23 Rigging mode entry submenu Selection In input mode 1 Press button 1 x – display next highest value 2 Press button 1 x –...
Page 529 Operating elements for crane operation 9.2 Short description of the operating elements Entering counterweight – Input mode on: Press button (1) 1 x – symbol turns green – Input: In input mode, press button 1 x – next combina- tion on display (2) à...
Page 530 Operating elements for crane operation 9.2 Short description of the operating elements Entering slewing range – Input mode on Press button (5) 1 x – symbol turns green – Input In input mode, press button 1 x – next permissible slewing range on display (4) 1 360°...
Page 531 Operating elements for crane operation 9.2 Short description of the operating elements Boom system display Boom system for displayed RCL code, 1 Main boom/auxiliary single-sheave boom 2 Heavy load lattice extension 2.1 Angle 2.2 Length 3 Boom extension 3.1 Angle 3.2 Length 3.3 Angle 4 Luffing jib...
Page 532 Operating elements for crane operation 9.2 Short description of the operating elements à Checks before operating the crane , Monitoring Displays – depend on rigging mode; submenu p. 11 - 31. RCL code display RCL code, four digits Reeving display 1 Required quantity of reeved ropes for displayed, maximum load (2) Counterweight display Required counterweight combination in tons (t) –...
Page 533 Operating elements for crane operation 9.2 Short description of the operating elements Lattice extension angle display The inclinable lattice extension is connected. – Display: Angle between lattice extension and main boom in degrees (°) – for displayed RCL code à p.
Page 534 Operating elements for crane operation 9.2 Short description of the operating elements Maximum load display – Display: Maximum load in tons (t) or kilopounds (klbs) for dis- played RCL code – Symbol (1) is red – maximum load reduced by reeving Press button (3) 1 x –...
Page 535 Operating elements for crane operation 9.2 Short description of the operating elements Current slewing angle display Position 0° to the rear 0°: Position 180° to the front 180°: +0.1 to +180.0°: Turned to the right from 0° –0.1 to –179.9°: Turned to the left from 0°...
Page 536 Operating elements for crane operation 9.2 Short description of the operating elements à Displaying the lifting capacity tables , p. 11 - 49 Lifting capacity table submenu – To open: Press the button 1 x – submenu opens, all crane movements are blocked, the lights ( ) light up Lifting capacity table display...
Page 537 Operating elements for crane operation 9.2 Short description of the operating elements à Displaying the lifting capacity tables , p. 11 - 49 Working range submenu Permissible working range display Applies to displayed RCL code and displayed telescope status 1 Permissible working range – surface under the curve 2 Maximum possible load 3 Maximum possible working radius Current position display...
Page 538 Operating elements for crane operation 9.2 Short description of the operating elements Other The key-operated switches have different functions, depending on the sym- bol (A) or (B). Key-operated RCL override switch – symbol (A) RCL shutdown overridden – – Turn to the right: crane functions released, no more monitoring;...
Page 539: Electrical System
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.19 Electrical system Voltage monitoring warning – On: Engine off – ignition on Engine on – power failure – switch off engine – Off: Engine on – no malfunction à...
Page 540 Operating elements for crane operation 9.2 Short description of the operating elements Slewable spotlight on/off – Switching on: Press down – Switching off: Press up à p. 11 - 109 Swinging the spotlight – Back: Press down – Forward: Press up à...
Page 541 Operating elements for crane operation 9.2 Short description of the operating elements Windscreen wiper/washing system Windscreen wiper on/off – Off: Press up – wiper goes to end position – Interval: Middle position – Continuous Press down operation: Roof window wiper on/off –...
Page 542: Hand-Held Control
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.21 Hand-held control Sockets for hand- The following applies to all sockets: held control – Pull plug: Engine off – ignition off – Insert plug: Ignition on à p.
Page 543 Operating elements for crane operation 9.2 Short description of the operating elements à Starting the engine – with the hand-held control , p. 10 - 15 Engine control panel 1 Voltage monitoring – On: Ignition on – Off: Ignition off 2 CAN monitoring –...
Page 544 Operating elements for crane operation 9.2 Short description of the operating elements à Outriggers control panel , p. 9 - 51. Outriggers control Brief description; panel Pre-select emergency operation 1 Main hoist 2 Telescoping mechanism 3 Derrick lattice extension 4 Auxiliary hoist 5 Derricking gear 6 Slewing gear Luffing jib...
Page 545 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 None Lower None Lower Lower Retract Raise None Lift Raise None None Slew to right None None None...
Page 546: Windows, Doors, Keys
Operating elements for crane operation 9.2 Short description of the operating elements 9.2.22 Windows, doors, keys Windows The handles on the windscreen and the rear window have the same func- tion. Risk of damage to the windscreen Do not open the windscreen if the Mega Wing Lift is in the rigging position. This avoids a collision between the windscreen and the Mega Wing Lift, which could damage the windscreen.
Page 547 Operating elements for crane operation 9.2 Short description of the operating elements From inside – Closing Pull unlocking lever (3), push door forwards by handle (1) – engages. Locking from inside not possible. – Opening Pull unlocking lever (2), push door back by handle (1) –...
Page 548 Operating elements for crane operation 9.2 Short description of the operating elements 9.2.23 Diagnostics The diagnostics connections may only be operated by the service staff. The following connections are below the cover (4). 1 ECOS diagnostics – (serial interface) 2 ECOS diagnostics – Can bus 3 RCL diagnostics 9 - 114 3 112 993 en...
Page 549 Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day ....10 - 10.1.1 Refuelling.
Page 550 3 112 993 en Operating manual GMK 6400...
Page 551: Starting/Turning Off The Engine - For Crane Operation
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day Starting/turning 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 552: Refuelling
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.1 Refuelling à Separate engine manufacturer’s operat- Only use permissible consumables; ing manual . Danger of fire from flammable gases Switch off the engine, the heater and all additional heaters before refuel- ling.
Page 553: Checks Before Starting The Engine
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.2 Checks before starting the engine On hydraulic tank The valve on the hydraulic tank must be open before starting the engine. Risk of damage to hydraulic pumps You may only start the engine when the valve on the hydraulic tank is open.
Page 554: Switching On The Ignition
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day Checking hand- held control The hand-held control must be removed for crane operation from the crane cab. • Check whether bridging plugs (1) to (4) are inserted in all the sockets; à...
Page 555: Lamp Test/Switching State Equalisation
Check whether lamps (1) and (2) light up briefly. If one or more lamps do not light up, refer to Manitowoc Crane Care. If the specified time is insufficient, you can perform the lamp test again as follows. Operating manual GMK 6400...
Page 556 Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day Performing lamp test • ö If necessary, open the main menu and press button (1) once. This opens the Settings submenu. •...
Page 557: Adjusting Display Brightness
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.5 Adjusting display brightness The brightness of the displays is automatically regulated by the ECOS and the RCL displays and depends on the brightness of the operating environ- ment.
Page 558: Start The Engine
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.6 Start the engine Refer to the separate operating manual provided by the engine manufac- turer for operating the engine. The engine can only be started if: –...
Page 559 If the lamp (1) does not go out, there is a fault in the flame start system; refer to Manitowoc Crane Care. • Wait until the lamp (1) goes out.
Page 560: Checks After Starting The Engine
à • Maintenance manual . Check the oil level; • Add oil if necessary. If the error message persists, refer to Manitowoc Crane Care à Warning submenu , If other symbols in this menu are displayed in red; p. 11 - 111.
Page 561: Monitoring Submenu
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.8 Monitoring submenu The Monitoring submenu shows the most important measured values. • ö If necessary, open the main menu and press the button (1) once.
Page 562: Setting The Idling Speed
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.9 Setting the idling speed à • Start the engine; p. 10 - 8 The display (1) in the Monitoring submenu shows the current engine speed. You can increase the idling speed for crane operation.
Page 563: Switching Off Economy Mode
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.10 Switching off Economy mode The Economy mode provides more efficient fuel consumption during crane operation. The Economy mode is switched on when you start the engine for crane operation.
Page 564: Overriding Torque Reduction
Starting/turning off the engine – for crane operation 10.1 When starting the engine for the first time of the day 10.1.11 Overriding torque reduction When the DEF supply is empty, torque reduction is activated via the engine control system. The monitoring elements are found in the Warning submenu. à...
Page 565: Starting The Engine - With The Hand-Held Control
Starting/turning off the engine – for crane operation 10.2 Starting the engine – with the hand-held control 10.2 Starting the engine – with the hand-held control Requirements You can only start the engine, if: à – The bridging plug is inserted in all unneeded sockets; p.
Page 566 Starting/turning off the engine – for crane operation 10.2 Starting the engine – with the hand-held control Blank page 10 - 16 3 112 993 en Operating manual GMK 6400...
Page 567: Turning Off The Engine
Starting/turning off the engine – for crane operation 10.3 Turning off the engine 10.3 Turning off the engine 10.3.1 During normal operation, with the ignition lock/with the hand- held control Risk of accident by suspended loads Never turn off the engine with a suspended load. You must have the control levers at hand in order to intervene at any time.
Page 568: In Emergencies, With The Emergency Stop Switches
Starting/turning off the engine – for crane operation 10.3 Turning off the engine 10.3.2 In emergencies, with 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.
Page 569 Crane operation 11.1 Before operating the crane ......... . . 11 - 11.1.1 CHECKLIST: Checks before operating the crane .
Page 570 11.4.9 Errors submenu ..........11 - 114 11.5 Working range limiter .
Page 571: 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 572 Crane operation 11.1 Before operating the crane à 3. – Switch on the cameras for the operation of the crane; p. 12 - 136. à – Adjust the slewable spotlights if necessary; p. 11 - 109. à 4. Earth the load, if necessary; p.
Page 573 Crane operation 11.1 Before operating the crane à 9. Remove key from the key-operated Override switches; p. 11 - 40. 10. Compare current rigging mode to display on RCL – enter current rig- à ging mode, if necessary; p. 11 - 23. 11.
Page 574 Crane operation 11.1 Before operating the crane 14. – Switch off the slewing gear for 0° and 180° working positions – sym- à bol (1) is red; p. 11 - 103. – Switch off houselock for other working positions – symbol (2) is red; à...
Page 575: Checking The Condition Of The Truck Crane
Crane operation 11.1 Before operating the crane 11.1.2 Checking 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 from flammable gases Turn off the engine and heating systems before refuelling.
Page 576 Crane operation 11.1 Before operating the crane à Checking the The hoist mirrors need to be folded out; p. 12 - 136. 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 from being drawn in and getting crushed.
Page 577: 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 – height 2 Back rest – angle (on both sides) 3 Seat –...
Page 578 Crane operation 11.1 Before operating the crane Front panel You can adjust the height of the front control panel. • (A) – Hold the front control panel by the han- dle (2). • Fold the pedal (1) upwards. • (B) – Adjust the front control panel to the desired height.
Page 579: Checking The Safety Equipment
Risk of accident when working with faulty safety devices It is prohibited to operate the crane with safety devices that are faulty, over- ridden or out of service. Have faulty safety devices repaired immediately by Manitowoc Crane Care. • Rated capacity Switch on the rated capacity limiter, do all of the checks and enter the cur- à...
Page 580 (1) and (2). If the emergency off switch is not working correctly, do not start work with the crane but notify Manitowoc Crane Care. Do not operate the emergency stop switch to turn off the engine in normal operation. Only operate the emergency stop switch in an emergency situa- tion.
Page 581 With the control lever actuated, stand up and check whether the crane movement comes to a standstill within approx. 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. Operating manual GMK 6400 3 112 993 en...
Page 582: 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 - 13), 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 583: Locking/Unlocking The Superstructure
Crane operation 11.1 Before operating the crane 11.1.6 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 584 The locking pin bolt (2) always has the same colour as the displayed symbol (1). If the error symbol (5) is displayed, contact Manitowoc Crane Care. Unlocking the The RCL shutdown procedure will be triggered and slewing disabled if you superstructure unlock the turntable when an RCL code for 0°...
Page 585: Switching The Houselock On/Off
Crane operation 11.1 Before operating the crane 11.1.7 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 586 Crane operation 11.1 Before operating the crane Switching on the houselock • Press in button (1) at the top until symbol (2) turns green The display will first show symbol (4) in yellow and when the houselock is switched on, it will show symbol (2) in green.
Page 587 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 - 15. houselock Risk of damage during slewing Always switch off the slewing gear before you operate the houselock.
Page 588 Crane operation 11.1 Before operating the crane Blank page 11 - 18 3 112 993 en Operating manual GMK 6400...
Page 589: Operation Of The Rated Capacity Limiter
Crane operation 11.2 Operation of the rated capacity limiter 11.2 Operation of the rated capacity limiter 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 590: Switching On The Rcl
Check whether you can hear a buzzer tone. Risk of accident if the safety devices are faulty If the lamps or buzzer fail, notify Manitowoc Crane Care and have the error 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 591 Crane operation 11.2 Operation of the rated capacity limiter After the test programme: – The lamps (1) and (2) light up – All power units are disabled The current display depends on whether the RCL either: – Had been switched off for up to 48 hours –...
Page 592 Crane operation 11.2 Operation of the rated capacity limiter After a standstill of more than 48 hours The Enter rigging mode submenu will open. Display (2) will show RCL code 1100 – the cor- responding rigging mode will be displayed. The display (1) shows the last reeving entered, e.g.
Page 593: Entering The Rigging Mode
Crane operation 11.2 Operation of the rated capacity limiter 11.2.2 Entering the rigging mode For a complete rigging mode input, you must enter, confirm and accept the rigging mode and the reeving. Opening the submenu • ö If necessary, open the main menu and press (1) button once.
Page 594 Crane operation 11.2 Operation of the rated capacity limiter Entering individ- With this type of input, select all the components of the rigging mode one ual components after the other. Danger of overturning due to incorrectly set rigging mode Values which have already been set may change when entering individual components.
Page 595 Crane operation 11.2 Operation of the rated capacity limiter To switch on input mode • Press one of buttons (1) to (4) for the desired component. The symbol turns green – input mode is switched on. Selecting values With the input mode switched on, you can select values that are permissible according to the Lifting capacity table .
Page 596 Crane operation 11.2 Operation of the rated capacity limiter After the selection procedure, there are three options: – Switching off the input mode. • Press button (1) once – symbol is grey. – Switching over the input mode. • Press the button for the next component once, e.g. button (2) – symbol is green.
Page 597 Crane operation 11.2 Operation of the rated capacity limiter – Outrigger span – with outrigger span monitoring The display (1) indicates if the outrigger span corresponding to the RCL code (6) is rigged. The display is identical for all outrigger beams (2).
Page 598 Crane operation 11.2 Operation of the rated capacity limiter – Slewing range Symbol (1) is green. Press buttons repeatedly until the display (2) indicates the required slewing range, e.g. 360°. You can only confirm rigging modes for slewing ranges other than 360°: –...
Page 599 Crane operation 11.2 Operation of the rated capacity limiter Entering the Entering the reeving does not have an effect on any other component that reeving value has already been entered. • Press button (5) repeatedly until the symbol for the hoist with which you want to lift the load has turned green.
Page 600 Crane operation 11.2 Operation of the rated capacity limiter Accepting the rigging mode • Check whether the current rigging mode of the truck crane corresponds to the displayed rigging mode. Risk of accident due to incorrectly set RCL If the current rigging mode varies from the displayed rigging mode, the maximum load displayed by the RCL will not correspond to the actually permissible lifting capacity according to the Lifting capacity table .
Page 601: Checks Before Operating The Crane
Crane operation 11.2 Operation of the rated capacity limiter 11.2.3 Checks before operating the crane Crane operation is only enabled when the Monitoring submenu is open. Opening the submenu After a standstill of less than 48 hours and after accepting a rigging mode, the Monitoring submenu will open automatically.
Page 602 Crane operation 11.2 Operation of the rated capacity limiter • Checks Check whether the current rigging mode of the truck crane corresponds to the displayed rigging mode. Risk of accident due to incorrectly set RCL If the current rigging mode varies from the displayed rigging mode, the maximum load displayed by the RCL will not correspond to the actually permissible lifting capacity according to the Lifting capacity table .
Page 603 Crane operation 11.2 Operation of the rated capacity limiter Example of how to switch over the display The load should be raised with the main hoist, for example. However, lamp II for the auxiliary hoist lights up and lamp I for the main hoist flashes. Switch over the display as follows: •...
Page 604: Displays During Crane Operation
Crane operation 11.2 Operation of the rated capacity limiter 11.2.4 Displays during crane operation The following information is constantly displayed in addition to the displays of the rigging mode: The current telescoping The displays (1) to (4) show the current tele- scoping of the telescopic sections I to IV in percent, e.g.
Page 605 Crane operation 11.2 Operation of the rated capacity limiter The 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, e.g. – 3°. The current overall height Overall height = vertical distance between the lower edge of the outrigger pad and the highest point of the main boom or lattice extension.
Page 606 Crane operation 11.2 Operation of the rated capacity limiter The currently raised load The display (1) shows the sum of the payload + lifting gear + hook block. The maximum load Display (2) shows the maximum load that can be lifted in the current rigging mode with the current working radius.
Page 607: Rcl Early Warning
Crane operation 11.2 Operation of the rated capacity limiter 11.2.5 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 (1).
Page 608 Crane operation 11.2 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 (4). –...
Page 609: Display During Errors
Crane operation 11.2 Operation of the rated capacity limiter 11.2.7 Display during errors If an error occurs, it will be displayed as fol- lows. – Depending on the type of error, the buzzer tone sounds once or as a continuous buzzer tone.
Page 610: Rcl Override
Crane operation 11.2 Operation of the rated capacity limiter 11.2.8 RCL override There are two types of RCL override, depending on the version. Risk of accident due to overridden or faulty RCL It is not permitted to work with an overridden or faulty RCL. Set down the load immediately and stop operating the crane if the RCL is faulty.
Page 611 Crane operation 11.2 Operation of the rated capacity limiter RCL override – symbol (B) The status display (1) is active. The following operating elements can be used to override the RCL: Key-operated RCL override switch Key-operated rigging switch Raise switch Status display The status display informs people in the dan- ger area of the truck crane:...
Page 612 Crane operation 11.2 Operation of the rated capacity limiter The lamps of the status display light up or flash depending on the RCL degree of utilisation and operation of the switches. Degree of utilisation Switch pressed 0 - 90% approx. greater than 90 - 100% 100%...
Page 613 Crane operation 11.2 Operation of the rated capacity limiter RCL shutdown There are different types of RCL shutdown: – Shutdown due to overload, approx. 100% of the maximum permissible load is exceeded, – Shutdown due to an error. If the RCL has shut down the crane movements, then: –...
Page 614 Crane operation 11.2 Operation of the rated capacity limiter Raising after RCL shutdown You can re-enable raising with the switch (1) in order to leave the shutdown range. The speed will then be reduced to 50%. Requirement – The engine for crane operation is running. Raising the main boom •...
Page 615 Crane operation 11.2 Operation of the rated capacity limiter Overriding RCL or lifting limit switch for rigging work For rigging work, you can: – Override the lifting limit switch, – Override the RCL and thus enable a degree of utilisation of up to 110%. For both overrides the speed of the movements which increase the load moment is reduced to 15%.
Page 616 Crane operation 11.2 Operation of the rated capacity limiter Cancelling the override The override will be cancelled when you: – Press the key-operated switch again. – Do not activate the control lever for 10 seconds. – Switch off the ignition. Risk of accident due to accidental override The key must not remain in the key-operated switch while the crane is oper- ating.
Page 617 Crane operation 11.2 Operation of the rated capacity limiter Overriding the RCL in an emergency Risk of accident due to overridden or faulty RCL It is not permitted to work with an overridden or faulty RCL. Set down the load immediately and stop operating the crane if the RCL is faulty.
Page 618 Crane operation 11.2 Operation of the rated capacity limiter Cancelling the override The override will be cancelled when you: – Switch off the ignition, – Press the key-operated switch again. The override will automatically be cancelled 30 minutes after the key-oper- ated switch has been pressed.
Page 619: Displaying The Lifting Capacity Tables
Crane operation 11.2 Operation of the rated capacity limiter 11.2.9 Displaying the lifting capacity tables Opening the submenu • Stop all crane movements – control lever in initial position. • In the main menu or Monitoring or submenu, press button (1) once. The Lifting capacity table submenu opens.
Page 620 Crane operation 11.2 Operation of the rated capacity limiter Curve (2) shows the permissible working range for the entered RCL code (9) and the tel- escope status (4). The working range ends at the maximum pos- sible working radius (3). Reduction of the working radius increases the enabled load along the curve (2) up to the maximum possi- ble load (1).
Page 621: Entering The Time/Date
Crane operation 11.2 Operation of the rated capacity limiter 11.2.10 Entering the time/date You can enter the time and date for the display (2). • Press the (1) button once. This opens the Settings submenu. • Press button (1) repeatedly until the desired value flashes.
Page 622 Crane operation 11.2 Operation of the rated capacity limiter Blank page 11 - 52 3 112 993 en Operating manual GMK 6400...
Page 623: Crane Operation With Main Boom
Crane operation 11.3 Crane operation with main boom 11.3 Crane operation with main boom 11.3.1 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 accident if the truck crane is not level The RCL calculates the working radius from the length and angle of the main boom.
Page 624 Crane operation 11.3 Crane operation with main boom Checking the wind Strong winds can result in the truck crane becoming overloaded. speed • Prior to and during crane operation, check whether the current wind speed is lower than the maximum permissible wind speed. Maximum permissible wind speed The maximum permissible wind speed (1) for the current rigging mode is specified at the bottom of the corresponding Lifting capacity table .
Page 625: Permissible Slewing Ranges And Working Positions
Crane operation 11.3 Crane operation with main boom 11.3.2 Permissible slewing ranges and working positions The following ranges are permissible for crane operation according to the Lifting capacity table . • 360° slewing Support the truck crane with the outrigger span required according to the Lifting capacity table.
Page 626: Main Hoist
Crane operation 11.3 Crane operation with main boom 11.3.3 Main hoist You can reeve the hoist rope of the main hoist on the main boom or on the lattice extension. Risk of accident from accidentally operating a hoist Always switch off the hoist that is not in use. Never operate the hoist if the hook block is unreeved and the hoist rope is completely wound onto the drum.
Page 627 Crane operation 11.3 Crane operation with main boom Switching on the After the ignition is switched on, all of the power units will be switched off main hoist and the lamps in the corresponding buttons will only light up dimly. •...
Page 628 Crane operation 11.3 Crane operation with main boom The maximum rope speed is continuously decreased automatically from a degree of utilisation of 80% onwards. Higher speeds are only enabled again when the degree of utilisation is below 80% and the control lever has been put in the initial position once.
Page 629: Auxiliary Hoist
Crane operation 11.3 Crane operation with main boom 11.3.4 Auxiliary hoist Risk of accident when operating the auxiliary hoist Read and observe all of the safety instructions in the section titled Main hoist , p. 11 - 56 before operating the auxiliary hoist. All safety instructions for the operation of the main hoist also apply to the auxiliary hoist, along with the information in this section.
Page 630 Crane operation 11.3 Crane operation with main boom • On the RCL, check whether the lamp II is on. à If lamp II flashes, switch over the display; p. 11 - 33. • Check whether the current reeving of the auxiliary hoist is displayed, à...
Page 631 Crane operation 11.3 Crane operation with main boom à You can limit the maximum hoist speed; p. 11 - 107. à You can switch on the high-speed mode for a higher speed; p. 11 - 96. Switching off the If the auxiliary hoist is not required, it should be switched off to avoid auxiliary hoist unintentional use.
Page 632: Lifting Limit Switch And Lowering Limit Switch
Crane operation 11.3 Crane operation with main boom 11.3.5 Lifting limit switch and lowering limit switch à Lifting limit switch To install/remove the lifting limit switch; p. 12 - 126. The lifting limit switch (1) prevents the hook block from being lifted up to the main boom head and damaging it.
Page 633 Crane operation 11.3 Crane operation with main boom Overriding the lifting limit switch When overriding, the shutdown of the lifting limit switch is cancelled and à the crane operation is no longer completely monitored; Overriding RCL or lifting limit switch for rigging work , p. 11 - 45 Risk of accident if the lifting limit switch is overridden You may only override the lifting limit switch if this is specified in the oper- ating instructions when carrying out maintenance or rigging work.
Page 634: Derricking Gear
Crane operation 11.3 Crane operation with main boom 11.3.6 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 the working area specified in the Lifting capacity table is left.
Page 635 Crane operation 11.3 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 - 108. 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 derrick-...
Page 636 Crane operation 11.3 Crane operation with main boom Re-enabling If the RCL has switched off the raising function due to an overload, you can raising function re-enable the raising function with switch (1). The speed will then be reduced to 50%. •...
Page 637 Crane operation 11.3 Crane operation with main boom Lowering the Lowering the boom out of the working range is enabled only without a load main boom to and if there is a rigging table for the current rigging mode. a horizontal Enabling is automatic, the rigging tables cannot be entered manually.
Page 638: Telescoping Mechanism
Crane operation 11.3 Crane operation with main boom 11.3.7 Telescoping mechanism A telescoping process requires locking and unlocking processes in the main boom. You can telescope the main boom in two ways. – Manual telescoping For manual telescoping, you must initiate all locking and unlocking processes at the right time.
Page 639 Crane operation 11.3 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 640 Crane operation 11.3 Crane operation with main boom 1. Unlocking the telescoping cylinder The locking pins (5) retract – the telescoping cylinder is unlocked. 2. Moving and locking the telescoping cylin- The telescoping cylinder moves into the sec- tion to be telescoped, e.g. telescopic section III (3).
Page 641 Crane operation 11.3 Crane operation with main boom 4. Telescoping, locking and setting down a telescopic section The telescoping cylinder pushes the telescopic section to a locking point. The weight is taken off the mechanism (10). The locking pins (7) extend into the cutouts (4). The telescopic section is automatically set down.
Page 642 Crane operation 11.3 Crane operation with main boom 1 Telescopic section I 2 Telescopic section II 3 Telescopic section III 4 Cutouts 5 Locking pins on the telescoping cylinder 6 Cutouts 7 Locking pin on the telescopic section 8 Telescoping cylinder (piston rod) 9 Basic section 10 Mechanism 11 - 72...
Page 643 Crane operation 11.3 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 ing length lifting capacities according to the Lifting capacity tables are enabled and dis- played automatically.
Page 644 Crane operation 11.3 Crane operation with main boom Telescope status The position of the telescopic sections, i.e. which telescopic section is extended to what extent, is referred to as telescoping. This section only deals with the displays on the RCL. The telescoping is also à...
Page 645 Crane operation 11.3 Crane operation with main boom Checks before When the ignition is turned on, ECOS registers the displayed telescoping starting work status from the current status of the telescoping mechanism and the previously saved locking and unlocking procedures. Normally, ECOS detects differences between the current and the displayed à...
Page 646 Crane operation 11.3 Crane operation with main boom Switching on the After the ignition is switched on, all of the power units will be switched off telescoping and the lamps in the corresponding buttons will only light up dimly. mechanism •...
Page 647 Crane operation 11.3 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 648 Crane operation 11.3 Crane operation with main boom You can set the desired engine speed (idling speed) with the button (1); à p. 10 - 12. You can limit the maximum telescoping speed in the Power unit speeds sub- à menu;...
Page 649 Crane operation 11.3 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 650 Crane operation 11.3 Crane operation with main boom Current telescoping The display (2) shows the current telescoping in percent for each telescopic section. The display (1) shows a diagram of the current telescope state. Position of the telescoping cylinder The display (4) shows how far the telescoping cylinder is extended, e.g.
Page 651 Crane operation 11.3 Crane operation with main boom Position of the locking pins The display (3) shows the current positions of the locking pins. 1 On the telescoping cylinder 2 On the telescopic section The current settings are shown in different col- ours.
Page 652 Crane operation 11.3 Crane operation with main boom To select unlock • Press the (1) button once. – If the telescopic section is locked: Symbol (1) will flash – Unlock telescoping cylinder is selected. – If the telescopic section is unlocked: Symbol (2) will flash –...
Page 653 Crane operation 11.3 Crane operation with main boom If symbol (1) is still flashing after approx. 10 seconds, this means that the locking pins are under load. • Release the control lever. The display (2) shows which movement you need to carry out to take the load off: –...
Page 654 Crane operation 11.3 Crane operation with main boom Extending/retract- Operating the telescoping cylinder (without telescopic section) is required ing the telescop- when the telescoping cylinder needs to be moved into a different telescopic ing cylinder section. Requirements – Telescoping mechanism on – symbol (3) is green, –...
Page 655 Crane operation 11.3 Crane operation with main boom Locking the The telescoping cylinder must be locked to a telescopic section so that the telescoping telescopic section can be telescoped. cylinder Requirements – Telescoping mechanism on – symbol (3) is green –...
Page 656 Crane operation 11.3 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. Requirements – Telescoping mechanism on – symbol (2) is green –...
Page 657 Crane operation 11.3 Crane operation with main boom If symbol (1) is still flashing after approx. 10 seconds, this means that the locking pins are under load. • Release the control lever. To relieve the load, carefully retract and extend a little. Risk of damage to the boom system If extending and retracting several times does not lead to the lock being released, you must not telescope any further against the stop.
Page 658 Crane operation 11.3 Crane operation with main boom Telescoping the You can telescope the telescopic section once it is unlocked. telescopic section Requirements – Telescoping mechanism on – symbol (3) is green – Telescoping cylinder locked – symbol (1) is grey –...
Page 659 Crane operation 11.3 Crane operation with main boom Locking telescopic Every telescopic section can be locked at the fixed lengths – fixed lengths; à sections p. 11 - 73. Requirements – Telescoping mechanism on – symbol (3) is green – Telescopic section unlocked – symbol (2) is yellow –...
Page 660 Crane operation 11.3 Crane operation with main boom Risk of damage to the telescoping cylinder Move the control lever until the telescopic section is locked and set down – the symbol must be yellow. This prevents the load from exerting pressure on the telescoping cylinder and allow the load to be enabled for fixed lengths.
Page 661 Crane operation 11.3 Crane operation with main boom Telescoping with When telescoping with teleautomation, you enter the desired fixed lengths teleautomation and then move the control lever in the required direction. Switching between the telescopic sections is carried out automatically by ECOS. If the desired telescoping status is not a fixed length, you can first telescope to the next closest fixed length with the teleautomation and then telescope further to the desired length manually.
Page 662 Crane operation 11.3 Crane operation with main boom – The displayed symbol, e.g. symbol (1) will flash if the control lever is moved incorrectly. – If the control lever movement is correct, ECOS telescopes automatically till a change in direction is required. Then the symbol for the new move- ment will be displayed, e.g.
Page 663 Crane operation 11.3 Crane operation with main boom Example of telescoping with teleautomation Assuming the current telescoping is 100/0/0/0 and the telescoping cylinder is locked in tele- scopic section I . The desired telescoping status should be 50/100/ 100/100. The display should correspond to the opposite diagram once you have entered the desired tele- scope status and confirmed it.
Page 664 Crane operation 11.3 Crane operation with main boom Retract telescopic section I – display (3) 0% Lock telescopic section I – pins (5) are green Unlock telescoping cylinder – pins (4) are red The telescoping cylinder moves into telescopic section IV – display (2) Lock telescoping cylinder –...
Page 665 Crane operation 11.3 Crane operation with main boom • Telescoping the Derrick the main boom to the horizontal position as described in section à Lowering the main boom to a horizontal position ; main boom when p. 11 - 67. horizontal The RCL will automatically switch to the corresponding rigging table.
Page 666: High-Speed Mode
Crane operation 11.3 Crane operation with main boom 11.3.8 High-speed mode The slewing gear cannot be operated at high speed. You can switch on the high-speed mode for a higher speed. Risk of accident due to the suddenly accelerating movements Reduce the engine speed before starting high-speed mode.
Page 667 Crane operation 11.3 Crane operation with main boom Hoists The main hoist and auxiliary hoist are always switched simultaneously to high-speed mode. Risk of accident due to overloading Make sure the lifted load is no more than 50% of the maximum load accord- ing to the Lifting capacity table (maximum degree of utilisation of 50%) before operating the hoists in high-speed mode.
Page 668: Slewing Gear
Crane operation 11.3 Crane operation with main boom 11.3.9 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 669 Crane operation 11.3 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 only light up dimly. •...
Page 670 Crane operation 11.3 Crane operation with main boom Slewing The following prerequisites must be fulfilled before slewing: à – Houselock is switched off; p. 11 - 15. – The superstructure is unlocked. à – Slewing is permissible with the current rigging mode; p.
Page 671 Crane operation 11.3 Crane operation with main boom • To slew to the left: Push the control lever to the left. • To slew to the right: Push the control lever to the right. You can regulate the speed by moving the control lever and changing the engine speed with the accelerator.
Page 672 Crane operation 11.3 Crane operation with main boom Braking the You may only brake the slewing movement with the slewing gear brake. slewing movement Risk of the main boom buckling Do not under any circumstances switch off the slewing gear to brake it. Only switch off the slewing gear after the superstructure has stopped turn- ing.
Page 673: Possible Movement Combinations
Crane operation 11.3 Crane operation with main boom Switch 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 674: Hydraulic Oil Cooling
Crane operation 11.3 Crane operation with main boom 11.3.11 Hydraulic oil cooling Depending on the truck crane version, there are one or two hydraulic oil coolers that regulate the hydraulic oil temperature automatically. • In addition to this, you should ensure that the maximum permissible hydraulic oil temperature of 80°C (176°F) is not exceeded The current hydraulic oil temperature is displayed in the Monitoring sub-...
Page 675: Settings And Displays For Crane Operation
Crane operation 11.4 Settings and displays for crane operation 11.4 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. 11.4.1 Inclining the crane cab With the appropriate equipment, you can incline the crane cab to the rear in...
Page 676: Setting Idling Speed
Crane operation 11.4 Settings and displays for crane operation 11.4.2 Setting idling speed à Setting the idling speed , p. 10 - 12. 11.4.3 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 677: Limiting The Power Unit Speeds
Crane operation 11.4 Settings and displays for crane operation 11.4.4 Limiting the power unit speeds You can enter what percentage of the maximum speed should be enabled for each power unit. • ö If necessary, open the main menu and press (1) button once The Power unit speeds submenu will open.
Page 678: Setting The Characteristic Curves For The Control Levers
Crane operation 11.4 Settings and displays for crane operation 11.4.5 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. The set control lever characteristic curve always applies to both control levers and to all power units moved with the control levers.
Page 679: Using The Slewable Spotlights
Crane operation 11.4 Settings and displays for crane operation 11.4.6 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 accident due to being dazzled during on-road driving When driving on the road, always direct the spotlight in such a way that the reflector points downwards.
Page 680: Displaying The Operating Hours
Crane operation 11.4 Settings and displays for crane operation 11.4.7 Displaying the operating hours You can view the operating hours for all power units in the Operating hours submenu. ö If necessary, open the main menu and press (1) button once. This opens the Settings submenu •...
Page 681: Warning Submenu
Crane operation 11.4 Settings and displays for crane operation 11.4.8 Warning submenu ECOS differentiates between warning messages and error messages (error à messages; p. 11 - 114). A warning message indicates that certain values do not correspond to a target value. In the event of a warning message, the follow- ing lamps will flash: –...
Page 682 Maintenance manual Check the oil level; • Add oil if necessary If the error message persists, refer to Manitowoc Crane Care Risk of damage to the engine if the oil pressure drops Turn off the engine as soon as possible and look for the cause if the lamp lights up or the warning buzzer sounds.
Page 683 Crane operation 11.4 Settings and displays for crane operation Refuelling The fuel tank is only filled up to a level of approx. 5%. à à • Refuel before the fuel is used up; p. 10 - 2, p. 4 - 8 If the fuel tank is almost empty, air will be sucked in and you will have to à...
Page 684: Errors Submenu
Crane operation 11.4 Settings and displays for crane operation Main boom lowers itself With the derricking gear switched off, the main boom has dropped by more à Switching on the derricking gear , p. 11 - 64 than 3°; Exiting the You can exit the submenu at any time.
Page 685: Working Range Limiter
Crane operation 11.5 Working range limiter 11.5 Working range limiter You can set and monitor four different limits in the working range limiter submenus: – A maximum overall height – A maximum working radius – A maximum slewing angle – Objects in the working range The monitoring of the programmed limits can be switched on and off separately.
Page 686: Opening The Working Range Limiter Submenu
Crane operation 11.5 Working range limiter 11.5.1 Opening the working range limiter submenu • ö If required, open the main menu The dot in symbol (1) indicates whether limit values are being monitored: – Dot is black: Monitoring switched off –...
Page 687 Crane operation 11.5 Working range limiter Limit values/current values The displays (1) to (3) indicate values for: 1 Overall height 2 Working radius 3 Slewing angle Every display shows the following values: 4 Limit value – red 5 Current value – blue In case of manual and switched on input, dis- à...
Page 688: Entering Limit Values
Crane operation 11.5 Working range limiter 11.5.3 Entering limit values This section describes how to enter unknown limit values by moving to the shutdown points. à Entering limit values/objects You can enter known limit values directly; manually , p. 11 - 124. Requirement Manual input must be switched off.
Page 689 Crane operation 11.5 Working range limiter The limit value for the working radius affects the representation of defined objects. Only points that are within the limit value (1) will be displayed. Slewing angle Slewing angles are entered in a submenu. Before entering values, monitoring (1) must be switched off –...
Page 690 Crane operation 11.5 Working range limiter Entering the permissible slewing range You must enter the slewing angles A and B separately. Risk of accident due to incorrectly set slewing angles Always slew the main boom to the shutdown point from the right with slewing angle A and from the left with slewing angle B.
Page 691 Crane operation 11.5 Working range limiter Entering objects Objects are entered in a submenu. Before entering values, the monitoring functions (1) to (3) must be switched à off – dot is black; p. 11 - 126. • Press the (1) button once. The Enter objects submenu will open Representation of points and objects Each point shown is numbered and defined by...
Page 692 Crane operation 11.5 Working range limiter Entering objects • (A) – With the buttons (10), select the first point, e.g. point (1) – blue • Move the main boom head (11) to just before the first point of the object •...
Page 693 Crane operation 11.5 Working range limiter Deleting points You can delete selected, individual points or delete all points at once. (A) – Selected points • Press the (1) button once The selected point will be deleted, e.g. point (4) – point data 0.0. (B) –...
Page 694: Entering Limit Values/Objects Manually
Crane operation 11.5 Working range limiter 11.5.4 Entering limit values/objects manually Limit values The limit values for the overall height, the working radius, and the slewing range are entered in the same way. – For overall height/working radius • Press the button once: For the overall height For the working radius –...
Page 695 Crane operation 11.5 Working range limiter Objects Objects are entered in a submenu. • Press the (1) button once. The Enter objects submenu will open • With the buttons (12), select the desired point, e.g. point (1) – blue • Press button (11) once –...
Page 696: Switching Monitoring Functions On/Off
Crane operation 11.5 Working range limiter 11.5.5 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. • Press the buttons for the required monitoring functions once 1 Overall height 2 Working radius 3 Slewing angle...
Page 697: Shutdown By Working Range Limiter
Crane operation 11.5 Working range limiter 11.5.6 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. Shutdown point reached for Disabled movements –...
Page 698: Work Break
Crane operation 11.6 Work break 11.6 Work break 11.6.1 In case of short work breaks Risk of accident by suspended loads Never turn off the engine with a load suspended. You must have the control levers at hand in order to intervene at any time. Always set down the load before you leave the crane cab.
Page 699: In Case Of Work Breaks Of More Than 8 Hours
Crane operation 11.6 Work break 11.6.2 In case of work breaks of more than 8 hours • Retract all telescopic sections • Set down the main boom on the boom rest • Switch off the slewing gear – The lamp in the (1) button must be dimly lit –...
Page 700: Heating And Air-Conditioning System
Crane operation 11.7 Heating and air-conditioning system 11.7 Heating and air-conditioning system • Do not cover grilles (1) and (2) – Air is drawn in through grilles (1) and (2) 11.7.1 Standard heating system • Switching on Start the engine. The heating output is only provided when the engine is running Heating You must set the fan, fresh air/recirculated air and the temperature.
Page 701 Crane operation 11.7 Heating and air-conditioning system Air distribution You can allow the air to flow out from various air vents. • Turn the switch (4) to the position for the required air vents A Air vents (1), (2), windscreen, centre B Air vents (3), cab floor C Air vents (1), (2), (3)
Page 702: Air-Conditioning System
Crane operation 11.7 Heating and air-conditioning system 11.7.2 Air-conditioning system You can use the air-conditioning system to cool and dry the air in the crane cab. Warnings 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 703 Crane operation 11.7 Heating and air-conditioning system Cooling The illustration only shows one sample setting. Always adjust the setting to the current conditions. • Press switch (1) down • Turn the switch (5) as far as it will go, to Cold •...
Page 704: Auxiliary Water Heater
Crane operation 11.7 Heating and air-conditioning system 11.7.3 Auxiliary water heater The batteries will run down 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. You can use the auxiliary water heater to: –...
Page 705 Crane operation 11.7 Heating and air-conditioning system Preheating the If the crane cab is to be preheated in addition to the engine, adjust the heat- crane cab ing system as follows: • Switch (1) to Warm setting • Switch (3) to the Recirculated air symbol •...
Page 706 Crane operation 11.7 Heating and air-conditioning system • Switching on Check whether the auxiliary heater is allowed to be operated at the cur- rent site of the truck crane before switching it on. Find out whether there are any possible sources of danger that could result in an explosion Risk of explosion when operating the auxiliary heater The auxiliary heater is not allowed to be operated: –...
Page 707 Crane operation 11.7 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 power supply is interrupted, all symbols in the display will flash and you must set the time and day again.
Page 708 Crane operation 11.7 Heating and air-conditioning system Storing the Heating is started automatically on schedule only if the time and the day of à heating start the week have been correctly set; p. 11 - 137. You can set three different automatic heating starts – up to seven days in advance.
Page 709 Crane operation 11.7 Heating and air-conditioning system Setting the After an automatic start, the heating system will switch off automatically as heating period soon as the set heating period has elapsed. The heating period applies to all saved heating starts. •...
Page 710 Crane operation 11.7 Heating and air-conditioning system Switching off This section only describes how to switch off the heater manually. If the auxiliary heater was switched on automatically, it will be switched off after à Setting the a particular heating period. You can set this heating period; heating period , p.
Page 711: Auxiliary Air Heater
Crane operation 11.7 Heating and air-conditioning system 11.7.4 Auxiliary air heater You can use the auxiliary air heater to preheat the crane cab or provide addi- tional heating. The batteries will run down if you operate the auxiliary heater with the engine switched off.
Page 712 Crane operation 11.7 Heating and air-conditioning system Temperature You can preselect a temperature for the crane cab. The preselected temper- ature is automatically set and maintained. Increasing the temperature: • Turn the switch (1) clockwise Reducing the temperature: • Turn the switch (1) counter-clockwise The higher the selected temperature is, the faster the fan of the auxiliary heater runs.
Page 713: Cranestar System
Crane operation 11.8 CraneSTAR system 11.8 CraneSTAR system 11.8.1 Overview Your truck crane is equipped with the CraneSTAR system. The CraneSTAR system is used to transmit crane data via mobile phone or satellite and thus offers various possibilities for remote diagnostics and for localising the truck crane.
Page 714 Crane operation 11.8 CraneSTAR system Blank page 11 - 144 3 112 993 en Operating manual GMK 6400...
Page 715 Rigging work 12.1 Rigging work checklists for crane operation with the main boom ..12 - 12.1.1 CHECKLIST: Rigging ..........12 - 12.1.2 CHECKLIST: Unrigging .
Page 716 12.7.9 Making/breaking the electrical connection ......12 - 82 12.7.10 Rigging counterweight ..........12 - 83 12.7.11 Raising and lowering 10 t counterweight blocks with a mounted auxiliary hoist 12 - 12.7.12...
Page 717: 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 718 Rigging work 12.1 Rigging work checklists for crane operation with the main boom Danger of overturning if the truck crane is free-standing When the truck crane is free on wheels, the superstructure may not be slewed. For the free on wheels working position, the truck crane is first supported and fully rigged.
Page 719 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à Earthing the truck crane , p. 12 - 13 10. Earth the truck crane, if necessary; à 11. Fold out all ladders; Ladders , p. 4 - 5. 12.
Page 720 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 16. Install the lifting limit switch; p. 12 - 126 17. Install anemometer, air traffic control light and camera on main boom; à Anemometer and air traffic control light , p. 12 - 132, à...
Page 721: 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 there. 1.
Page 722 Rigging work 12.1 Rigging work checklists for crane operation with the main boom 6. Depending on transport: à – Attach the hook block to the bumper; p. 12 - 110 – Set down the hook block and unreeve the hoist rope; à...
Page 723 Rigging work 12.1 Rigging work checklists for crane operation with the main boom à 10. Remove anemometer and the air traffic control light; p. 12 - 132 11. Remove camera on main boom; à Camera on main boom , p. 12 - 137. à...
Page 724 Rigging work 12.1 Rigging work checklists for crane operation with the main boom Blank page 12 - 8 3 112 993 en Operating manual GMK 6400...
Page 725: Choosing A Suitable Site
Rigging work 12.2 Choosing a suitable site 12.2 Choosing a suitable site Choose the position of your truck crane at the site with care. Observe the fol- lowing aspects: – Check whether the ground has sufficient load bearing capacity. You may à...
Page 726 Rigging work 12.2 Choosing a suitable 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 t/m CAPACITY OF THE GROUND (lbs/ft Backfilled, not artificially compacted ground: 0 to 10 (0 to 2050)
Page 727 Rigging work 12.2 Choosing a suitable site Ground bearing area • Now calculate the required ground bearing area à • Check that the surface of the outrigger pad ( p. 1 - 15) is larger than the calculated ground bearing area. If the surface of the outrigger pad is smaller, you will need to enlarge the ground bearing area Danger of overturning if the ground bearing area is too small Ensure that the actual ground bearing area is at least as large as specified...
Page 728: Safe Distance From Slopes And Pits
Rigging work 12.2 Choosing a suitable 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 729: Earthing The Truck Crane
Rigging work 12.2 Choosing a suitable 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 730: Safe Distance From Electrical Cables
Rigging work 12.2 Choosing a suitable site 12.2.4 Safe distance from electrical cables Always observe the respective national regulations when working in the vicinity of electrical lines. Risk of accident due to electric shock This truck crane is not insulated. If the truck crane, its equipment, its load/lifting tackle or the guide ropes touch an electric cable, this will cause serious injury or even death.
Page 731 Rigging work 12.2 Choosing a suitable site For example, according to DIN VDE 0105 Voltage Safe distance (A) up to 1 000 V 1 m (3.3 ft) from 1 000 V to 110 000 V 3 m (9.8 ft) from 110 000 V to 220 000 V 4 m (13.1 ft) over 220 000 V to 380 000 V 5 m (16,4 ft)
Page 732 Rigging work 12.2 Choosing a suitable site Blank page 12 - 16 3 112 993 en Operating manual GMK 6400...
Page 733: Rigging Work After Driving With A Trailer
Rigging work 12.3 Rigging work after driving with a trailer 12.3 Rigging work after driving with a trailer If the main boom was resting on a trailer (dolly) while driving the truck crane, you must perform the following before working with the crane: à...
Page 734: Switching Off The Slewing Gear Freewheel
Rigging work 12.3 Rigging work after driving with a trailer 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 accident with the slewing gear freewheel switched on Switch off the slewing gear freewheel before working with the crane.
Page 735: Switching Off Boom Pre-Tensioning
Rigging work 12.3 Rigging work after driving with a trailer 12.3.3 Switching off boom pre-tensioning You must switch off the boom pre-tensioning before you raise the main boom off the trailer. 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 736 Rigging work 12.3 Rigging work after driving with a trailer Blank page 12 - 20 3 112 993 en Operating manual GMK 6400...
Page 737: Connecting/Disconnecting The Hand-Held Control
Rigging work 12.4 Connecting/disconnecting the hand-held control 12.4 Connecting/disconnecting the hand-held control Functionality of the sockets Socket Released operations 1 At the front of – Rigging MWL the main boom 2 On the derrick- – Derricking gear emergency operation ing cylinder 3 At the rear on –...
Page 738 Rigging work 12.4 Connecting/disconnecting the hand-held control Connecting the hand-held control • Open the cap (2) and pull the bridging plug (3) out of the socket (1) • Insert the plug (4) into the socket (1) and secure it with the cap (2) •...
Page 739: Starting The Engine For Driving For Rigging Work
Rigging work 12.5 Starting the engine for driving for rigging work 12.5 Starting the engine for driving for rigging work The engine for driving must be running for rigging work, e.g., to move the outriggers. You can start the engine for driving: –...
Page 740 Rigging work 12.5 Starting the engine for driving for rigging work Starting the All activities and inspections required to start the engine must be carried out à engine before starting the engine; p. 4 - 1. • Wait until the lamps (1) and (2) light up If the lamp (2) does not go on or flash after about 20 seconds, there is a mal- à...
Page 741: Starting/Turning Off The Engine From The Crane Cab
Rigging work 12.5 Starting the engine for driving for rigging work 12.5.2 Starting/turning off the engine from the crane cab Requirements The following requirements must be met before you can start the engine from the crane cab: – The hand-held control has been disconnected and bridging plugs have been plugged into all superstructure and carrier sockets –...
Page 742 Rigging work 12.5 Starting the engine for driving for rigging work After starting the The engine runs at idling speed. The engine speed cannot be changed. engine You can operate the functions from the crane cab in the Outriggers sub- à...
Page 743: Starting/Turning Off The Engine From The Outrigger Control Units
Rigging work 12.5 Starting the engine for driving for rigging work 12.5.3 Starting/turning off the engine from the outrigger control units Requirements The following requirements must be met before you can start the engine for driving from the outrigger control units: –...
Page 744 Rigging work 12.5 Starting the engine for driving for rigging work Blank page 12 - 28 3 112 993 en Operating manual GMK 6400...
Page 745: Outriggers
Rigging work 12.6 Outriggers 12.6 Outriggers Danger of crushing from 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 move- ments. 12.6.1 CHECKLIST: Extending the outriggers This checklist is not a complete operating manual.
Page 746 Rigging work 12.6 Outriggers 5. Enlarge the ground bearing area if necessary; à Determining the required ground bearing area , p. 12 - 9, à Enlarging the ground bearing area , p. 12 - 44. 6. Extend the supporting cylinders until none of the wheels are touching à...
Page 747: Checklist: Retracting The Outriggers
Rigging work 12.6 Outriggers 12.6.2 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 there. à 1. Retract the outrigger cylinders as far as possible; p.
Page 748: Permissible Outrigger Spans
Rigging work 12.6 Outriggers 6. Turn off the engine: à – After operating it from the control units; p. 4 - 25. – After operating it from the crane cab or using the hand-held control; à p. 10 - 17. 7.
Page 749: Preparing The Truck Crane
Rigging work 12.6 Outriggers 12.6.4 Preparing the truck crane In the driver's cab Levelling the truck crane • Align the truck crane horizontally with the level adjustment system; à Operating the level adjustment system , p. 5 - 60. Locking the suspension à...
Page 750: Setting The Outrigger Spans
Rigging work 12.6 Outriggers 12.6.5 Setting the outrigger spans Only extend the outrigger beams to the permissible span. Danger of overturning if the outrigger beams are not correctly extended Always extend all outrigger beams to the required outrigger span even if you are only working on one side.
Page 751 Rigging work 12.6 Outriggers Outrigger span 8.70 x 7.40 m (28.5 x 24.3 ft) (A) – Requirements – Pin (1) is removed – Pin (2) inserted in holder (3) (B) – Setting and securing • Extend the outrigger beam up to the mark- ing (4).
Page 752 Rigging work 12.6 Outriggers Outrigger span 8.70 x 5.00 m (28.5 x 16.4 ft) (A) – Requirements – Pin (1) is removed – Pin (2) is inserted (B) – Setting and securing • Extend the outrigger beam up to the mark- ing (3).
Page 753: Extending/Retracting Outrigger Beams
Rigging work 12.6 Outriggers 12.6.6 Extending/retracting outrigger beams Risk of accident if outrigger beams cannot be seen Cordon off the area where you intend to extend and retract the outrigger beams. Nobody is allowed to be in this area. Observe the moving outrigger beams or have them observed by a banks- man who is in visual contact with you.
Page 754 Rigging work 12.6 Outriggers If the hand-held control is connected, the Outrigger operating units are inac- From the control units tive. Starting the engine • Remove the hand-held control if necessary, and start the engine from the à driver's cab; p.
Page 755 Rigging work 12.6 Outriggers With the hand- The hand-held control needs to be connected to the carrier. held control • Connect the hand-held control to the required socket (1) or (2): 1 For the right-hand outrigger beam 2 For the left-hand outrigger beam à...
Page 756 Rigging work 12.6 Outriggers Pre-selecting outriggers You can only pre-select outriggers on the side to which the hand-held con- trol is connected. • Press the button for the required outriggers once: 1 Front left 2 Front right 3 Rear left 4 Rear right 1 + 3 Both on left 2 + 4 Both on right...
Page 757 Rigging work 12.6 Outriggers The following operating elements are found in the Outriggers submenu. From the crane Starting the engine à • Start the engine from the crane cab; p. 10 - 8. • Switch off the slewing gear. Opening the submenu •...
Page 758 Rigging work 12.6 Outriggers If the symbol (3) appears, this means that the slewing gear is switched on – the symbols (1) and (2) remain grey. • Switch off the slewing gear. Extending/retracting outrigger beams • Observe the safety instructions for operating the outrigger beams; à...
Page 759: Moving The Outrigger Pads Into Working/Driving Position
Rigging work 12.6 Outriggers 12.6.7 Moving the outrigger pads into working/driving position The illustrations show one outrigger pad. The pulling direction of the other outrigger pads may differ from this. Moving them into working position • (A) – Pull out the pin (1). •...
Page 760: Enlarging The Ground Bearing Area
Rigging work 12.6 Outriggers 12.6.8 Enlarging the ground bearing area If the surface of the outrigger pads is too small, you must enlarge the à Determining the ground bearing area by packing the outrigger pads; required ground bearing area , p. 12 - 9. For packing, use only suitable materials that will withstand the outrigger pressure, e.g.
Page 761: Extending/Retracting Supporting Cylinders
Rigging work 12.6 Outriggers 12.6.9 Extending/retracting supporting cylinders Danger of overturning due to insufficient load bearing capacity of the ground Enlarge the ground bearing area if the ground cannot withstand the result- ing outrigger pressure. This prevents the ground under the outrigger pad from giving way and causing the truck crane to tilt and overturn.
Page 762 Rigging work 12.6 Outriggers If the hand-held control is connected, the Outrigger operating units are inac- From the control units tive. Starting the engine • Disconnect the hand-held control, if necessary, and start the engine either: à – From the driver's cab; p.
Page 763 Rigging work 12.6 Outriggers à • With the hand- Connect the hand-held control to any socket on the carrier; p. 12 - 22. held control Starting the engine à • Press the button (1) – the engine starts; p. 10 - 15. Pre-selecting high-speed mode/normal speed •...
Page 764 Rigging work 12.6 Outriggers Extending/retracting supporting cylinders • Observe the safety instructions for operating the supporting cylinders; à p. 12 - 45 • Press the button combination for the desired movement: 1 Extend 2 Retract The pre-selected supporting cylinders move until you let go of the respec- tive button or until the respective end position has been reached.
Page 765 Rigging work 12.6 Outriggers Pre-selecting outriggers • Press the button once next to the symbol for the desired outrigger 1 Both at front 2 Both at rear 3 Rear left 4 Rear right 5 Both on left 6 Both on right 7 Front left 8 Front right 9 All...
Page 766: Levelling The Truck Crane On Outriggers
Rigging work 12.6 Outriggers 12.6.10 Levelling the truck crane on outriggers You must level the truck crane before crane operation and possibly correct its horizontal alignment during crane operation. Inclination After switching on the ignition, various inclination indicators display the indicators current alignment.
Page 767 Rigging work 12.6 Outriggers – Outriggers 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 768 Rigging work 12.6 Outriggers à • Manual alignment Check that the prerequisites are met; p. 12 - 51 • Extend all supporting cylinders until none of the wheels is touching the ground. • Level the truck crane with the supporting cylinders horizontally until the lamp (1) is the only one lighting up in the measuring range 1°;...
Page 769 Rigging work 12.6 Outriggers Automatic During the automatic alignment procedure, the supporting cylinders are alignment only extended to prevent any wheels from touching the ground after the alignment. à • Check that the prerequisites are met; p. 12 - 51. •...
Page 770 Rigging work 12.6 Outriggers Automatic procedure 1. All supporting cylinders are extended one after the other until the out- rigger pads touch the ground. 2. All supporting cylinders extend simultaneously so that none of the wheels touch the ground anymore. 3.
Page 771: Levelling The Free-Standing Truck Crane
Rigging work 12.6 Outriggers 12.6.11 Levelling the free-standing truck crane The suspension is deactivated (locked) if the truck crane is in the Free on wheels working position. The suspension has to remain switched off until the truck crane is on outrig- gers.
Page 772 Rigging work 12.6 Outriggers Now all wheels are lowered to the ground and are in the right position for the horizontal alignment. To switch off the suspension • Press the (2) button once – dot is black. The symbol (1) is red if the suspension is switched off. To secure the truck crane •...
Page 773: Outrigger Pressure Display
Rigging work 12.6 Outriggers 12.6.12 Outrigger pressure display After switching on the ignition, the outrigger pressure displays indicate the current outrigger pressure for all supporting cylinders. The set unit (t or klbs) is shown next to the displays. Outrigger cylinders retracted or extended as far as possible will lead to an incorrect outrigger pressure display.
Page 774 Rigging work 12.6 Outriggers Blank page 12 - 58 3 112 993 en Operating manual GMK 6400...
Page 775 Rigging work 12.7 Rigging/unrigging the counterweight 12.7 Rigging/unrigging the counterweight Depending on the version, the GMK 6400 can be equipped with a counter- weight mass of 15 t (33 069 lbs) to 135 t (297 624 lbs). 12.7.1 Counterweight sections Depending on the execution, there is version A or B.
Page 776: 12.7 Rigging/Unrigging The Counterweight
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.2 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 777: Slinging Points On The Counterweight Sections
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.3 Slinging points on the counterweight sections Risk of accident if used improperly Attach the various counterweight sections only to the intended slinging points and use lifting gear of sufficient lifting capacity. Only lift the sections one by one, since the slinging points are not designed for lifting stacked sections.
Page 778: Checklist: Counterweight, Rigging
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.4 CHECKLIST: Counterweight, rigging This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there. 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 779 Rigging work 12.7 Rigging/unrigging the counterweight 5. If necessary, lift and set down further counterweight sections individu- à ally, one after another; p. 12 - 67. à 6. Secure the counterweight sections; p. 12 - 79. 7. Slew the superstructure into the 0° to the rear position and lock; à...
Page 780 Rigging work 12.7 Rigging/unrigging the counterweight 10. Lift the counterweight onto the turntable, lock it and retract the lifting cylinder; à Rigging counterweight , p. 12 - 83. 11. Disconnect the hand-held control; à Connecting/disconnecting the hand-held control , p. 12 - 21. 12.
Page 781: Checklist: Counterweight, Unrigging
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.5 CHECKLIST: Counterweight, 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 there. 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 782 Rigging work 12.7 Rigging/unrigging the counterweight 5. Enter the current rigging mode with the presently rigged counterweight à version on the RCL; p. 11 - 23. à Rigging the auxiliary hoist , 6. If required, remove the auxiliary hoist; p. 12 - 91. 7.
Page 783: Assembling Counterweight Combination
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.6 Assembling counterweight combination Danger of overturning when slewing with a rigged counterweight When a counterweight version is rigged, check whether slewing is permit- ted with the current rigging mode (outrigger span, working radius). Correct à...
Page 784 Rigging work 12.7 Rigging/unrigging the counterweight Setting down 10 t The counterweight version A illustrated here shows a special equipping sections/blocks version that is no longer available. version A à Setting down Counterweight version B shows the standard equipment; 10 t sections/blocks version B , p. 12 - 74. Risk of overturning if counterweight rigging sequence is incorrect When rigging, always place/raise the 10 t sections and 10 t blocks alter- nately at the left and right sides.
Page 785 Rigging work 12.7 Rigging/unrigging the counterweight Combinations for The following counterweight combinations can be combined on the coun- the basic equip- terweight platform. ment in version A Risk of accident due to an incorrect counterweight mass Only combine the counterweights in such a manner that the counterweight mass corresponds to the specifications in this section and in the Lifting capacity table .
Page 786 Rigging work 12.7 Rigging/unrigging the counterweight 55 t (121 254 lbs) – 15 t base plate – Four 10 t sections 75 t (165 347 lbs) – 15 t base plate – Four 10 t plates – Two 10 t blocks 95 t (209 439 lbs) –...
Page 787 Rigging work 12.7 Rigging/unrigging the counterweight 115 t (253 532 lbs) – 15 t base plate – Four 10 t plates – Six 10 t blocks 135 t (297 624 lbs) – 15 t base plate – Four 10 t plates –...
Page 788 Rigging work 12.7 Rigging/unrigging the counterweight All counterweight sections with additional equipment are illustrated in the diagram with the maximum counterweight mass of 135 t (297 624 lbs). – The base plate (1) must always be at the bot- – The counterweight sections (2) can be exchanged among each other –...
Page 789 Rigging work 12.7 Rigging/unrigging the counterweight When rigging Risk of accident due to uncovered openings Cover the recesses of the slinging points with the covers provided. In this way you avoid stepping into the recesses and injuring yourself. Do not just place the cover on the last pair of 10 t plates. When you place a cover onto every pair of right and left 10 t plates, then there is no danger of tripping when unrigging.
Page 790 Rigging work 12.7 Rigging/unrigging the counterweight Setting down 10 t sections/blocks version B Risk of overturning if counterweight rigging sequence is incorrect When rigging, always place/raise the 10 t blocks alternately on the left and right sides. Otherwise the truck crane will be overloaded at one side or the counterweight may fall from the carrier.
Page 791 Rigging work 12.7 Rigging/unrigging the counterweight Combinations for The following counterweight combinations can be combined on the coun- the basic equip- terweight platform. ment in version B Risk of accident due to an incorrect counterweight mass Only combine the counterweights in such a manner that the counterweight mass corresponds to the specifications in this section and in the Lifting capacity table .
Page 792 Rigging work 12.7 Rigging/unrigging the counterweight 35 t (77 162 lbs) – 15 t base plate – Two 10 t blocks 45 t (99 208 lbs) – 15 t base plate – Three 10 t blocks 55 t (121 254 lbs) –...
Page 793 Rigging work 12.7 Rigging/unrigging the counterweight 75 t (165 347 lbs) – 15 t base plate Six 10 t blocks 95 t (209 439 lbs) – 15 t base plate – Eight 10 t blocks 115 t (253 532 lbs) –...
Page 794 Rigging work 12.7 Rigging/unrigging the counterweight 135 t (297 624 lbs) – 15 t base plate – Twelve 10 t blocks All counterweight sections with additional equipment are illustrated in the diagram with the maximum counterweight mass of 135 t (297 624 lbs).
Page 795: Securing/Releasing 10 T Blocks
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.7 Securing/releasing 10 t blocks Risk of accident from falling counterweight blocks Secure the 10 t blocks with the tensioning device. This prevents the blocks from slipping or falling down and injuring some- one. Tensioning device In the rigged state, the 10 t blocks must be secured with the tensioning device.
Page 796 Rigging work 12.7 Rigging/unrigging the counterweight Securing 10 t blocks The height of a 10-t counterweight section corresponds to the length of approx. 15 chain links. • Insert the chain (2) into the chain tensioner (1). • Feed the chain (2) with the chain tensioner (1) from above through respective counter- weight combination.
Page 797: Establishing/Disconnecting The Hydraulic Connection
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.8 Establishing/disconnecting the hydraulic connection Establishing • Remove the caps from the ports (3). • Remove the hoses (2) from the brackets (1) and connect them to the ports (3). Disconnecting You must disconnect the hydraulic connection before lifting the 15-t base plate from the carrier.
Page 798: Making/Breaking The Electrical Connection
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.9 Making/breaking the electrical connection Risk of malfunction in the superstructure electronics! Always turn off the ignition in the crane cab before you establish or break the electrical connection. This prevents malfunctions and error messages in the superstructure electronics.
Page 799: Rigging Counterweight
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.10 Rigging counterweight Risk of crushing when raising and lowering Make sure nobody is on the counterweight platform while the counter- weight is being lifted or lowered. Before raising and lowering, remove all objects that could become jammed or crushed.
Page 800 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight To rig the counterweight, you must extend the lifting cylinder in order to rigging raise the counterweight. Then you must lock the counterweight on the superstructure and then extend the lifting cylinder into the 15 t base plate. Extending the lifting cylinders •...
Page 801 Rigging work 12.7 Rigging/unrigging the counterweight à • Closing the safety valve; p. 12 - 87. Risk of accident from falling counterweight Always close the safety valve if the counterweight is locked to the turntable. This prevents the locking pins, for example, from being unintentionally retracted because a button is erroneously pushed, causing the entire coun- terweight to fall down.
Page 802 Rigging work 12.7 Rigging/unrigging the counterweight Unlocking the counterweight à • Open the safety valve; p. 12 - 87. • Press the button (1). The lamp lights up. • Press the key combination (2), until the lamps (3) are lit. If a locking pin has not yet reached the Locked end position, the correspond- ing lamp will flash.
Page 803 Rigging work 12.7 Rigging/unrigging the counterweight Counterweight safety valve Closing safety valve After you have locked the counterweight on the turntable: • Close the valve – lever (1) at right angles to the line. The locking pins are secured against acciden- tal activation.
Page 804: Raising And Lowering 10 T Counterweight Blocks With A Mounted Auxiliary Hoist
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.11 Raising and lowering 10 t counterweight blocks with a mounted auxiliary hoist You will require the following equipment with a sufficient load bearing capacity: – An auxiliary crane (depending on the rigging mode of the truck crane) –...
Page 805: Slewing With Rigged Counterweight
Rigging work 12.7 Rigging/unrigging the counterweight 12.7.12 Slewing with rigged counterweight Slewing with a rigged counterweight is only permissible when: – The necessary outrigger span is rigged – The respective RCL code is shown – The permissible working radius according to Lifting capacity table is main- tained For slewing with rigged Mega Wing Lift: à...
Page 806 Rigging work 12.7 Rigging/unrigging the counterweight 7.98 x (26.1 Rigged outrigger span 8.70 x (28.5 x) 2.71 m 5.00 m 6.30 m 7.40 m 8.50 m 8.50 m (8.9 ft) (16.4 ft) (20.4 ft) (24.3 ft) 27.9 ft) (27.9 ft) 1.00 m (3.3 ft) (auxiliary...
Page 807: Rigging The Auxiliary Hoist
Rigging work 12.8 Rigging the auxiliary hoist 12.8 Rigging the auxiliary hoist This chapter describes rigging the auxiliary hoist with the truck crane. The auxiliary hoist can also be rigged with an auxiliary crane. The auxiliary hoist must be removed for on-road driving with a maximum of 12 t axle load.
Page 808: Slinging Points And Transport
Rigging work 12.8 Rigging the auxiliary hoist 12.8.2 Slinging points and transport Slinging points Risk of accident if used improperly Only attach the auxiliary hoist to the slinging points provided. Always use à Dimensions and weights of lifting gear with sufficient lifting capacity; removable parts –...
Page 809 Rigging work 12.8 Rigging the auxiliary hoist Transport Risk of damage to the auxiliary hoist Attach the auxiliary hoist to the separate vehicle so that it cannot slip off. Insert the hydraulic hoses and the electric cable into the specially designed shaft.
Page 810: Checklist: Mounting The Auxiliary Hoist
Rigging work 12.8 Rigging the auxiliary hoist 12.8.3 CHECKLIST: Mounting the auxiliary hoist This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there. Requirements –...
Page 811 Rigging work 12.8 Rigging the auxiliary hoist 4. Connect the hand-held control to the rear right of the turntable and start à the crane engine; p. 12 - 21. à 5. Bolt the 15 t base plate to the auxiliary hoist; p.
Page 812: Checklist: Removing The Auxiliary Hoist
Rigging work 12.8 Rigging the auxiliary hoist 12.8.4 CHECKLIST: Removing the auxiliary hoist This checklist is not a complete operating manual. There are accompanying operating instructions which are indicated by cross-references. Observe the warnings and safety instructions specified there. Requirements –...
Page 813 Rigging work 12.8 Rigging the auxiliary hoist à CHECKLIST: Counterweight, 5. Continue rigging the counterweight; unrigging , p. 12 - 65, point 5. and point 6. 6. Release the locking pin between the auxiliary hoist and the 15 t base à...
Page 814: Lifting The Auxiliary Hoist Onto The 15 T Base Plate
Rigging work 12.8 Rigging the auxiliary hoist 12.8.5 Lifting the auxiliary hoist onto the 15 t base plate à • Slinging points , Sling the auxiliary hoist; p. 12 - 92. • Hoist the auxiliary hoist onto the 15 t base plate.
Page 815: Raising/Setting Down The Catcher
Rigging work 12.8 Rigging the auxiliary hoist 12.8.6 Raising/setting down the catcher When operating the auxiliary hoist, the catcher must be raised so that the cable run is not impeded by the upper hook block. To raise and lower the catcher you must: à...
Page 816: Establishing/Disconnecting The Hydraulic Connection
Rigging work 12.8 Rigging the auxiliary hoist 12.8.7 Establishing/disconnecting the hydraulic connection Establishing The connection must be established before the auxiliary hoist can be locked and operated. • Remove the caps from the ports (3). • Remove the hoses (2) from the brackets (1) and connect them to the ports (3).
Page 817: Making/Breaking The Electrical Connection
Rigging work 12.8 Rigging the auxiliary hoist 12.8.8 Making/breaking the electrical connection Establishing The connection must be established before the auxiliary hoist can be locked and operated. • Remove plug (2) from socket (1) and insert it into socket (3). •...
Page 818: Locking/Unlocking The Auxiliary Hoist
Rigging work 12.8 Rigging the auxiliary hoist 12.8.9 Locking/unlocking the auxiliary hoist Auxiliary hoist The hydraulic cylinders of the locking pins are blocked with a safety valve. safety valve The valve is located on the rear right-hand side of the auxiliary hoist, at the same height as the treadle.
Page 819 Rigging work 12.8 Rigging the auxiliary hoist Locking à Open the safety valve; p. 12 - 102. • Press the button (1). The lamp lights up. • Press the key combination (2), until the lamps (3) are lit. The counterweight is now locked at the turntable. If a locking pin has not yet reached the Locked end position, the correspond- ing lamp will flash.
Page 820 Rigging work 12.8 Rigging the auxiliary hoist Releasing the locking pin à • Open the safety valve; p. 12 - 102. • Press the button (1). The lamp lights up. • Press the key combination (2), until the lamps (3) are lit. If a locking pin has not yet reached the Unlocked end position, the corres- ponding lamp will flash.
Page 821: Checking The Auxiliary Hoist For Correct Functioning
Rigging work 12.8 Rigging the auxiliary hoist 12.8.10 Checking the auxiliary hoist for correct functioning After mounting the auxiliary hoist you must check that it functions properly when the control lever is extended and check the functioning of the slewing indicator.
Page 822: Securing The Upper Hook Block In The Catcher
Rigging work 12.8 Rigging the auxiliary hoist 12.8.11 Securing the upper hook block in the catcher If the upper hook block remains in the catcher during transport or during operation, it must be secured there. • Check that the pins (3) are inserted and secured with retaining pins on both sides.
Page 823: Permissible Applications For The Auxiliary Hoist
Rigging work 12.8 Rigging the auxiliary hoist 12.8.13 Permissible applications for the auxiliary hoist The auxiliary hoist may be used: à – As a replacement for the main hoist; p. 12 - 107, – During alternating operation with main hoist and auxiliary hoist on the à...
Page 824 Rigging work 12.8 Rigging the auxiliary hoist Alternating operation with the main and the auxiliary hoist For equipment having a second head sheave (1) on the main boom, you can simultaneously reeve the main and auxiliary hoist ropes and alternately work with both hoists.
Page 825: Rigging Work On The Main Boom
Rigging work 12.9 Rigging work on the main boom 12.9 Rigging work on the main boom 12.9.1 Hook block on the bumper Picking up the Depending on the driving mode, you must pick up the hook block from the à Driving modes , p.
Page 826 Rigging work 12.9 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; Danger of accident if the view is obstructed The reeved rope lines obstruct the view of the runway.
Page 827: Hook Block On A Separate Vehicle
Rigging work 12.9 Rigging work on the main boom 12.9.2 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 828 Rigging work 12.9 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 829 Rigging work 12.9 Rigging work on the main boom • Detach the lifting limit switch weight (2) à from the hoist rope; p. 12 - 129. à • Unreeve the hoist rope; p. 12 - 118. • Secure the hook block (1) for transport. •...
Page 830: Reeving And Unreeving The Hoist Rope
Rigging work 12.9 Rigging work on the main boom 12.9.3 Reeving and unreeving the hoist rope You must reeve a certain number of rope lines, depending on the required lifting capacity. Four reeved rope lines correspond, for example, to 4-fold reeving.
Page 831 Rigging work 12.9 Rigging work on the main boom Reeving the hoist rope Danger due to slack rope Only use hook blocks and sling gear of the minimum weight prescribed in the Lifting capacity table , depending on the reeving and boom length. This prevents slack rope forming at large heights when lifting without a load.
Page 832 Rigging work 12.9 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 833 Rigging work 12.9 Rigging work on the main boom Rope end fitting • Insert the rope end fitting (5) at the fixed point (1) and secure the pin (2). Securing the hoist rope • Pull the rod (3) and fold the bracket (4) downwards.
Page 834 Rigging work 12.9 Rigging work on the main boom Unreeving the hoist rope • Pull out the rod (5). • Remove the retaining pins and pull out the rod (3). Fold the bracket (4) upwards. Insert the rod (3). • Fold down the sheet metals (1);...
Page 835: Possible Reeving Methods On The Main Boom
Rigging work 12.9 Rigging work on the main boom 12.9.4 Possible reeving methods on the main boom Possible reevings on lattice extensions and the auxiliary single-sheave à Lattice extension operating instructions. boom top; The maximum lifting capacity of individual hook blocks does not corre- spond to the maximum lifting capacity of the GMK 6400 together with this hook block.
Page 836 Rigging work 12.9 Rigging work on the main boom 5 sheave hook block Maximum lifting capacity of the hook block: 160 t (352 740 lbs) Max. lifting capacity with the GMK 6400 Reeving Maximum lifting capacity 123.3 t (271 800 lbs) 112.1 t (247 100 lbs) 100.9 t (222 400 lbs) 89.7 t (197 700 lbs)
Page 837 Rigging work 12.9 Rigging work on the main boom 1 sheave hook block Maximum lifting capacity of the hook block: 40 t (88 185 lbs) Max. lifting capacity with the GMK 6400 Reeving Maximum lifting capacity 33.6 t (74 000 lbs) 22.4 t (49 300 lbs) 11.2 t (24 700 lbs) Hook tackle...
Page 838 Rigging work 12.9 Rigging work on the main boom With 10 head sheaves 11 sheave hook block Maximum lifting capacity of the hook block: 320 t (705 500 lbs) Max. lifting capacity with the GMK 6400 Reeving Maximum lifting capacity 224 t (493 000 lbs) In case of additional equipment, the hoist rope à...
Page 839 Rigging work 12.9 Rigging work on the main boom 7 sheave hook block Maximum lifting capacity of the hook block: 200 t (440 900 lbs) Max. lifting capacity with the GMK 6400 Reeving Maximum lifting capacity 168.2 t (398 600 lbs) 157.0 t (346 100 lbs) 145.8 t (321 400 lbs) 134.6 t (296 700 lbs)
Page 840 Rigging work 12.9 Rigging work on the main boom 3 sheave hook block Maximum lifting capacity of the hook block: 100 t (220 462 lbs) Max. lifting capacity with the GMK 6400 Reeving Maximum lifting capacity 78.5 t (173 000 lbs) 67.3 t (148 300 lbs) 56.1 t (123 600 lbs) 44.9 t (98 900 lbs)
Page 841 Rigging work 12.9 Rigging work on the main boom Hook tackle Maximum lifting capacity of the hook tackle: 16 t (35 274 lbs) Max. lifting capacity with the GMK 6400 Reeving Maximum lifting capacity 11.2 t (24 700 lbs) Maximum reeving For maximum reeving, you require an auxiliary single-sheave boom top and a hook block with at least 10 sheaves.
Page 842: Installing/Removing The Lifting Limit Switch
Rigging work 12.9 Rigging work on the main boom 12.9.5 Installing/removing the lifting limit switch à Function of the lifting limit switch; p. 11 - 62. 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 843 Rigging work 12.9 Rigging work on the main boom If only one lifting limit switch has been installed • Check whether the bridging plug is in the socket that is not being used. If, for example, the lifting limit switch (3) is installed on the left, the bridging plug (2) must be in the socket (1) on the right.
Page 844 Rigging work 12.9 Rigging work on the main boom Attaching the lifting limit switch weight • Attach the lifting limit switch weight (1). If two hoist ropes are reeved, you must attach a lifting limit switch weight to each of the two lifting limit switches.
Page 845 Rigging work 12.9 Rigging work on the main boom Removing the This section describes complete removal. lifting 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 846 Rigging work 12.9 Rigging work on the main boom Removing the right lifting limit switch • Pull the plug from the socket (1). • Remove the bridging plug (3) from the dummy socket (2) and plug it into the socket (1).
Page 847: Locking/Unlocking The Lifting Limit Switch
Rigging work 12.9 Rigging work on the main boom 12.9.6 Locking/Unlocking the lifting limit switch Locking If a hoist rope has been reeved and two lifting limit switches are installed, you must lock the lifting limit switch not used in order to enable all crane operations.
Page 848: Anemometer And Air Traffic Control Light
Rigging work 12.9 Rigging work on the main boom 12.9.7 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 getting damaged due to air currents.
Page 849 Rigging work 12.9 Rigging work on the main boom Switching the air traffic control light on and off: Switching on: Press in switch (1) at the bottom Switching off: Press in switch (1) at the top Removing You must remove the rod with the anemometer/air traffic control light à...
Page 850 Rigging work 12.9 Rigging work on the main boom Blank page 12 - 134 3 112 993 en Operating manual GMK 6400...
Page 851: Other Rigging Work
Rigging work 12.10 Other rigging work 12.10 Other rigging work 12.10.1 Railings on the turntable Risk of accidents when railings are not folded out! The railings provide protection from falling. Always fold out the railings before moving onto the auxiliary hoist. Always fold the railings out when you are standing on the counterweight or the auxiliary hoist to perform rigging work.
Page 852: Cameras For Crane Operation
Rigging work 12.10 Other rigging work 12.10.2 Cameras for crane operation Cameras on the hoists One camera (1) on each of the main and auxil- iary hoists, transfers the image of the rope drums to the monitor (2) in the crane cabin. Switching on the monitor •...
Page 853 Rigging work 12.10 Other rigging work Camera on main For crane operation you have to install the camera and switch it on. boom For on-road driving, you have to switch off the camera again and remove it. The camera (1) may only be installed on a truck crane equipped with the appropriate receiver (2).
Page 854 Rigging work 12.10 Other rigging work Installing • Insert the camera (2) into the clamp (1) and secure it with the retaining pin. • Insert the plug (4) in the socket (3). • Lay the cable (5) in such a way that it is not damaged.
Page 855 Driving with rigged truck crane 13.1 Driving path ............13 - 13.2 Permissible rigging modes and axle loads .
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Page 857: Driving With Rigged Truck Crane
Driving with rigged truck crane 13.1 Driving path Driving with rigged truck crane This section describes driving the truck crane with the counterweight à Lattice extension operating rigged. If a lattice extension is rigged as well; instructions . Risk of accident by partially obstructed view of the truck crane When driving the truck crane, always stay in visual or radio contact with a banksman who can observe the parts you are unable to see, e.g.
Page 858: Permissible Rigging Modes And Axle Loads
Driving with 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 859 Axle load table All axle loads specified apply to 445/95 R 25 tyres and a reeved 1-sheave hook block, weight 850 kg (1 875 lbs). Counter- Telescope Status Main Boom Superstruc- Axle Load weight Angle ture Position in t (x 1.000 lbs) I - II - III - IV in t in %...
Page 860: Before Driving
Driving with rigged truck crane 13.3 Before driving 13.3 Before driving 13.3.1 Securing the superstructure against slewing Danger of overturning by the superstructure slewing while driving the truck crane Always secure the superstructure before driving the rigged truck crane to prevent it from slewing.
Page 861: Checking Tyre Pressure And Wind Speed
Driving with rigged truck crane 13.3 Before driving 13.3.2 Checking tyre pressure and wind speed à • Tyres , Ensure that all the tyres are at the prescribed pressure levels; p. 1 - 14. Risk of damage to the tyres You may only drive the truck crane if the tyres are at the prescribed pres- sure level.
Page 862: Putting The Truck Crane On The Wheels
Driving with rigged truck crane 13.3 Before driving 13.3.3 Putting the truck crane on the wheels Danger of overturning by unevenly retracting the outrigger cylinders Retract the outrigger cylinders evenly. This prevents the truck crane from overturning when retracting each outrigger cylinder. Risk of damage to the axle lines Retract the outrigger cylinders evenly.
Page 863 Driving with rigged truck crane 13.3 Before driving Levelling the truck crane Risk of damage to the tyres and suspension struts Do not exceed the maximum permissible axle load of 32 t when levelling the truck crane. Monitor the display while levelling and adjust the axle loads as necessary. •...
Page 864: Transmission/Connections
Driving with rigged truck crane 13.4 While driving 13.3.4 Transmission/connections Transmission • In order to – drive forward, switch to DM – drive backward, switch to RM. An acoustic signal is given with addi- tional equipment à Selecting the transmission mode; p.
Page 865 Driving with rigged truck crane 13.4 While driving Warnings while driving If a buzzer tone sounds in the driver's cab, stop the truck crane immediately and check whether: – The permissible lateral tilt (1) of max. 1° – The operation pressure (2) of 210 bar (3045 psi) in the suspension has been exceeded In this case, you must re-level the truck crane using the Raise axle function...
Page 866: After Driving
Driving with rigged truck crane 13.5 After driving 13.5 After driving à • Switch separate steering off after driving; p. 5 - 69. • Engage the parking brake. • Support the truck crane with the outrigger span required for the job according to the Lifting capacity table and raise it until none of the wheels à...
Page 867 Malfunctions during crane operation 14.1 Emergency stop switch..........14 - 14.2 What to do when a malfunction occurs during crane operation .
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Page 869: 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 Only actuate the emergency stop switch if it is no longer possible to stop the crane movements with the normal operating elements. The emergency stop switch stops the crane movements suddenly.
Page 870 Malfunctions during crane operation 14.1 Emergency stop switch Blank page 14 - 2 3 112 993 en Operating manual GMK 6400...
Page 871: What To Do When A Malfunction Occurs During Crane Operation
Lock the truck crane to prevent unauthorised use. Remove the ignition key and lock away the hand-held control. • Inform your supervisor. • Try to eliminate the malfunction. Inform Manitowoc Crane Care if you cannot correct the malfunction. • Load cannot be Secure the danger zone using cordons and warning signs.
Page 872 Malfunctions during crane operation 14.2 What to do when a malfunction occurs during crane operation Blank page 14 - 4 3 112 993 en Operating manual GMK 6400...
Page 873: Fuses
Replace blown fuses only with new fuses of the same amperage. This pre- vent parts from being overloaded and damaged or the fuse from being immediately damaged again. Notify Manitowoc Crane Care if a fuse with the same amperage fails again once the ignition is switched on. Risk of fire Never repair a blown fuse with other electrically conductive materials.
Page 874: Fuses On The Turntable
Malfunctions during crane operation 14.3 Fuses 14.3.1 Fuses on the turntable • Open the cover (1). • Open the distribution box behind it. There are fuse groups F1, F2 and F3. • Remove the screws (2) and fold the plate down.
Page 875 Malfunctions during crane operation 14.3 Fuses Designation Amperage Function F2/1 Lifting limit switch F2/2 – Unassigned F2/3 Slewing gear brake F2/4 Flame start system F2/5 ESX 4 supply Emergency operation with hand-held F2/6 control F2/7 Oil cooler F2/8 Additional oil cooler Designation Amperage Function...
Page 876 Malfunctions during crane operation 14.3 Fuses Fuse arrangement: Pos. Designation Amperage ESX 1 UE ESX 1 D+ ESX 1 8.5 V ESX 0 UE ESX 0 D+ ESX 0 8.5 V 14 - 8 3 112 993 en Operating manual GMK 6400...
Page 877: Fuses In The Crane Cab
Malfunctions during crane operation 14.3 Fuses 14.3.2 Fuses in the crane cab • Loosen the screws (2) and remove the cover (1). The fuse groups F3, F4 and F5 consist of eight fuses each. The following tables show the designations of the individual fuses, including their amperage and functions.
Page 878 Malfunctions during crane operation 14.3 Fuses Designation Amperage Function F4/1 Engine electronic system (ADM) 24 V/12 V voltage transformer Crane cab lighting F4/2 Air traffic control light Radio Engine electronic system diagnostics plug F4/3 Camera on the turntable Camera on the main boom F4/4 Air-conditioning system F4/5...
Page 879: Rcl Fuses
Malfunctions during crane operation 14.3 Fuses 14.3.3 RCL fuses à Error When a fuse is blown, a corresponding error code is displayed; codes table , p. 14 - 27. • Loosen the screws (2) and remove the cover (1). • Loosen the screws (4) and fold down the plate (3) to the front.
Page 880: Troubleshooting
Malfunctions during crane operation 14.4 Troubleshooting 14.4 Troubleshooting This section does not include all malfunctions. When a lamp (1) lights up; à Warning submenu , p. 11 - 111. 14.4.1 Malfunctions on the engine Malfunction Cause Solution Engine does not start – Driving mode switched on Switch over to crane opera- Starter does not turn...
Page 881: Malfunctions On The Main Hoist/Auxiliary Hoist
Function disabled by ECOS If necessary, acknowledge speed mode function not error once and briefly turn off working the ignition – if error persists, notify Manitowoc Crane Care No Lifting function Fuse RCL F6 blown Replace blown fuse; à p. 14 - 11 Fuse F3/3 blown Replace blown fuse;...
Page 882: Malfunctions In The Hoist Cameras
à Manufacturer’s oper- monitor. essary; ating manual . Connection between camera Check cable connection and and monitor is disconnected. notify Manitowoc Crane Care if necessary. 14.4.4 Malfunctions in the main boom camera Malfunction Cause Solution No image appears on the Fuse on the crane cab blown Replace blown fuse;...
Page 883: Malfunctions In The Derricking Gear
Derricking function not Function disabled by ECOS If necessary, acknowledge working error once and briefly turn off the ignition – if error persists, notify Manitowoc Crane Care Fuse RCL F6 blown Replace blown fuse; à p. 14 - 11 Fuse F3/3 blown Replace blown fuse;...
Page 884 Fault in hydraulics/electrical Note the error codes à à ing cylinder locking function system p. 14 - 17, p. 14 - 31 not working and notify Manitowoc Crane Care 14 - 16 3 112 993 en Operating manual GMK 6400...
Page 885 Telescoping function not Function disabled by ECOS If necessary, acknowledge working error once and briefly turn off the ignition – if error persists, notify Manitowoc Crane Care Fuse RCL F6 blown Replace blown fuse; à p. 14 - 11 Fuse F3/3 blown Replace blown fuse;...
Page 886 The symbol usually disappears shortly after switching on the ignition. If the symbol does not go out or is displayed while operating the crane, this may be due to an RCL shutdown or blown F1/2 fuse. Contact Manitowoc Crane Care if none of these are the cause.
Page 887: Malfunctions In The Slewing Gear
Function disabled by ECOS If necessary, acknowledge error once and briefly turn off the ignition – if error persists, notify Manitowoc Crane Care Slewing only possible in one Shutdown angle of a limited Enter the RCL code for a slew-...
Page 888: Malfunctions In The Hydraulic System/Hydraulic Oil Cooler
4 - 25 Pre-selected function cannot Another function has been Pre-select the desired function be performed pre-selected Operation not possible Malfunction in the control sys- Manitowoc Crane Care must be notified 14 - 20 3 112 993 en Operating manual GMK 6400...
Page 889: Malfunctions On The Outriggers
à bridging plug not inserted p. 12 - 22 None of the specified causes Solenoid valves not working Manitowoc Crane Care must apply be notified Operating manual GMK 6400 3 112 993 en 14 - 21...
Page 890: Troubleshooting On The Rcl
RCL programme version Always note down the number of the programme version after a malfunc- tion occurs and before notifying Manitowoc Crane Care. • ö If required, open the main menu The display (1) indicates the programme version.
Page 891 Malfunctions during crane operation 14.4 Troubleshooting Error messages in If the rated capacity limiter detects an error, an error message is shown on the RCL control unit. the Monitoring submenu There are different types of error messages: – Error messages without shutdown –...
Page 892 Malfunctions during crane operation 14.4 Troubleshooting Error message with shutdown – All crane movements are turned off which are not required for the correction of the error. – A continuous buzzer tone sounds. After five seconds, you can switch off the buzzer tone using button (5).
Page 893 Malfunctions during crane operation 14.4 Troubleshooting • Displays in the Stop all crane movements and bring both control levers into zero posi- Error submenu tion. • Press the (2) button once. The button is only active when the lamp (1) flashes or lights up.
Page 894 Malfunctions during crane operation 14.4 Troubleshooting Error message display For each error there is: – The error code (3) – The symbols for: 4 The error group 5 The faulty component 6 The error type – Possibly the error location (1) – the respec- tive places (2) flash in red •...
Page 895 14 - 30 Angle sensor 2 switched off Have malfunction corrected Lattice extension not con- Electrically connect lattice extension; nected or sensor faulty if error persists, notify Manitowoc Crane Care Operating manual GMK 6400 3 112 993 en 14 - 27...
Page 896 Minimum load value not When the main boom is set down, reached raise main boom and acknowledge the error. Notify Manitowoc Crane Care if the error cannot be acknowledged Fuse F1 blown Fuse F2 blown à Fuse F3 blown Replace blown fuse;...
Page 897 Malfunctions during crane operation 14.4 Troubleshooting Error code Cause Solution à Rigging state unconfirmed Confirming the rigging mode , p. 11 - 29. à RCL overridden Cancel override; p. 11 - 40 Slewing gear switched on Switch off the slewing gear with RCL code for working position 0°...
Page 898 Malfunctions during crane operation 14.4 Troubleshooting Switch off sensor/ For values measured twice, you can switch off the faulty sensor/tachogen- tachogenerator erator in the case of an error and continue working with one sensor/tacho- generator for a short time. Danger due to RCL failure Have the error resolved before the next crane job.
Page 899: Malfunctions Ecos - Superstructure
"error" display. ECOS programme Always note down the number of the programme version before notifying version Manitowoc Crane Care in the event of a malfunction. • ö If required, open the main menu The display (1) shows the number of the current programme version.
Page 900 Malfunctions during crane operation 14.4 Troubleshooting Error messages If ECOS detects an error, an error message is shown: – Lamp (1) flashes – Lamp (2) flashes Open the Errors submenu for more information. • Press the (2) button once. The button is only active when the lamp (1) flashes or lights up.
Page 901 4 The error type The error code (5) consists of four digits, e.g. 2332. • Always note the error code before contact- ing Manitowoc Crane Care You can exit the Errors submenu at any time. Exiting the submenu • Press the (1) button once.
Page 902: Malfunctions On The Cranestar System
TCU control unit is disconnected. The lamps (1) and (2) light up and the Errors submenu shows the error code 29.6.1.0. Data transmission errors will be reported externally, e.g. by Manitowoc Crane Care If an error occurs, check: –...
Page 903 Malfunctions during crane operation 14.4 Troubleshooting • Check the fuses (1) and replace them if nec- essary. Designation Amperage F3401 F3402 Antenna plugs • Check whether the plugs (1) and (2) are plugged in: 1 Plugs for GSM/GPS antenna 2 Plug for satellite antenna Operating manual GMK 6400 3 112 993 en 14 - 35...
Page 904 Flashes four times per second – Slow flash: Flashes once per second • Observe the functions of the lamps and forward the information to Manitowoc Crane Care if necessary. 14 - 36 3 112 993 en Operating manual GMK 6400...
Page 905 Malfunctions during crane operation 14.4 Troubleshooting This table assigns possible errors to the lamp functions. Function Lamp Slow flash Quick flash – 24 V DC from 0 V DC from battery – 24 V DC from battery or ignition off for a battery –...
Page 906 Malfunctions during crane operation 14.4 Troubleshooting Blank page 14 - 38 3 112 993 en Operating manual GMK 6400...
Page 907: Emergency Operations And Programmes
Malfunctions during crane operation 14.5 Emergency operations and programmes 14.5 Emergency operations and programmes This section contains all the information about possible emergency opera- tions and emergency programmes. The following are available: – Mechanical emergency operation for retracting – Telescoping emergency programme submenu –...
Page 908: 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 - 40 3 112 993 en...
Page 909 Malfunctions during crane operation 14.5 Emergency operations and programmes Mechanical emer- The following requirements must be met before unlocking manually: gency operation – The main boom must be lowered to the horizontal position so that the tel- escopic section cannot retract by itself –...
Page 910 Malfunctions during crane operation 14.5 Emergency operations and programmes Releasing the lock • (A) – Extend about 35 mm (0.11 ft), so that the cutout (4) is accessible. • (B) – Screw a set screw into the bore (1). The locking pins (2) must retract behind the tele- scopic section (3).
Page 911: Telescoping Emergency Programme
Malfunctions during crane operation 14.5 Emergency operations and programmes 14.5.2 Telescoping emergency programme In the event of a malfunction in the telescoping mechanism, you can retract the main boom with the Telescoping emergency programme. The emergency programme is not intended for crane operation and is therefore restricted to a certain amount of time.
Page 912 After pressing the button, locking or unlocking is performed immediately. • Note the error code (4) first if you intend to contact Manitowoc Crane Care before exe- cuting the emergency programme. 14 - 44 3 112 993 en Operating manual GMK 6400...
Page 913 Malfunctions during crane operation 14.5 Emergency operations and programmes Risk of damage to the main boom Never telescope the main boom if there is an error on the length indicator and on the proximity switch at the same time. It would then not be possible for you to monitor operations, and compo- nents in the main boom could be damaged, or a situation could arise in which the main boom can no longer be extended or retracted.
Page 914 Risk of accidents from sudden retraction of a telescopic section! Press the button for unlocking the telescopic section not more than twice. If this does not start the unlocking procedure, contact Manitowoc Crane Care – The telescoping cylinder is locked, symbol (3) is grey.
Page 915 • Retract the telescopic section slowly and as far as possible. • Press the button (2) once. • Extend to about 35 mm. The telescopic section is locked. In Locked posi- tion: – the locking pins (3) are green, – the symbol (1) is grey, –...
Page 916 Extending and locking the telescoping cylinder You may not select Lock while the telescoping cylinder is retracting or extending. Under no circumstances should you press the button (1). Risk of damage to the main boom! If you select Lock while the telescoping cylinder is moving, the locking pins on the telescopic section are slid out immediately and they can damage or tear the electrical or hydraulic components in the main boom.
Page 917 Malfunctions during crane operation 14.5 Emergency operations and programmes Error on proximity Faulty proximity switches are shown in violet. switch The displays (A), (B) and (C) only show the current positions when all the corresponding proximity switches are free of error. Several proximity switches are related to the displays (A), (B) and (C).
Page 918 Malfunctions during crane operation 14.5 Emergency operations and programmes Required checks When the Locked position can no longer be shown, always conduct the fol- lowing checks before unlocking: • Carefully retract and extend the telescoping cylinder or telescopic section In the Locked position, the length shown on the displays (1) should vary only slightly, i.e.
Page 919 Malfunctions during crane operation 14.5 Emergency operations and programmes 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: locking points – Want to lock the telescoping cylinder –...
Page 920 Malfunctions during crane operation 14.5 Emergency operations and programmes Locking points for the telescopic sections The telescopic section must not be set down for locking or unlocking. The cutout (1) must be clear. That is why you have to extend the telescoping cylinder further than with a return run.
Page 921: Entering The Current Telescoping
Malfunctions during crane operation 14.5 Emergency operations and programmes 14.5.3 Entering the current telescoping ECOS no longer displays the current telescoping: – If you telescoped in emergency mode – If the power supply was interrupted in the course of saving data In these cases, you must enter the current telescoping, e.g.
Page 922 Malfunctions during crane operation 14.5 Emergency operations and programmes Applying values • Press the left dead man's switch (2). • Also press button (5) once – symbol (3) appears. • Press the buttons (1) in the following order: Å Æ Å Ç The symbols (4) confirm the entry.
Page 923: Emergency Operation With The Hand-Held Control
Malfunctions during crane operation 14.5 Emergency operations and programmes 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 924 Malfunctions during crane operation 14.5 Emergency operations and programmes To pre-select a power unit • Press the button for the desired power unit once, e.g. the button (1) for the main hoist When the function is enabled, the lamp in the button lights up. With the telescoping mechanism, teleautomation with the target 0/0/0/0 is always selected at the same time –...
Page 925 Malfunctions during crane operation 14.5 Emergency operations and programmes The following table shows all the button combinations. Engaged buttons are shown in black: Pre-selected power unit Telescoping Derricking Slewing Lattice Button Hoists mechanism gear gear extension combination None Lower boom None Lower Lower boom...
Page 926 Malfunctions during crane operation 14.5 Emergency operations and programmes Stopping The movement continues until you let go of the function button or the end operations position is reached. You can stop operations with the emergency stop switch if they do not stop by Stopping à...
Page 927: Hydraulic Emergency Operation
Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6 Hydraulic emergency operation 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. in the event of an engine failure.
Page 928: Connecting/Disconnecting Hoses
Malfunctions during crane operation 14.6 Hydraulic emergency operation Emergency supply 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 à Emergency supply of another crane , crane;...
Page 929 Malfunctions during crane operation 14.6 Hydraulic emergency operation On the superstructure • Connect the thicker hose (2) to the connec- tion (1). • Connect the thinner hose (4) to the connec- tion (3). Disconnecting After the emergency operation, you must disconnect the hoses and the transformer.
Page 930: Switching Emergency Operation On/Off
Malfunctions during crane operation 14.6 Hydraulic emergency operation • Remove the hoses (2) from the connections (1). • Close the hoses and the connections with the caps. • Remove the transformer (3). 14.6.3 Switching emergency operation on/off The emergency operation (or emergency supply of another crane) is switched on and off in the driver's cab.
Page 931: Establishing The Required Hydraulic Circuits
Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6.4 Establishing the required hydraulic circuits To establish an hydraulic circuit, switch over the required valves. Switching over The valves 1 to 7 are numbered. valves For crane operation • Switch the valves 1 to 7 inwards. Danger from mutual interference of the power units For crane operation, always switch all the valves 1 to 7 inwards.
Page 932 Malfunctions during crane operation 14.6 Hydraulic emergency operation For emergency operation • Remove the cover over the valves 1 to 7. • Switch the valves 1 to 7 to the positions for the required crane movement – as shown in the following table.
Page 933: Performing Emergency Operation
Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6.5 Performing emergency operation If the required hydraulic circuit has been established, you can make the cor- responding 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 934 Malfunctions during crane operation 14.6 Hydraulic emergency operation • Derricking Determine the maximum permissible working radius for the current rig- ging mode according to 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 935: After Emergency Operation
Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6.6 After emergency operation You must restore the truck crane to its original state after finishing emer- gency operation. à • Switching off Switch off emergency operation; p. 14 - 62. emergency •...
Page 936: Emergency Supply Of Another Crane
Malfunctions during crane operation 14.6 Hydraulic emergency operation 14.6.7 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 • Operating manual of Attach the hoses (4);...
Page 937 Index Operating manual GMK 6400 3 112 993 en...
Page 938 3 112 993 en Operating manual GMK 6400...
Page 939 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 de- scribed and named in detail in the overviews of chapter 3 and chapter 9 Truck Crane Description .
Page 940 Index Blank page 15 - 2 3 112 993 en Operating manual GMK 6400...
Page 941 Index Access ladders on the carrier ......... . . 4 - 4 Adjusting the mirrors for driving .
Page 942 Index While towing ............7 - 8 CHECKLIST at low temperatures Driving .
Page 943 Index Inclining ............11 - 105 Operating elements Auxiliary air heater .
Page 944 Index Warning message ..........5 - 47 Documentation supplied .
Page 945 Index Adjusting the brightness of the display – in the driver’s cab ....4 - 15 Operating elements in the crane cab in submenu for outriggers ........9 - 24 in the errors submenu .
Page 946 Index Emergency stop devices Engine for crane operation ........10 - 18 for the engine .
Page 947 Index Final drive Operating elements in the driver's cab ....... 3 - 47 Front flap Opening and closing .
Page 948 Index Houselock Switching off ........... . 11 - 17 Switching on .
Page 949 Index Hazard warning system ..........3 - 56 Instruments .
Page 950 Index Hand-held control ..........14 - 20 Hoist cameras .
Page 951 Index Symbols used ........... . 1 - 21 Outrigger pressure display .
Page 952 Index Railings on the turntable ..........12 - 135 Raise axle Short description of the operating elements .
Page 953 Index Other rigging work Folding mirror in/out ......... 12 - 136 Folding the railings on the turntable in/out .
Page 954 Index Switching off ........... . 12 - 18 Switching on .
Page 955 Index Operating speeds ..........1 - 18 Superstructure .
Page 956 Index Stopping ........... . . 5 - 32 Switching on .
Page 957 Index Shutdown ........... . . 11 - 127 Switching monitoring function on/off .
Page 958 Index 15 - 20 3 112 993 en Operating manual GMK 6400...

Manitowoc GROVE GMK 6400 Operating Manual

1 1 Overview

Overview

Accidents

Branch Offices

Warranty Specifications

Terms Used

Technical Data

Documentation Supplied

Notes on the Operating Instructions

Conversion Table for US Measuring Units

Training - Information

Identification

EC Declaration of Conformity

2 2 Basic Safety Instructions

3 3 Operating Elements for Driving

Operating Elements for Driving

Overview of the Operating Elements

Short Description of the Operating Elements

4 4 Starting/Turning off the Engine for Driving

Starting the Engine from the Driver's Cab

Starting/Turning off the Engine for Driving

Turning off the Engine

Air Intake Inhibitor

5 5 Driving

Before Driving

Driving

Operating the Transmission

Driving and Turning off the Truck Crane

Off-Road Driving

Separate Steering

Heating and Air-Conditioning System

Towing a Trailer

6 6 Driving Modes and Rigging for On-Road Driving

Driving Modes and Rigging for On-Road Driving

Driving Modes

Rigging Work for Driving with a Trailer

Removing/Installing Main Boom

Installing/Removing Outrigger Beams

Installing/Removing the Supporting Box

7 7 Malfunctions in Driving Mode

Emergency Stop Switch

Malfunctions in Driving Mode

What to Do When a Malfunction Occurs in Road Traffic

Towing the Truck Crane

Other Emergency Operations

Wheels and Tyres

Fuses

Troubleshooting

Procedure During Malfunctions

9 9 Operating Elements for Crane Operation

Operating Elements for Crane Operation

Overview of the Operating Elements

Short Description of the Operating Elements

10 10 Starting/Turning off the Engine - for Crane Operation

Starting/Turning off the Engine - for Crane Operation

When Starting the Engine for the First Time of the Day

Starting the Engine - with the Hand-Held Control

Turning off the Engine

11 11 Crane Operation

Before Operating the Crane

Crane Operation

Operation of the Rated Capacity Limiter

Crane Operation with Main Boom

Settings and Displays for Crane Operation

Working Range Limiter

Work Break

Heating and Air-Conditioning System

Cranestar System

Quick Links

Chapters

Troubleshooting

Related Manuals for Manitowoc GROVE GMK 6400

Summary of Contents for Manitowoc GROVE GMK 6400