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GROVE GMK4090
Manitowoc GROVE GMK4090 - User Manual
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Operating manual
3 302 736 en
14.03.2018
2
Table of Contents
Main Page
Default Chapter
13
Table of Contents
13
Overview
43
Accidents
43
Branch Offices
45
Manitowoc Crane Care
45
Dealer List
45
Warranty Specifications
45
Terms Used
46
Technical Data
49
Maximum Lifting Capacity (DIN/ISO/EN)
49
Maximum Lifting Capacity (ASME B 30.5)
49
Dimensions and Weights of the Truck Crane, Axle Loads
50
Dimensions and Weights of Removable Parts
52
Carrier
57
Superstructure
61
Documentation Supplied
63
Questions on Documentation
64
Notes on the Operating Manual
65
What Do the Symbols Used Mean
65
How Is the Operating Manual Structured
67
How Do I Find the Information I Need
69
What Information Is Available for Operations Planning
72
Conversion Table for US Measuring Units
73
Training - Information
75
Identification
76
EC Declaration of Conformity
78
Notes on the Engine Data Card
79
Basic Safety Instructions
81
Intended Use
81
Improper Use
82
Organisational Measures
83
Personnel Qualifications
85
Safety Instructions for Driving the Truck Crane
86
Safety Instructions for Crane Operation
87
Instructions on Transporting Persons
90
Operating Elements for Driving
93
Overview of the Operating Elements
93
On the Outside of the Truck Crane
94
Driver's Cab
98
15 Steering Column/Steering Wheel
99
Instrument Panel
99
Transmission Operating Elements
102
On-Board Computer
105
Tachograph
108
Heating and Air-Conditioning System
109
CCS Control Unit
113
CCS - Menu-Dependent Displays
114
CCS - Start Menu
115
CCS - Overview Menu Groups
116
Carrier Menu Group
118
Menu Group, Settings
121
Menu Group Information
124
Various Controls Menu Group
128
Emergency Operations Menu Group
129
Outrigger Control Units
130
Short Description of the Operating Elements
131
Definition of Information Relating to Directions of Movement
132
General Rules for Buttons and Symbols on the Display
133
Engine
134
Adblue System
136
Battery Master Switch
137
Electrical System
138
Crane Control CCS
139
Transmission
141
Reverse Camera
144
Birdview System 270
145
Transfer Case
147
Final Drive
148
Brakes
149
Steering/Separate Steering
151
Suspension
155
Lighting/Windscreen Wipers/Horn
156
Level Adjustment System
159
Trip Recorder/Speedometer
161
Diagnostics
162
Push-Up Roof
162
On-Board Computer
163
Front Flap
164
Windows and Doors
165
Access Ladders and Ladders
167
Starting the Engine for Driving - Switching It off
171
Starting the Engine from the Driver's Cab
171
CHECKLIST: Starting the Engine
171
CHECKLIST: at Low Temperatures
174
Filling up
175
Checks before Starting the Engine
178
Switching the Ignition on
179
Lamp Test/Equalisation of the Switching States
181
Display - Setting the Brightness
182
Starting the Engine
184
Checks after Starting the Engine
186
Setting the Idling Speed
188
Switch off the Engine
189
At the Ignition Lock and with the Outrigger Control Units
189
Using the Emergency Stop Switches
190
Air Intake Inhibitor
191
Driving
193
Before Driving
193
CHECKLIST: Checks before On-Road Driving
193
Check the Condition of the Truck Crane
199
Adjusting the Seat and the Steering Column
205
Switching the Suspension On/Off
208
Setting the Tachograph
210
Time, Setting
215
Displaying and Resetting Operating Hours
216
Operating the Transmission
217
Switching on
217
Switching the Transmission to the Neutral Position
218
Selecting the Direction of Travel and Starting Gear
219
Changing Operating Mode
221
Starting
222
Driving and Changing Gears
223
Changing the Driving Direction
225
Stopping
225
On the Roller Type Dynamometer
226
Preheating Transmission
226
Driving the Truck Crane and Switching It off
227
Checks Whilst Driving
227
Cruise Control
230
Temposet
232
Driving Downhill
233
Driving Uphill
236
Overriding Torque Reduction
237
Switching the Truck Crane off
238
Fold-Up Berth
240
Off-Road Driving
241
Transfer Case - Switching the Off-Road Gear On/Off
242
Longitudinal and Transverse Differential Locks
243
Operating the Level Adjustment System
245
Freeing Truck Crane Stuck in Terrain
249
Separate Steering
251
Switching to Separate Steering
252
Switching to Normal Steering Mode
255
Switching Units of Measure
256
Radio
256
Heating and Air-Conditioning System
257
Standard Heating System
257
Air-Conditioning System
260
Auxiliary Water Heating System
262
Auxiliary Air Heater
268
Towing a Trailer
273
Driving Modes
279
6.1 Driving Modes
280
Information on How to Use the Tables
280
Maximum Permitted Speeds with an Axle Load of over 12 T (26,500 Lbs)
284
Weighing the Truck Crane
285
Rigging Work for Driving with a Dolly
289
Switching on the Slewing Gear Freewheel
290
Switching on the Boom Floating Position
291
Switching on Boom Pre-Tensioning
292
Installing/Removing the Outrigger Beams
293
CHECKLIST: Removing the Outrigger Beams
294
CHECKLIST: Installing the Outrigger Beams
296
Centre of Gravity Data
298
Preparations - for Removal
298
Preparations - on the Truck Crane
299
Removing/Attaching Outrigger Pads
300
Disconnecting/Establishing Hydraulic Connection
302
Disconnecting/Establishing the Electrical Connection
303
Unscrewing/Screwing in the Spacers
304
Disconnecting/Establishing the Connections to the Supporting Box
306
Pulling Out/Inserting the Outrigger Beam
306
Transporting the Outrigger Beams
310
Note on Error Messages with Removed Outrigger Beams
310
Transport
311
Transport with Transport Vehicle
311
CHECKLIST: Checks before Transport
312
Drive the Truck Crane on to the Transport Vehicle
314
Transport by Ship
316
Malfunctions in Driving Mode
317
Emergency Stop Switch
317
Procedure During Malfunctions
318
What to Do When a Malfunction Occurs in Road Traffic
318
Procedure During Engine Malfunctions
319
Procedure During Transmission Malfunctions
320
Warning and Error Messages
321
Warning or Malfunction Messages on the Instrument Panel
321
Warning and Malfunction Messages on the On-Board Computer Display
325
Warning Messages on the CCS Display
329
Error Messages on the CCS Display
333
Troubleshooting
335
Malfunctions on the Engine
335
Faults on the Adblue System
337
Differential Lock Malfunctions
338
Transfer Case Malfunctions
338
Malfunctions in the Transmission
339
Malfunctions of the Steering
340
Malfunctions of the Service Brake
341
Malfunctions of the Level Adjustment System
342
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
342
Malfunction in the CCS Control Unit
342
Emergency Operation and Breakdown Assistance
343
Starting the Truck Crane Externally
343
Battery Charger
344
Towing the Truck Crane
345
Wheel Change
349
Inflating the Tyres Yourself
353
Emergency Operation, Steering 3Rd Axle Line
355
Tilting/Lowering the Driver's Cab
359
Operating Elements for Crane Operation
373
Overview of the Operating Elements
373
Exterior of the Truck Crane
374
Crane Cab
378
Control Panels
384
Control Lever Assignment
386
CCS Control Unit
388
Menu-Independent Displays
390
CCS - Start Menu
391
CCS - Overview Menu Groups
394
Superstructure Menu Group
398
Menu Group Outrigger/Driving
401
Rcl/Telescoping Menu Group
409
Active Working Range Limiter Menu Group
419
Information 1 Menu Group
424
Heating/Engine/Additional Equipment Menu Group
427
Telescoping Emergency Program Menu Group
432
Settings Menu Group
435
Information 2 Menu Group
441
Various Controls
446
RCL Control Unit
447
Menu-Independent Displays
449
RCL - Menus
450
Hand-Held Control
454
Outriggers Control Units
455
Short Description of the Operating Elements
459
Definition of Information Relating to Directions of Movement
459
General Rules for Buttons and Symbols on the Display
460
Engine
461
Adblue System
462
Seat Contact Switch and Dead Man's Switch
464
Crane Control CCS
465
Outrigger - Crane Cab
470
Outrigger Control Units
473
Raise Axle
476
Inclination Indicators
478
Outrigger Pressure Displays
479
Anemometer Displays
479
Counterweight Menu
480
Main Hoist
484
Auxiliary Hoist
486
Slewing Gear
488
Derricking Gear
490
Telescoping Mechanism
492
Hydraulic System
498
Superstructure Lock Menu
499
Remote Control
502
Rated Capacity Limiter (RCL)
503
Electrical System
515
Lighting, Windscreen Wiper/Washing System
516
Hand-Held Control
520
Windows and Doors
524
Diagnostics
526
Other
526
Short Description of the Operating Elements - Driving from the Crane Cab
527
Driving Menu
527
Transmission
529
Final Drive
531
Brakes
532
Steering
533
Starting/Switching off the Engine - for Crane Operation
537
When Starting the Engine for the First Time in the Day
537
Starting the Engine - from the Crane Cab
539
Check the Fuel Level and Adblue Level
539
Checks before Starting the Engine
540
Switching the Ignition on
541
Comparison of Switching States
542
Display - Setting the Brightness
542
Starting the Engine
543
Checks after Starting the Engine
544
Setting the Idling Speed
545
Starting the Engine - with the Hand-Held Control
546
Switch off the Engine
547
At the Ignition Lock and with Hand-Held Control
547
With the Idling Button
547
Using the Emergency Stop Switches
548
Crane Operation
549
Before Operating the Crane
549
CHECKLIST: Checks before Operating the Crane
549
Check the Condition of the Truck Crane
553
Adjusting the Crane Cab Seat and Front Control Panel
556
Checking the Safety Equipment
557
Earthing the Load
560
Preheating Hydraulic Oil
561
Locking/Unlocking the Superstructure
562
Switching the Houselock On/Off
564
Standard Slewing Range Type
567
Permissible Slewing Ranges and Working Positions
567
Maxbase Slewing Range Type
569
Specifications in the Lifting Capacity Tables
570
Enabled Slewing Ranges
573
Lifting Capacities and Slewing Ranges for Outrigger Spans Without Separate Lifting Capacity Tables 11
574
Operation of the Rated Capacity Limiter
575
Switch on the RCL
576
Enter Rigging Mode
578
Pre-Selecting Telescoping
586
Confirm the Rigging Mode and Lifting Capacity Table
587
Checks before Operating the Crane
591
Display During the Crane Operation
595
RCL Early Warning
603
RCL Shutdown
603
Displaying the Lifting Capacity Tables
605
RCL Override - Version a
609
RCL Override - Version B
613
Datalogger
614
Crane Operation with Main Boom
619
Checks During Crane Operation
619
Main Hoist
622
Auxiliary Hoist
626
Lifting Limit Switch and Lowering Limit Switch
629
Derricking Gear
632
Telescoping Mechanism
636
High-Speed Mode
659
Slewing Gear
661
Switching the Reduction of Slewing Speed on and off
667
Possible Movement Combinations
668
Settings and Displays for Crane Operation
669
Inclining the Crane Cab
669
Setting the Idling Speed
670
Adjusting the Wiper Stroke Interval of the Windscreen Wiper
670
Limiting the Power Unit Speeds
671
Economy Mode
672
Switching Units of Measure
674
Setting the Characteristic Curves for the Control Levers
675
Using the Slewable Spotlights
676
Overriding Torque Reduction
678
Displaying the Operating Hours
679
Working Range Limiter
681
Viewing Current Settings
682
Opening the Working Range Limiter Menu
683
Enter Limit Values - for the Overall Height
684
Enter Limit Values - for the Working Radius
686
Enter Limit Values - for the Slewing Range
688
Enter Limit Values - for the Hoist Rope Travel
691
Shutdown by Working Range Limiter
693
Work Break
695
In Case of Short Work Breaks
695
In Case of Work Breaks of more than 8 Hours
696
Heating and Air-Conditioning System
697
Standard Heating System
697
Air-Conditioning System
699
Auxiliary Heater
701
Cranestar System
704
Overview
704
Position of the Components
704
Rigging Work
705
Rigging Work Checklists for Crane Operation with the Main Boom
705
CHECKLIST: Rigging
705
CHECKLIST: Unrigging
711
Choice of a Suitable Positioning Site
715
Determining the Required Load-Bearing Area
715
Safe Distance from Slopes and Pits
718
Earthing the Truck Crane
719
Safe Distance from Overhead Power Lines
720
Rigging Work after Driving with a Dolly
723
Switching off the Boom Floating Position
723
Switching off the Slewing Gear Freewheel
724
Switching off Boom Pre-Tensioning
725
Connecting/Disconnecting the Hand-Held Control
727
Starting the Engine for Rigging
731
Starting/Shutoff the Engine - with the Hand-Held Control
731
Starting/Shutoff the Engine - from the Outrigger Control Units
733
Slewing Range - Only with the Standard Slewing Range Type
735
Representation in the Lifting Capacity Tables
735
Enabled Outrigger Spans
736
Outriggers - Overview - Maxbase Slewing Range Type
737
Definitions
737
Representation in the Lifting Capacity Tables
739
Enabled Outrigger Spans
740
Outrigger Operation
745
CHECKLIST: Extending the Outriggers
745
CHECKLIST: Retracting the Outriggers
747
Preparing the Truck Crane
748
Setting the Outrigger Spans
750
Extending/Retracting Outrigger Beams
753
Moving the Outrigger Pads into Operating/Driving Position
757
Enlarging the Load-Bearing Area
759
Extending/Retracting Supporting Cylinders
760
Levelling the Truck Crane on Outriggers Horizontally
764
Levelling the Free-Standing Truck Crane
768
Operating the Axle Raising System
770
Outrigger Pressure Display
772
Rigging/Unrigging the Counterweight
775
Information on Rigging
775
Counterweight Sections
777
Identification
778
Slinging Points on the Counterweight Sections
779
CHECKLIST: Rigging the Counterweight
780
CHECKLIST: Unrigging the Counterweight
782
Assembling Counterweight Combination
783
Removing/Installing the Counterweight on the Turntable
789
Counterweight Hoist Unit
809
Setting down Counterweight for Driving
817
Slewing with Rigged Counterweight
819
Rigging Work on the Main Boom
821
Hook Block on the Bumper
821
Hook Block on a Separate Vehicle
823
Hook Block, Separable
826
Hook Block with Ballast Plates
828
Reeving and Unreeving the Hoist Rope
830
Rigging Aid for the Hoist Rope
836
Installing/Removing the Lifting Limit Switch
845
Locking/Unlocking the Lifting Limit Switch
850
Anemometer and Air Traffic Control Light
851
Other Rigging Work
855
Railings on the Turntable
855
Open/Close Coverings at the Turntable
856
Folding the Mirrors in and Out, and Adjusting Them
857
Cameras for Crane Operation
858
Step at the Crane Cab
863
Storage Compartments
865
Slinging Points for Personal Protective Equipment
866
13 Driving with a Rigged Truck Crane
867
Driving with a Rigged Truck Crane
867
Driving Distance
867
Permissible Rigging Modes and Axle Loads
868
To Drive Without a Load
871
To Drive with a Load
871
Axle Loads
871
Before Driving the Rigged Truck Crane
872
Check the Tyre Pressures and Wind Speed
872
Secure the Superstructure against Slewing
872
Putting the Truck Crane on the Wheels - with Raise Axle Function
873
Putting the Truck Crane on the Wheels - with the Outriggers
875
Driving from the Driver's Cab
877
Preparing to Drive
877
Whilst Driving
878
After Driving
879
Driving from the Crane Cab
881
Preparing to Drive
882
Opening/Closing the Driving Menu
882
Steering
886
Operating the Transmission
892
Whilst Driving
893
Possible Connections
894
After Driving
896
14 Malfunctions During Crane Operation
897
Malfunctions During Crane Operation
897
Emergency Stop Switch
897
What to Do When Malfunctions Occur During Crane Operation
898
Warning and Error Messages
899
Warning Messages on the CCS Display
899
Error Messages on the CCS Display
903
Warning Messages on the RCL Display
905
Troubleshooting
909
Malfunctions on the Engine
909
Malfunctions on the Main Hoist/Auxiliary Hoist
909
Malfunctions in the Hoist Cameras
911
Malfunctions in the Main Boom Camera
911
Malfunctions on the Derricking Gear
912
Malfunctions in the Telescoping Mechanism
913
Malfunctions on the Slewing Gear
914
Malfunctions on the Counterweight Hoist Unit
916
Malfunctions in the Hydraulic System/Hydraulic Oil Cooler
916
Malfunctions When Operating with the Hand-Held Control
917
Malfunctions When Inclining the Crane Cab
917
Malfunctions of the Outriggers
918
Malfunctions When Raising the Axles
918
Malfunctions on the CCS/RCL Control Units
919
Malfunctions When Driving from the Crane Cab
919
Malfunctions on the Turntable Lock
920
Malfunctions on the Cranestar System
920
Emergency Operations and Programs
923
Mechanical Emergency Activation for Retracting
924
Telescoping Emergency Program
927
Entering the Current Telescoping
935
Emergency Operation with the Hand-Held Control
937
Notes on Slewing in Emergency Operation
940
Rotate for Overridden Slewing Gear Shutdown
943
Hydraulic Emergency Operation with the Hand Pump
945
Switching over the Crane's Hydraulic System
946
Establishing the Required Hydraulic Circuits
947
Performing Emergency Activation
950
After Emergency Activation
950
Applications and Function
952
CHECKLIST: Emergency Operation
954
CHECKLIST: after Emergency Operation
955
Connecting/Removing Transformer - for Self-Sufficiency
956
Switching Emergency Operation On/Off
958
Connecting/Removing Transformer - for External Energy Source
959
Establishing the Required Hydraulic Circuits
960
Performing Emergency Operation
964
Emergency Supply of Another Crane
966
Fuses in the Crane Cab
968
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Manitowoc GROVE GMK4090 Specifications
General
Brand
Manitowoc
Model
GROVE GMK4090
Category
Construction Equipment
Language
English
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