Operating Instructions Part 1 Carrier

Vehicle serial number: 2 084 548 en

26.06.2000
(01.02.2000)
 Important note

Duplications of any kind and excerpts

from this document are not subject to the
alterations service. Original documents of
Deutsche GROVE GmbH are marked with
the blue serial number of the truck crane
on the cover page.

Duplications and print-outs of data carriers on

which Deutsche GROVE GmbH has delivered
this document are also not subject to the
alterations service.

©
Copyright reserved by Deutsche GROVE GmbH
01.02.2000

The passing on or duplication of this document as well as the use and disclosure of its contents are
prohibited unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration
of patent or utility model are reserved.
 These operating instructions consist of two parts:
– Part 1 – Carrier

– Part 2 – Superstructure

Part 1 comprises the following chapters:

1 Overview

2 Basic safety instructions

3 Information for applications engineering

4 Description of the truck crane – vehicle section

5 Vehicle engine

6 Driving the truck crane

7 Malfunctions on the carrier

8 Technical information about the carrier

9 Alphabetical index

Chapters 10 to 17 are in part 2 – Superstructure

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Operating Instructions GMK 6300 2 084 548 en

INHALTSVERZEICHNIS

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2 084 548 en Operating Instructions GMK 6300

 _______________________________________________________________________________________ 1
1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
1.1 Vehicle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
1.3 Overview and contents of truck crane user information . . . . . . 1 - 5
1.3.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 5
1.3.2 Lattice extension operating manual (additional equipment) . . . . . . . . . 1- 6
1.3.3 Maintenance manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6
1.3.4 Lifting capacity table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6
1.3.5 Outrigger load table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.3.6 Safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.3.7 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.3.8 Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.4 Instructions for use of this document . . . . . . . . . . . . . . . . . . 1 - 8
1.4.1 How are the operating instructions laid out? . . . . . . . . . . . . . . . . . 1- 8
1.4.2 How are the pages of the operating manual formatted? . . . . . . . . . . . 1- 9
1.4.3 How can I find the necessary information quickly and easily? . . . . . . . . 1 - 10
1.4.4 Definition of direction information . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
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Operating Instructions GMK 6300 2 084 548 en

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2 084 548 en Operating Instructions GMK 6300

 Overview
1.1 Vehicle identification

1 Overview

1.1 Vehicle identification

These operating instructions are intended only for the truck crane of
which the serial number is specified on the front cover.
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Operating Instructions GMK 6300 2 084 548 en 1-1
Overview
1.1 Vehicle identification

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1-2 2 084 548 en Operating Instructions GMK 6300

 Overview
1.1 Vehicle identification

The following plates and numbers have been fitted to the truck crane for
identification:

1 The superstructure name plate at the front of the crane operator’s cab
containing serial number and description of the crane model.

2 The CE mark on the name plate (only with truck cranes that are
delivered to member countries of the EU).

3 The chassis name plate on the passenger seat console containing the
chassis number and designation of the crane model.

4 The chassis number at the front right above the first axle line, in the
web plate of the frame.

The location of ID numbers for removable rigging parts (e.g. counterweights,

lattice extension, auxiliary hoist) is specified in the corresponding chapters.
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Operating Instructions GMK 6300 2 084 548 en 1-3

Overview
1.2 EC declaration of conformity

1.2 EC declaration of conformity

This declaration of conformity is a supplement to the delivery protocol
given to the operator upon delivery of the truck crane (only on truck
cranes which are delivered to EC member coutries).

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 Overview
1.3 Overview and contents of truck crane user information

1.3 Overview and contents of truck crane user information

1.3.1 Operating Instructions

These operating instructions contain information required to operate the

truck crane.

In chapter 2 you will find Basic safety instructions. Please read and observe
these instructions, even if you are familiar with the safety manual. These
Basic safety instructions are in this chapter only; special safety instructions
which indicate concrete dangers are contained in the text. There the
action related to the danger is described.

Chapter 3 contains Information for applications engineering. It is intended pri-

marily for the truck crane operator and those responsible for applications
engineering.
This chapter contains
– the required qualifications of those involved in applications
engineering,
– special safety instructions,
– information that is relevant to applications engineering.

Chapters 4 to 6 contain information required for driving the truck crane:

a description of all structural and operational components, clearly defined
check lists for rigging modes and work, and the operating instructions for
on-road and off-road driving.

In chapter 7 there is information on Troubleshooting for the carrier of the

truck crane.

Chapter 8 includes the Technical description of the individual parts and func-
tional elements of the carrier as well as its Technical data.

Chapter 9 contains the alphabetical index at the end of part 1 – carrier.

Chapters 10 to 12 contain information required for Operating the crane sec-

tion, i.e. work with the truck crane: a description of all components and
control elements, information about operating the crane engine as well
as the crane itself.
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Operating Instructions GMK 6300 2 084 548 en 1-5
Overview
1.3 Overview and contents of truck crane user information

Chapter 13 deals with rigging the truck crane. There are individual sec-
tions with information on Selecting a suitable site, rigging of support and
counterweight and Rigging work on the main boom.
Chapter 14 describes the installating and dismantling of the auxiliary hoist.
Chapter 15 contains information about Troubleshooting on the superstructu-
re of the truck crane.
The technical description of the individual components and functional parts
of the vehicle part as well as its technical data is found in chapter 16.
The alphabetical indexes in chapter 17 will help you when you are looking
for certain procedures and terms in the operating instructions.

1.3.2 Lattice extension operating manual (additional equipment)

If the truck crane has been equipped with a lattice extension, a boom ex-
tension, an auxiliary single-sheave boom top, or other additional equip-
ment, the Lattice extension operating manual will be supplied. It contains
all the information about combination possibilities, rigging, operation,
transport and the technical data of the additional equipment.

1.3.3 Maintenance manual

The maintenance manual is intended for maintenance personnel.

The maintenance manual does not contain information on repair work.
The maintenance manual consists of
– instructions for cleaning the truck crane,
– run-in instructions,
– inspection and servicing intervals,
– maintenance tables,
– specifications for the required lubricants and fuels and
– a description of the maintenance work on both the vehicle section and
crane section.

1.3.4 Lifting capacity table

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These tables contain data concerning the load bearing capacity, the per-
missible wind speed and the SLI code of the truck crane in various rigging
modes and boom positions.

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 Overview
1.3 Overview and contents of truck crane user information

1.3.5 Outrigger load table

These tables contain data concerning the outrigger pressure on the

pressure points of the support in relation to the load, radius, rigging
mode and boom direction.

1.3.6 Safety manual

The Safety manual is intended to warn the crane operator of the hazards
that may occur during normal operation of the truck crane. It illustrates
how to avoid these hazards from the onset and how to react should they
occur.

The Safety manual contains

– general safety instructions,
– safety instructions that apply to truck crane driving,
– safety instructions for rigging and working with truck cranes, and
– safety instructions for crane operation under specific operating conditions.
Observing the information and carrying out the measures which are given
in the Safety manual is the responsibility of the crane operator and a pre-
requisite for the safe operation of the truck crane.

1.3.7 Spare parts list

The Spare parts list contains all available genuine spare parts and ordering
instructions.

1.3.8 Circuit diagrams

Circuit diagrams are used for troubleshooting and intended for trained
maintenance personnel and GROVE Product Support at the respective
location.

Enclosed are:
– the compressed-air circuit diagram,
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– the hydraulic circuit diagram and

– the electrical circuit diagram.

Operating Instructions GMK 6300 2 084 548 en 1-7

Overview
1.4 Instructions for use of this document

1.4 Instructions for use of this document

These operating instructions are not a training manual for prospective
crane operators! All descriptions are written explicitly for crane operators
who have been trained to operate truck cranes.
This operating manual is for reference; it contains brief or detailed ex-
planations of operating steps and procedures depending on the foreknow-
ledge of the crane operator.

1.4.1 How are the operating instructions laid out?

The Operating Instructions consist of Part 1 – Carrier and Part 2 – Super-

structure. One individual part, however, does not constitute a complete
set of Operating Instructions; both parts must be included with the truck
crane. The basic safety measures, also for crane operation, as well as
general information can be found only in Chapter 1. The individual parts
consist of
– the descriptions of the operating and control instruments their
designation, location and function,
– the check lists, which describe the respectively required crane or
rigging mode.
The individual rigging steps are listed in the correct order for extensive
rigging procedures. The accompanying handling descriptions are
referred to in the individual points. These descriptions look at the indivi-
dual rigging steps in detail and give the necessary warning and safety
instructions.

G
The check lists and the handling instructions should always be considered
as a single unit for the complete description of a rigging procedure.
The handling instructions alone always describe only one individual rig-
ging step in detail. The necessary rigging steps for the complete rigging

S
procedure and their order can only be found in the checklist.

In the check lists there are cross-references to the respective accompany-

ing sections in which the required actions are described along with the
dangers involved.
As the crane operator you are obliged to read these sections
– before using the truck crane for the first time
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– and whenever you are still unsure about operation of the truck crane.

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 Overview
1.4 Instructions for use of this document

Safe operation of the truck crane simply with the check lists is only possible
– once you have mastered the necessary activities as they are described
– in the respective sections and
– if you are aware of all dangers which could arise and know how to
– prevent them.
If in doubt always read the accompanying section which is referred to in
the check list before working with the truck crane.

1.4.2 How are the pages of the operating manual formatted?

Each page of the operating manual consists of a wide text column and a
narrow column containing several functions.

The narrow column contains as required graphic and / or text information.

This includes
– the five symbols for danger, environmental protection and general
information,
– the symbols for the switches, keys and lamps required to operate the
truck crane,
– graphic illustrations of the individual functional and structural elements
of the truck crane,
– the chapter and section numbers,
– the headings of the smallest sections, in which, e. g. the course of a
single procedure is explained.

The following text passages are highlighted in italics:

– the descriptions of operating instruments such as switches, pushbut-
tons or lamps,
– cross-referenced section titles.

Text passages in which sentences are preceded by a hyphen (as in this

section) are lists. This formatting structure is used to separate the text
components for easier comprehension.

Sentences preceded by a bold dot contain specific instructions, such as

• Switch the automatic gearbox into neutral position N.
These passages require that you carry out a specific action.
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Operating Instructions GMK 6300 2 084 548 en 1-9
Overview
1.4 Instructions for use of this document

Switch elements and indicator lamps which have the same symbol are
only represented by one single symbol when they are mentioned in com-
mon relevance, e. g.
• Press the Suspension locking system rocker switch down.
u The Suspension locking system indicator lamp should illuminate.

1.4.3 How can I find the necessary information quickly and easily?

These operating instructions contain the following reference aids

– the table of contents at the front of the operating instructions,
– the table of contents of each chapter on the coloured sheet preceding
the respective chapter,
– the index at the back of the operating instructions, and
– cross-references in the text.
The General table of contents and the individual Chapter table of
contents provide a thematic overview of the operating instructions.

The Index (in Chapters 9 and 17 in these operating instructions) lists key
words and terms alphabetically and indicates the page on which the re-
spective word is defined or the corresponding operation is described.
You will find instructions for the use of the index on page 1-16.

The text itself contains a number of cross-references to other text passa-

ges which contain additional or detailed information about a particular
term.
These cross-references are indicated by means of an arrow (➠).

Whenever you require further information on a subject, you should

always turn to the page to which the arrow refers.

Furthermore, using the cross-references you can systematically fami-

liarise yourself with general and particular information on the truck crane
or look up the function of individual elements.
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1 - 10 2 084 548 en Operating Instructions GMK 6300

 Overview
1.4 Instructions for use of this document

Example of cross- This will be explained using the example of switching on the transverse
reference usage differential lock.

The following seven sample pages show how the cross-references guide
you through the Operating Instructions. The example starts with the over-

H
all view and goes on to the function of an individual switch.

The sample pages in this example originate from Operating Instructions

for the GMK 3050 and can deviate from the actual Operating Instructions!

9 Drivers cab ➠ p. 4 - 6

4-4 4-5

C0646

On page 4 - 4 of our example there is the overall view of the truck crane
with the position numbers 1 to 17. You will find the designation of the
truck crane part labelled with the number 9 on the opposite page 4 - 5.
There under the number 9 is Driver’s cab. The accompanying cross-
reference (➠) refers you to page 4 - 6.
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Operating Instructions GMK 6300 2 084 548 en 1 - 11
Overview
1.4 Instructions for use of this document

1 Side instrument panel ➠ p. 4 - 14

4-6

C0647

Page 4 - 6 gives an overview of the driver’s cab.

Item number 1 designates the side instrument panel. The operating
elements on the side instrument panel are given on page 4 - 14 according
to the cross-reference.

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 Overview
1.4 Instructions for use of this document

6 Rocker switch for transverse differential lock ➠ p. 4 - 22

h
6

4 - 14 4 - 15

C0648

The side instrument panel is shown on page 4 - 14. In our example the
magnifying glass is directed at the symbol designated by the item num-
ber 6. On the opposite page 4 - 15 under number 6 you will find the
designation Rocker switch for transverse differential lock. You will find infor-
mation on this switch on page 4 - 22.
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Operating Instructions GMK 6300 2 084 548 en 1 - 13
Overview
1.4 Instructions for use of this document

Rocker switch for transverse differential lock

h
Locks the transverse differentials in all driven axle lines.
May only be activated when the vehicle is stationary or is moving at
a speed of no more than 3 km/h.

To switch on: Press rocker switch down.

To switch off: Press rocker switch up;

➠ p. 6 - 34

4 - 22

C0649

On page 4 - 22 in the section functional description of the display and operating

instruments instrument panel you will find the symbol as well as the designa-
tion of the accompanying operating instrument: Rocker switch for transverse
differential lock.

Furthermore you will find a brief functional description of this switch.

You are referred to page 6 - 34 for further information.

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 Overview
1.4 Instructions for use of this document

Activating ● Stop the truck crane or allow it to roll at a speed of max. 3 km/h.
transverse
differential locks ● Straighten the steering.
● Switch on the Level adjustment system key switch.
Press the rocker switch
h ●
Press the Transverse differential rocker switch lock down.
Carefully start the truck crane and wait until the Transverse differential lock
indicator lamp lights up. The indicator lamp will flash if one or more of
the transverse differential locks has not been activated. It will not light up
continuously until the transverse differential locks of all axle lines have
been activated.

6 - 34

C0650

The section Transverse differential locks in the axle lines is on page 6 - 34 of

our example. There the function and operation of the transverse differen-
tial locks is described in detail. You are also given warning information
which will help prevent you from incorrectly operating the transverse
differential locks and causing damage.
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Operating Instructions GMK 6300 2 084 548 en 1 - 15
Overview
1.4 Instructions for use of this document

Explanations of The index has the following structure:

how to use the
index The names of parts or modules for which you are looking are listed in
alphabetical order at the very left at the beginning of the line.
The following are indented under these terms:
– operations (e.g. outrigger beams / extend) or
– sub-terms (e.g. steering / display and operating elements) or

H
– sub-terms connected to operations (e.g. hydraulic system / preheat
hydraulic oil).

The first search word is always a noun which is followed by an operation

or a sub-term.

1.4.4 Definition of direction information

This section defines several terms which are used in the descriptions of
the operating elements in these operating instructions.

Basic rule Forwards always means towards the driver’s cab,

backwards always means towards the carrier rear lights.

In the driver’s cab front, rear, right and left refer to the carrier.
The driver’s cab is always at the front. This also applies when these terms
are used to describe the control levers in the driver’s cab.

In the crane cab front, rear, right and left refer to the superstructure. The
front is always in the direction of the main boom head. This also applies
when these terms are used to describe the control levers in the crane cab.

Buttons and Switches and buttons on the instrument panels are always pressed up
switches and down. In the illustrations of switches and buttons this means:

up, when pressing (1)

down, when pressing (2)
This applies whether the switch is installed horizontally, vertically or at
an angle. Up and down always refers to the way the switch or button is
illustrated in these operating instructions.
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 _______________________________________________________________________________________ 2
2 Fundamental safety instructions for crane operators . . . 2- 1
2.1 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
2.2 Proper use 2 - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 4
2.4 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 6
2.5 Safety instructions that apply to truck crane driving . . . . . . . . . 2- 7
2.6 Safety instructions for truck crane work . . . . . . . . . . . . . . . . . 2- 7
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2 084 548 en Operating Instructions GMK 6300

 Fundamental safety instructions for crane operators
2.1 Warnings and symbols

2 Fundamental safety instructions for crane

operators

2.1 Warnings and symbols

The following definitions and symbols are used in the operating instruc-
tions to highlight particularly important information:

G
This symbol indicates hazards related to the described operation that
may cause personal injury. The type of danger (e.g. risk of death, perso-
nal injury or crushing) precedes the warning sign.

S
Here dangers are referred to which could put objects at risk, e. g. damage
to the truck crane, the load or the environment.

B
This symbol alerts you to situations where you are in danger of receiving
an electric shock.

O
This symbol is to remind you that you are working with substances which
pose a risk to the environment. Take particular care. Further information
about handling substances which are harmful to the environment;
➠ Maintenance manual, chapter Safety and environmental protection.

The vertical line to the left of the text indicates: This text regardless of its
length belongs to the warning symbol.

H The hand with the pointing finger indicates passages that contain additio-
nal instructions and tips with regard to truck crane operation.
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Operating Instructions GMK 6300 2 084 548 en 2-1
Fundamental safety instructions for crane operators
2.2 Proper use

s
This symbol indicates that the topic is continued on the next page.
So turn to the next page!

Horizontal lines always point to the start or the end of an example. The text in
examples is in a different font.

2.2 Proper use

The GMK 6300 truck crane is constructed in accordance with the state of
the art and the recognised safety regulations. Nevertheless, personal
injury to the operator or a third party as well as damage to the crane and
other property may occur during use.

The truck crane may only be modified with the consent of the manufacturer.

The GMK 6300 truck crane must be in proper working condition and may
only be used for its intended purpose, while taking into account safe
operation and any possible hazards.
Malfunctions that may affect the safe operation of the unit are to be
corrected immediately.

Without the corresponding special equipment, the truck crane GMK 6300
may only be operated at an ambient temperature of –25 to +40 °C.

The GMK 6300 truck crane is to be used exclusively for the vertical lifting
of loads whose weight and centre of distribution are known. A hook block
must be reeved on the hoist rope and such lifting must be done only in
the permitted rigging modes. Any other use of the crane is considered
improper.

The manufacturer is not liable for damage resulting from the improper or
unauthorised use of the GMK 6300 truck crane. The user shall take on full
responsibility for any such use.

Proper use also entails

– observing all crane documentation, consisting of the operating in-
structions, the lifting capacity table, the outrigger pressure table and
the safety manual,
– following the inspection and maintenance requirements specified in the
maintenance manual.
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 Fundamental safety instructions for crane operators
2.2 Proper use

Improper use includes:

– Transporting loads on the carrier,
– Pushing, pulling or lifting loads with the level adjustment system, the
beams or the outrigger cylinders,
– Pushing, pulling or lifting loads off the ground using the slewing gear,
the derricking gear or the telescoping gear,
– Pulling off fixed objects using the crane,
– Two-hook operation with the boom extension and two-hook operation
on the main boom head without additional equipment,
– Two-hook operation,
– Operation when crane is not on outriggers (free on wheels),
– Defining SLI codes that do not correspond to the actual rigging mode,
– Working with an overridden SLI or overridden lifting limit switch,
– After SLI deactivation, the radius must be increased by pulling the rai-
sed load at an angle (e. g. with a chain hoist).
– Misuse of the outrigger pressure display as a safety function to prevent
overturning after an SLI shutdown (outrigger pressure greater than 0 t),
– Road driving in an unauthorised driving mode (axle load, dimension),
– Moving the rigged crane in an unauthorised driving mode,
– The transportation of raised loads by moving the truck crane,
– Using equipment that is not authorised for use with the crane,
– Transporting people in any way with the lifting tackle, upon the load, or
in the crane cab while driving
– Carrying passengers outside the driver’s cab,
– Loading and unloading work, i.e. continuous operation without a
corresponding break,
– Usage for any kind of sport or recreation event, especially for
“bungee jumping”.
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Operating Instructions GMK 6300 2 084 548 en 2-3

Fundamental safety instructions for crane operators
2.3 Organisational measures

2.3 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 remo-
ved from the truck crane. You need to have read and understood the
operation and safety instructions in these operating instructions and to
comply with them when working.
In addition to the operating instructions and the lifting capacity table, ob-
serve all general, statutory and otherwise applicable regulations concer-
ning accident prevention and environmental protection. You must have
read and understood these and work accordingly.
This includes:
– the use of hazardous materials,
– wearing personal protective equipment,
– traffic regulations or
– all regulations concerning the operation of a crane.

Ensure that those appointed to work on the truck crane are given the infor-
mation required to carry out the work before starting operations. Give
your employees (e. g. banksmen, slingers, rigging personnel) appropriate
instruction.
Ensure that the maintenance personnel possess the necessary know-how
to safely operate the crane. Ensure that the maintenance personnel have
access to the Operating Instructions.
Only properly trained or instructed personnel may carry out work on the
truck crane.
Responsibilities related to crane operation, rigging, maintenance and re-
pair work must be clearly defined.
Ensure that only the appointed employees operate the truck crane.
Do not leave long hair down or wear loose clothing or jewellery (including
rings) when working with the crane. These could cause injury by, for
example, getting caught or pulled in.
Use your personal protective equipment whenever necessary or pre-
scribed.
Observe all safety and warning signs on the truck crane.
Ensure that all safety and warning signs on the truck crane remain legible.
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 Fundamental safety instructions for crane operators
2.3 Organisational measures

Note the operational organization on the site. Report your arrival to site
management. Ask for the personnel authorized to issue instructions.

Familiarize yourself with the location and operation of the fire extin-
guishers on every site.

Note the fire alarm and fire fighting facilities on the site.

Should the operating behaviour of the truck crane change in such a man-
ner that safety is affected or if you doubt the truck cranes operating safe-
ty, stop the machine immediately and inform the appropriate responsible
persons.

Do not modify any programs in programmable control systems

(e. g. the SLI).

Do not modify or mount attachments to the truck crane without the con-
sent of the manufacturer if such changes could affect the safety of the
unit. This also applies to
– installing safety devices,
– setting safety devices and valves.
Welding work on load-bearing parts may only be conducted by properly
qualified personnel following authorisation by the manufacturer. To avoid
any damage, especially to electronic parts, there are certain steps you
must take before doing any welding work. So always consult GROVE
Product Support before doing any welding work.

Ensure that both the prescribed periods and the periods specified in the
operating and maintenance instructions for regular testing, inspection
and maintenance work are maintained.

Replace the hydraulic hose lines at the prescribed intervals or have them
replaced, even if no safety defects are noticeable.

Replacement parts must fulfil the technical requirements prescribed by

the manufacturer. Genuine spare parts always meet these requirements.

It is imperative that appropriate service equipment be used when carrying

out repair work.
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Fundamental safety instructions for crane operators
2.4 Personnel qualifications

2.4 Personnel qualifications

These operating instructions are not a training manual for prospective
crane operators!
All descriptions are written explicitly for crane operators who have been
trained to operate truck cranes.

Employees in training may only operate the truck crane under strict super-
vision.

Only reliable personnel may operate the truck crane.

As a truck crane operator you are obliged to fulfil a number of

requirements:
– You must possess a driving licence for this type of vehicle that is valid
in the country in which you are working.
– You must have general knowledge of crane operation and any qualifica-
tions that may be required by the country in which you are working.
– You must be familiar with and have understood the operating
instructions.
– You must be familiar with and have understood the accident prevention
regulations.
– You must fulfil all physical and mental requirements for truck crane
operation, e.g. perfect sight and hearing and the ability to react quickly.
Please refer to the section titled You as crane driver and operator in the
Safety manual.

Only experienced personnel familiar with the applicable accident

prevention regulations are authorised to sling loads and train crane
operators.

Your responsibilities as a crane operator (including those concerning

traffic regulations) must be clearly defined. You must be in a position to
refuse to carry out any instructions given to you by a third party that
violate safety regulations.

Only trained, experienced personnel with special knowledge in the fields

of hydraulics, pneumatics and electrical equipment may carry out main-
tenance work on the truck crane.

Deutsche GROVE GmbH offers general and model-related courses for

crane operators and crane technology.
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 Fundamental safety instructions for crane operators
2.5 Safety instructions that apply to truck crane driving

2.5 Safety instructions that apply to truck crane driving

Walk around the truck crane before beginning to drive. Check the con-
dition of the truck crane carefully using the check lists in the operating
instructions. Do not assume that everything is in working order simply
because it was in working order when work was last completed.

Before driving, check whether all covers and safety devices are correctly
in place and whether they are in proper working order.

Use the appropriate access aids when checking overhead crane parts.
Do not use parts of the crane to gain access to these areas.

Keep all handles, steps, step treads and ladders free of dirt, snow and ice.

Check all operating and control elements in the driver’s cab before
starting the vehicle engine.

Monitor all warning and indicator lamps as well as the control instru-
ments when the engine is started!

Lock the truck crane after operation to prevent unauthorised use.

2.6 Safety instructions for truck crane work

Carefully select a safe site for the truck crane to stand from where you can
safely work.

Walk around the truck crane before beginning crane work. Check the
condition of the truck crane carefully using the check lists in the operating
instructions. Do not assume that everything is in working order simply
because it was in working order when work was last completed.

Before commencing work with the crane, check daily that all covers and
safety devices are correctly fitted and in an acceptable condition.

Check the safety devices each day before beginning work (SLI, lifting limit
switch, dead man’s switch, emergency stop switch for crane control).

Use the appropriate access aids when carrying out overhead rigging or
maintenance work. Do not use parts of the crane to gain access to these
areas.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 2-7
Fundamental safety instructions for crane operators
2.6 Safety instructions for truck crane work

Only step onto machine sections which are equipped with appropriate steps
and railings and therefore guarantee safety. During rigging and maintenance
work on machine sections above body height which have no apparatus for
stepping onto them, use the extendable ladder which accompanies the
machine (e. g., when reeving the hoist cable on the boom nose.

Keep all handles, steps, step treads and ladders free of dirt, snow and ice.

Check all operating and control elements in the crane operator’s cab
before starting the crane engine.

Monitor all warning and indicator lamps as well as the control instru-
ments when the engine is started!

Make sure that there are no unauthorised people in the vicinity of or on

the truck crane when rigging. Secure the danger zone using cordons and
label them as such.

When lifting a load, raise the boom to balance out the increase in radius
caused by the boom bending so that the load is lifted up when in a verti-
cal position and does not drag, injure helpers or fall into the hoist rope
diagonally (e. g. from a vehicle or scaffold). Inform banksmen and helpers
about this as well.

Support the truck crane with the supporting span for the current rigged
counterweight before turning the superstructure.

Ensure that the truck crane is horizontally aligned before carrying out
crane work.

Only use equipment (counterweight sections, lattice extensions) that

belongs to your truck crane. The serial number of both the truck crane
and the equipment must be identical.

Simultaneously lifting loads with two cranes is particularly dangerous.

Use extreme caution when carrying out this type of work.

When work is interrupted, always put the load down and never leave the
truck crane if a load is raised.

Lock the truck crane when you leave the cab to prevent unauthorised use.

Crane work carried out in the vicinity of supply lines such as oil, gas or
other supply lines is dangerous and requires that special precautionary
measures be taken. Please refer to the section titled Crane operation under
special operating conditions in the Safety manual and observe the relevant
national regulations.
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 _______________________________________________________________________________________ 3
3 Information for applications engineering . . . . . . . . . . . . 3- 1
3.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1.2 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
3.1.3 Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
3.2 Applications engineering . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
3.2.1 Application engineering requirements . . . . . . . . . . . . . . . . . . . . 3 - 3
3.2.2 Details about applications engineering contained in the user information . 3 - 4
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Operating Instructions GMK 6300 2 084 548 en

 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 Information for applications engineering
3.1 Safety instructions

3 Information for applications engineering

3.1 Safety instructions

3.1.1 Proper use

When scheduling applications, please remember that the GMK 6300 truck
crane may only be used for applications that do not violate any laws,
regulations or the Proper use of the unit as specified by the manufacturer.
Please refer to the section titled Proper use, p. 2-2.

3.1.2 Organizational measures

The manufacturer of your truck crane has no direct influence on the way
you use, operate or maintain the crane. You are therefore responsible for
ensuring the safe operation of the crane and the fulfillment of all laws and
regulations.

Ensure that the operating instructions are supplemented with any instruc-
tions required for special operational features, such as
– organization,
– work procedures,
– personnel,
– compulsory supervision and registration.

When using oils, lubricants and other chemical substances, ensure that
the safety regulations that apply to the respective product are strictly
observed.

Ensure that process materials and replaced parts are disposed of in an

environmentally friendly manner.

Monitor the work of the employees – at least occasionally – and ensure

that they are working in accordance with the operating instructions in a
responsible, conscientious manner and are aware of the related operatio-
01.02.2000

nal hazards.

s
Operating Instructions GMK 6300 2 084 548 en 3-1
Information for applications engineering
3.1 Safety instructions

Use only equipment that belongs to your particular truck crane, such as
counterweight sections and lattice extensions.
The serial number of both the truck crane and the equipment must be
identical.

Observe the lifting capacity table belonging to the truck crane or included
in the Operating Instructions. If the truck crane can be operated with
different counterweight versions, the counterweight sections may only be
assembled according to the counterweight versions given in the lifting
capacity table.

When loading the truck crane, please observe the national regulations
that apply to transport. In addition, please observe the prescribed safety
measures of the shipper (e. g. the carrying agent or railway carrier).

3.1.3 Personnel qualifications

Only qualified personnel may operate the truck crane. Please refer to
page 2-6 in the section titled Personnel qualifications.

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 Information for applications engineering
3.2 Applications engineering

3.2 Applications engineering

3.2.1 Application engineering requirements

Plan each application carefully. Gather information concerning the route,

including in particular
– the distance,
– the route,
– overhead clearances and
– the load bearing capacity of bridges.

Gather information about the job including

– the load bearing capacity and stability of the ground (soil, buildings),
– the weight and dimensions of the loads to be lifted,
– the type of load (degree of risk involved),
– required stroke length and radius,
– restricted movement due to buildings etc.

Have the necessary equipment arranged, such as

– lifting gear,
– counterweight,
– blocks for support etc.

H
Organise transportation and obtain any necessary driving permits.

When planning to use the luffing jib, be sure (especially in a steep posi-
tion) that the backmast can project to the rear up to 6.00 metres over the
set-up counterweight. This is especially true for places with little freedom
of movement (for example, between buildings).

Poor planning leads to improvisation – and improvisation is the cause of

many accidents!
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Operating Instructions GMK 6300 2 084 548 en 3-3

Information for applications engineering
3.2 Applications engineering

3.2.2 Details about applications engineering contained in the user

information

Extensive information must be available for applications engineering in

order to guarantee the safe, trouble-free, efficient use of the truck crane:

The operating instructions contain

– dimensions and weights (➠ p. 8-8),
– driving modes permitted on public roads (➠ p. 6-5),
– dimensions and weights of detachable equipment (➠ p. 8-9, p. 16-9),
– dimensions and turning circle radii for manoeuvring (➠ p. 8-13),
– permitted span (➠ p. 13-17),
– size of outrigger pads (➠ p. 8-11).

The lifting capacity table contains

– operating areas (operating-area curve of the boom),
– load bearing capacities for the permitted rigging modes,
– load bearing capacities for the permitted spans,
– SLI coding,
– permitted wind speeds,
– load reduction in certain rigging modes.

The outrigger pressure table contains

– outrigger pressures on the ground under the outrigger for various
rigging modes and boom directions

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 _______________________________________________________________________________________ 4
4 Description of the truck crane – vehicle section . . . . . . . 4- 1
4.1 Overview of the operating and display instruments . . . . . . . . . 4 - 1
4.1.1 Overview of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
4.1.2 Overview of driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 4
4.1.3 Front instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
4.1.4 Side instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
4.2 Functional description of the display and operating instruments 4 - 22
4.2.1 Instrument panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 22
4.2.2 Other operating instruments in the vehicle section . . . . . . . . . . . . . . 4 - 40
01.02.2000

Operating Instructions GMK 6300 2 084 548 en

 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4 Description of the truck crane – vehicle section

4.1 Overview of the operating and display instruments

This section only contains the operating and display instruments for
driving that are located on the outside of the truck crane or in the driver’s
cab.

4.1.1 Overview of the vehicle

The figures on the following pages illustrate the location of the operating
and control instruments that are required to drive the truck crane and are
found on the outside of the vehicle.

All operating and control instruments required for crane operation are
described in Chapter 10.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 4-1
Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

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4-2 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Access ladders to superstructure ➠ p. 4-41

2 Undercarriage-hydraulic system shutoff cocks ➠ p. 5-9
3 Battery master switch ➠ p. 5-8
4 Vehicle engine dipstick and oil filler ➠ p. 5-5
5 Compressed-air system emergency filler connection ➠ p. 7-7
6 Left-hand wing mirror ➠ p. 6-14
7 Driver’s cab ➠ p. 4-4
8 Vehicle engine coolant reservoir ➠ p. 5-7
9 Hydraulic oil tank, inspection glass ➠ p. 5-8
10 Proximity mirror ➠ p. 6-14
11 Wide-angle mirror ➠ p. 6-14
12 Right-hand wing mirror ➠ p. 6-14
13 Vehicle engine ➠ p. 5-1
14 Holder for extendable ladder ➠ p. 4-43
15 Windscreen washing system reservoir ➠ p. 6-11
16 Fuel tank fill plug ➠ p. 6-12
17 Automatic gearbox dipstick and oil filler ➠ p. 5-6
18 Central lubrication system grease container Maintenance
instructions

19 Ladder ➠ p. 4-42
20 Wheel chocks ➠ p. 6-32
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Operating Instructions GMK 6300 2 084 548 en 4-3

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.2 Overview of driver’s cab

7 8 9 10 11 12 13 14 15 16

19 18 17 C0933

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Side instrument panel ➠ p. 4-16

2 Adjustable driver’s seat ➠ p. 6-13
3 Rocker switch for separate steering ➠ p. 4-31
4 Steering wheel with adjustable steering column ➠ p. 6-13
5 Multipurpose switch ➠ p. 4-32
6 Retarder foot-operated switch ➠ p. 6-26
7 Front instrument panel ➠ p. 4-8
8 Ignition lock ➠ p. 4-32
9 Service brake pedal ➠ p. 6-20
10 Accelerator ➠ p. 6-20
11 Tiller switch eddy current retarder ➠ p. 4-29
(additional equipment)

12 Fuse box (under the guard) ➠ p. 7-17

13 Parking brake lever ➠ p. 4-28
14 Diagnostic plug for vehicle engine service ➠ p. 4-43
(under the covering)

15 Fire extinguisher (additional equipment) ➠ p. 4-44

16 Glove compartment

17 Folding berth (additional equipment) ➠ p. 4-44

18 Third seat (additional equipment)

19 Suspension operation pressure status display ➠ p. 4-28

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Operating Instructions GMK 6300 2 084 548 en 4-5

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

Over the The following fittings are mounted over the wind screen below the roof of
windscreen the driver’s cab:

1 2 3 4 5

C0712

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Sun screen
2 Loudspeaker
3 Radio
4 Air conditioning (additional equipment) or ➠ p. 4-37
roof ventilator (additional equipment)
5 Cab lighting ➠ p. 4-38
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Operating Instructions GMK 6300 2 084 548 en 4-7

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.3 Front instrument panel

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4-8 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Ventilating nozzle ➠ p. 4-36

2 Status display for supply pressure brake ➠ p. 4-28
circuits I and II

3 Status display for oil temperature in hydraulic system ➠ p. 4-30

4 Status display for automatic gearbox oil temperature ➠ p. 4-23
5 Status display for automatic gearbox oil pressure ➠ p. 4-23
6 Indicator lamp for hydraulic oil return flow filter ➠ p. 4-30
7 Control lamp eddy current retarder (additional ➠ p. 4-29
equipment)

8 ABS warning light for trailer (additional equipment) ➠ p. 4-28

9 Warning lamp for steering circuit I ➠ p. 4-30
10 Indicator lamp for driving direction ➠ p. 4-32
11 Automatic gearbox oil filter indicator lamp ➠ p. 4-23
12 Suspension locking system indicator lamp ➠ p. 4-29
13 Indicator lamp for steering circuit II ➠ p. 4-30
14 Indicator lamp for driving direction for trailer ➠ p. 4-32
(additional equipment)

15 Rocker switch with indicator lamp for hazard warning ➠ p. 4-33

system

16 Rocker switch for suspension locking system ➠ p. 4-29

17 Roof ventilator rocker switch (additional equipment) ➠ p. 4-36
18 Rocker switch with indicator lamp for wing-mirror ➠ p. 4-33
heating
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Operating Instructions GMK 6300 2 084 548 en 4-9

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

01.02.2000

4 - 10 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Trip recorder with tachometer ➠ p. 6-14

2 “Boom not placed down” warning lamp (additional ➠ p. 4-39
equipment) 1)

“Danger of collision” warning lamp (only with GMK 6300

additional equipment with telescopic swing-away Lattice
lattice extension) 1) extension
operating
manual
1)
If the truck crane is with both sets of additional equipment, this lamp
will take on both functions.
01.02.2000

Operating Instructions GMK 6300 2 084 548 en 4 - 11

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

°C

40 120

2 3

4 5 6 7 8 9
l L @ h p q
f c 5 4 t z
0 q w e r t
z
à
æ r ! . : è
u i o p a
C0709

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4 - 12 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Ventilating nozzle ➠ p. 4-36

2 Status display with warning lamp for vehicle engine ➠ p. 4-22
coolant temperature

3 Status display for fuel reserve ➠ p. 4-22

4 Warning lamp for supply pressure brake circuits I and II ➠ p. 4-28
5 Warning lamp for charge indicator ➠ p. 4-22
6 Indicator lamp for full-beam headlight ➠ p. 4-33
7 Indicator lamp for transverse differential lock in all ➠ p. 4-27
driven axle lines

8 Indicator lamp for vehicle engine air filter ➠ p. 4-22

9 Warning lamp for engine faults battery charge indicator ➠ p. 4-32
10 Indicator lamp for vehicle parking brake ➠ p. 4-28
11 Indicator lamp for drive of second axle line / ➠ p. 4-27
longitudinal differential locks

12 Indicator lamp for off-the-road gear ➠ p. 4-26

13 Indicator lamp for on-road gear ➠ p. 4-26
14 Indicator lamp for vehicle engine coolant level ➠ p. 4-22
15 Indicator lamp for flame-start device ➠ p. 4-22
(additonal equipment)

16 Indicator lamp for engine electronic ➠ p. 4-23

17 Rocker switch with fog lamp and tail light indicator ➠ p. 4-33
lamp (additonal equipment)

18 Rocker switch with indicator lamp for rotating beacon ➠ p. 4-33

19 Parking light / headlight rocker switch ➠ p. 4-33
20 Rocker switch for adjusting speed ➠ p. 4-23
21 Switching on/off the cruise control rocker switch ➠ p. 4-23
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Operating Instructions GMK 6300 2 084 548 en 4 - 13

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

2 4
1 3

5 6

C0714

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Heating temperature regulator ➠ p. 4-35

2 Recirculated air / fresh air regulator ➠ p. 4-35
3 Driver’s side air distribution regulator ➠ p. 4-35
4 Passenger side air distribution regulator ➠ p. 4-35
5 Driver’s side heater fan knob ➠ p. 4-35
6 Passenger side heater fan knob ➠ p. 4-35
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Operating Instructions GMK 6300 2 084 548 en 4 - 15

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

4.1.4 Side instrument panel

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4 - 16 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Rocker switch for off-the-road gear transfer case ➠ p. 4-26

2 Rocker switch for transfer case neutral position ➠ p. 4-26
3 Rocker switch for on-road gear transfer case ➠ p. 4-26
4 Rocker switch for transverse differential lock in all ➠ p. 4-27
driven axle lines

5 Indicator lamp for additional heating system ➠ p. 4-36

(additional equipment)

6 Separate steering indicator lamp ➠ p. 4-31

7 Rocker switch with automatic gearbox driving mode lock ➠ p. 4-25
button

8 Switch with diagnostic warning lamp for automatic ➠ p. 4-24

gearbox

9 Drive 2nd axle line/transverse differential lock rocker ➠ p. 4-27

switch

10 Rocker switch with separate steering lock button ➠ p. 4-30

11 Unlocked steering warning lamp ➠ p. 4-31
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Operating Instructions GMK 6300 2 084 548 en 4 - 17

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 2 3 4

=#
vÄ
<Å
ôÆ
5 6 7 8

C0958

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 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Warning light for the automatic gearbox shift lock ➠ p. 4-25

2 Switch for limited driving range 1 ➠ p. 4-25
automatic gearbox

3 Switch for limited driving range 2 ➠ p. 4-25

automatic gearbox

4 Switch for limited driving range 3 ➠ p. 4-24

automatic gearbox

5 Driving range switch R automatic gearbox ➠ p. 4-24

6 Neutral position switch N automatic gearbox ➠ p. 4-24
7 Switch for driving range D automatic gearbox ➠ p. 4-24
8 Switch for limited driving range 4 ➠ p. 4-24
automatic gearbox
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Operating Instructions GMK 6300 2 084 548 en 4 - 19

Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

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4 - 20 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – vehicle section
4.1 Overview of the operating and display instruments

1 Rocker switch for level adjustment system, right ➠ p. 4-34

2 Key switch for level adjustment ➠ p. 4-34
3 Rocker switch for level adjustment system, front ➠ p. 4-34
4 Rocker switch for level adjustment system, rear ➠ p. 4-34
5 Rocker switch for level adjustment system, left ➠ p. 4-34
6 Indicator lamp for raising vehicle level ➠ p. 4-34
7 Indicator lamp for no on-the-road level ➠ p. 4-34
8 Rocker switch with indicator lamp for additional ➠ p. 4-36
heating system (additional equipment)*)

9 Rocker switch for raising/lowering vehicle level ➠ p. 4-34

10 Indicator lamp for lowering vehicle level ➠ p. 4-34
11 Rocker switch for raising/lowering truck crane ➠ p. 4-35
12 Rocker switch for on-the-road level ➠ p. 4-35
13 additional heating system with timer*) ➠ p. 4-38
(additional equipment)

14 Return press button ➠ p. 4-39

15 Heating system display ➠ p. 4-38
16 Flow push button ➠ p. 4-39
17 “Heating system switched on” indicator lamp ➠ p. 4-39
18 Storage location 1 push-button ➠ p. 4-39
19 Storage location 2 push-button ➠ p. 4-39
20 Display/set time push button ➠ p. 4-38
21 Switch heating system on/off push-button ➠ p. 4-39
22 Automatic heating start indicator lamp ➠ p. 4-39

*) Either 8 or 13 possible as additional equipment.

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Operating Instructions GMK 6300 2 084 548 en 4 - 21

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

4.2 Functional description of the display and operating

instruments
Definition of direction information for using operating elements; ➠ p. 1-16.

4.2.1 Instrument panels

Vehicle engine

Indicator lamp for flame-start (additional equipment)

z The lamp will go on if the motor is stated when its cold.
It goes out when the motor is ready to start (waiting time can be up to
20 seconds, depending on the temperature of the motor coolant);
➠ Starting a cold vehicle engine, p. 5-11.
Warning lamp for vehicle engine oil pressure
L The oil pressure cannot fall while the vehicle is being driven.
The warning lamp for vehicle engine oil pressure goes on if the oil pressure
falls to below 0.4 bar; ➠ p. 5-10, ➠ p. 5-13.

Vehicle engine coolant temperature display

°C
The temperature of the coolant may only increase to 95 °C on uphill
40 120
routes; ➠ p. 6-23.

C0012

Indicator lamp for vehicle engine coolant level

t Illuminates if the coolant level is too low; ➠ p. 6-23.

Indicator lamp for vehicle engine air filter

p Illuminates when the air filter is dirty.
Change the filter element; ➠ Maintenance manual.

Status display for fuel reserve

Never allow the fuel tank run completely empty! ➠ p. 6-12.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Engine electronics warning lamp

à This lights up when the motor is off and the ignition is switched on.
It goes out after the engine has been started.
It lights when the engine is running and there is an engine electronic
system malfunction; ➠ p. 7-21.

Switching on/off the cruise control rocker switch

Switching on: Press up the rocker switch for the desired speed
(min. 30 km/h).
Switching off: Press rocker switch down;

➠ p. 6-28.

Rocker switch for setting the speed

: To increase Press rocker switch up.
speed:
To decrease Press rocker switch down;
speed:

➠ p. 6-28.

Automatic
gearbox ➠ Operating the automatic gearbox, p. 6-17
Status display for the automatic gearbox oil temperature
°C
The gear oil temperature may not exceed 110 °C during on-road driving
50 150
with overridden torque converter; ➠ p. 6-24.

C0008

Status display for the automatic gearbox oil pressure

bar
The gearbox oil pressure must be between 10 to 12 bar while driving and
0 25
when in neutral gear N; ➠ p. 6-25.

C0007

Automatic gearbox oil filter warning lamp

m
01.02.2000

Illuminates if the gear box oil filter is dirty. Change the filter element;
➠ Maintenance Manual.

s
Operating Instructions GMK 6300 2 084 548 en 4 - 23
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Switch with diagnostic warning lamp for automatic gearbox

. For determining an error code when the automatic gearbox malfunctions.
(Only for qualified repair staff; ➠ p. 6-19.)

Switch for driving range R of the automatic gearbox

= May only be engaged when the vehicle is stationary and the vehicle
engine is running at idling speed.
The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly.
The truck crane drives backwards in driving range R; ➠ p. 6-18.

Switch for neutral position N of the automatic gearbox

> May only be pressed when the vehicle is stationary. The parking brake or
service brake must be used to brake the vehicle.
The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly.
The automatic gearbox must always be shifted to neutral position N in
order to start the undercarriage engine; ➠ p. 6-17.

Switch for driving range D of the automatic gearbox

< May only be engaged when the vehicle is stationary and the vehicle
engine is running at idling speed.
The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly.
The gearbox always runs in second gear and switches automatically
between gears by means of the hydraulic torque converter; ➠ p. 6-18.

Switch for limited driving range 4 automatic gearbox

ô The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly. The gearbox runs in second
gear and only switches between the second and fourth gears and back.

Switch for limited driving range 3 automatic gearbox

Æ The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly. The gearbox runs in second
gear and only switches between the second and third gears and back.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Switch for limited driving range 2 automatic gearbox

Å The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly. The gearbox only runs in
second gear.
Driving range 2 is suitable for driving off-road.

Switch for limited driving range 1 automatic gearbox

Ä The pressing of the switch is confirmed with an acoustic signal and the
indicator lamp in the switch lights up briefly. The gearbox only runs in
first gear.
In the first gear the full braking power of the engine can be used for travel-
ling downhill.
Driving range 1 is for manoeuvring and off-the-road travel or icy
conditions.

Warning lamp for shift lock in automatic gearbox

# Illuminates when a malfunction of the automatic gearbox occurs.
An acoustic signal sounds for ca. 10 seconds and the gearbox in locked
position is activated; ➠ p. 6-18.

Rocker switch with lock button for automatic gearbox driving mode
î Driving mode E (= Economy): The gearbox will only shift at lower engine
speeds into the next highest gear.
Driving mode E for driving on flat, even surfaces.

Driving mode P (= Power): The gearbox will shift at higher engine speeds
into the next highest gear. Acceleration power and speed on inclining
routes is higher than that of driving mode E.
Driving mode P for driving uphill or off-road.

Driving mode E: Press rocker switch up.

Driving mode P: Press rocker switch down.

➠ p. 6-19.
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Operating Instructions GMK 6300 2 084 548 en 4 - 25
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Transfer case ➠ Off-the-road gear, p. 6-36

Rocker switch for transfer case on-the-road gear
4 May only be pressed when the vehicle is stationary and the automatic
gearbox is in neutral position N.
Activate on-the-road gear: Press rocker switch down.

Indicator lamp for on-the-road gear

4 Illuminates when on-the-road gear is active.
Goes out in neutral position and off-the-road gear.

Rocker switch for transfer case off-the-road gear

5 May only be pressed when the vehicle is stationary and the automatic
gearbox is in neutral position N.
Engage the off-the-road gear: Press rocker switch down.

Indicator lamp for off-the-road gear

5 Illuminates when off-the-road gear is active.
Goes out in neutral position and on-the-road gear.

Rocker switch for transfer case neutral position

v May only be pressed when the vehicle is stationary and the automatic
gearbox is in neutral position N.
To switch on: Press rocker switch down.

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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Axle drive The drive of the second axle line / longitudinal differential locks and the
transverse differential locks can only be switched on when the off-the-
road gear is switched on and the key-operated switch of the level adjust-
ment system is pressed; ➠ p. 6-41.
Rocker switch for drive of second axle line / longitudinal differential locks
c Activates the drive of the first, fourth and fifth axle lines as well as the
drive of the second axle line. The longitudinal differential locks in the
transfer case and in the fourth axle line are switched on simultaneously.
May only be activated when the vehicle is stationary or is moving at a
speed of no more than 3 km/h.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.

➠ p. 6-37.
Indicator lamp for drive of 2nd axle line / longitudinal differential locks
c To check the switch states:
– Drive of 2nd axle line, on/off
– Longitudinal differential lock in transfer case on/off,
– Longitudinal differential lock on the 4th axle line on/off
Illuminates when one of the three numbered switch states is mechanically
switched on.
Goes out when all three of the numbered switch states are mechanically
switched off (if present).
➠ p. 6-37.

Transverse differential lock in all driven axle lines rocker switch

h Locks the transverse differentials in all driven axle lines.
May only be activated when the vehicle is stationary or is moving at a
speed of no more than 3 km/h.
To switch on: Press rocker switch down.
To switch off: Press rocker switch up; ➠ p. 6-39.

Indicator lamp for transverse differential lock in all driven axle lines
h Illuminates if all transverse differential locks have been switched on.
Flashes if all transverse differential locks have not be switched on or off.
Goes out if all transverse differential locks have been switched off;
➠ p. 6-39.
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Operating Instructions GMK 6300 2 084 548 en 4 - 27
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Brakes
Status display for supply pressure brake circuits I and II
4 5
6
3 7 The operating pressure is approx. 8 bar.
2 8

1 9
The pressure in both brake circuits must be over 5.5 bar for driving mode;
0 bar 10 ➠ p. 6-22.
C0005

Warning lamp for supply pressure brake circuits I and II

l Goes out if the supply pressure in both brake circuits is over 5.5 bar.
Illuminates if the supply pressure decreases to less than approx. 5 bar;
➠ p. 6-22.

Parking brake lever

Release parking brake: Lift the locking ring on the parking brake lever and
push the parking brake lever forward as far as it will go.
Locking the parking brake: Pull the parking brake lever back until it locks
into place.
C0027
Operation as an auxiliary brake: The braking force can be continuously
regulated with the parking brake lever. The allows the parking brake to be
also used as an auxiliary brake.

Test position when driving with a trailer:

The parking brake lever can also be pressed in and pulled back into the
Test position of the parking brake when towing a trailer; ➠ p. 6-68.

Indicator lamp for vehicle parking brake

f Goes out if parking brake is released.

ABS warning light for trailer (additional equipment)

y Goes out when driving speed exceeds approx. 6 km/h. Illuminates when a
malfunction occurs in the trailer ABS; ➠ p. 6-22.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Tiller switch for eddy current retarder (additional equipment)

Switching on the eddy current retarder:
Set the tiller switch from the 0 position to a switch stage from 1 – 4.

Switching off the eddy current retarder:

Set the tiller switch in the 0 position; ➠ p. 6-30.

Indicator lamp for eddy current retarder (additional equipment)

ê Goes on if the eddy current retardar is on; ➠ p. 6-30.

Suspension
Rocker switch for suspension locking system
u Locks all suspension cylinders in the respective position;
➠ p. 6-8,
➠ Preparing the outriggers, p. 13-20.
To switch on: Press rocker switch down.
To switch off: Press rocker switch up.

Indicator lamp for suspension locking system

u Illuminates if the suspension is locked.
Goes out if suspension locking system is released;
➠ p. 6-8,
➠ Prepare the outrigger, p. 13-20.
Suspension operating pressure status display
Displays the operating pressure on the individual axle lines in the suspen-
sion groups.

1 Suspension operating pressure

2 Suspension operating pressure

3 Suspension operating pressure

4 Suspension operating pressure

5 Suspension operating pressure

6 Suspension operating pressure

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Operating Instructions GMK 6300 2 084 548 en 4 - 29
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Hydraulics
Status display for hydraulic system oil temperature
°C
The hydraulic oil temperature should not exceed 70 °C in normal driving
mode; ➠ p. 6-25.

C0006

Indicator lamp for hydraulic oil return flow filter

g Illuminates if both the filters are dirty.
Change the filter elements; ➠ Maintenance Manual.

Steering Separate steering; ➠ p. 6-45.

Steering circuit warning light I
d Illuminates if the oil pressure in steering circuit I decreases while driving.
Does not go out until the truck crane is travelling at a speed of approx.
10 km/h; ➠ p. 6-22.

Warning lamp for steering circuit II

e Illuminates if the oil pressure in steering circuit II decreases while driving;
➠ p. 6-22.
Separate steering rocker switch with lock button
b Is only active when the key-operated switch Level adjustment system is pres-
sed. By pressing the switch, the separate steering is switched on and off;
the necessary locking and unlocking procedures begin on the axle lines,
the hydraulics are switched over and electronics are switched on or off.

Switching on separate steering: Release rocker switch and press

down

Switch off separate steering: Release rocker switch and press up

➠ Switch on the separate steering, p. 6-46.

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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

“Steering unlocked” warning lamp

? Lights up as soon as the first lock is released.
It goes out when all locking procedures have been finished.
➠ p. 6-46.
Separate steering indicator lamp
b Lights up when all unlocking procedures have been finished, the hydrau-
lic system for separate steering is switched over and the electronics of the
separate steering is ready.
It goes out when all locking procedures have been finished, the hydraulic
system has been switched over to on-road driving and the electronics of
the separate steering has been switched off; ➠ p. 6-46.
Flashes if there is a malfunction in the separate steering or electronics.
➠ p. 7-26.
Separate steering rocker switch
b Steers the wheels of the 5th and 6th axle lines
Turn to the left: push control lever to the left;
Turn to the right: push control lever to the right;

➠ p. 6-47.
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Operating Instructions GMK 6300 2 084 548 en 4 - 31
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Electrical system
Ignition lock
0 Ignition off, vehicle engine off, key can be removed
1 Power supply on for:
Heating, automatic gearbox diagnosis switch,
Radio/telephone (additional equipment)
2 Ignition on
3 Starting position

➠ p. 5-10

Warning lamp for charge indicator

q Illuminates if the ignition is switched on and the vehicle engine is
switched off.
Goes out after the vehicle engine is started; ➠ p. 5-10; ➠ p. 5-13.

Multipurpose switch
1 Horn
2 Headlight flasher
3 Low-beam headlight
4 High-beam headlight
5 Driving direction indicator, right
6 Driving direction indicator, left
7 Windscreen washer
8 Windscreen wiper
0 = off
I = interval
II = slow
III = fast

Indicator lamp for driving direction

i
Indicator lamp for driving direction for trailer (additional equipment)
j
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Rocker switch for parking light / headlight

! Switch off light: Press rocker switch up
Parking light: Rocker switch in mid-position
Headlight: Press rocker switch down
The headlight is switched from low-beam to high-beam by means of the
multipurpose switch.
The instrument lighting is switched on with the parking light / headlight.

Indicator lamp for full-beam headlight

@
Rocker switch with fog lamp and tail light indicator lamp (accessory)
æ The rear fog light and the fog lamps may only be switched on with low-
beam headlight.
Switch fog lamp / rear light off: Press rocker switch up
Switch fog lamp on: Rocker switch in mid-position
Switch fog lamp / rear light on: Press rocker switch down
The indicator lamp in the rocker switch illuminates when the rear fog light
is switched on.

Rocker switch with hazard warning system indicator lamp

k To switch on: Press rocker switch down.
The indicator lamp in the rocker switch flashes.
To switch off: Press rocker switch up.

Rocker switch with indicator lamp for rotating warning beacon

r To switch on: Press rocker switch down.
The indicator lamp in the rocker switch illuminates.
To switch off: Press rocker switch up.

Rocker switch with indicator lamp for wing-mirror heating

s To switch on: Press rocker switch down.
The indicator lamp in the rocker switch illuminates.
To switch off: Press rocker switch up.
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Operating Instructions GMK 6300 2 084 548 en 4 - 33
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Level adjustment ➠ Level adjustment system, p. 6-40;

Key switch for level adjustment system
To switch on: Insert key into the switch. Turn the key to the right, push
in the lock cylinder and turn the key to the left. The key
cannot be pulled out.
To switch off: Turn key to right. The resiliency causes the lock cylinder
C0018 to go back to its original position. Pull out the key.
The following functions may only be used when the key switch for the
level adjustment system is activated:
– Carrier level adjustment system
– Transverse differential locks
– Drive of the second axle line / longitudinal differential locks
In driving range D, the automatic gearbox only engages gears 1 and 2
when the level adjustment system is on.

Rocker switch for raising / lowering vehicle level

: To preselect the vertical direction of movement for the Level adjustment left /
forward / backward / right rocker switch
Raising the vehicle level: Press rocker switch up.
Lowering the vehicle level: Press rocker switch down.

Indicator lamp for raising vehicle level

8 Illuminates if the Raise / lower vehicle level rocker switch has been pressed
up.

Indicator lamp for lowering vehicle level

9 Illuminates if the Raise / lower vehicle level rocker switch has been pressed
down.

Rocker switch for left / forward / backward / right level adjustment

6897 Raises or lowers the truck crane to the left, forward, backward or to the
right (depending on the position of the Raise / lower vehicle level rocker
switch).

Indicator lamp for no on-the-road level

{ Illuminates when the truck crane Level adjustment key switch is not at
on-the-road level.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Rocker switch for on-the-road level

{ To switch on: Press rocker switch down, until on-the-road level is
reached.
The No on-the-road level indicator lamp goes out when the truck crane has
reached the on-the-road level.

Rocker switch for raising / lowering truck crane

| Raising the truck crane: Press rocker switch up.
Lowering the truck crane: Press rocker switch down.

Driver’s cab Heating system regulation ➠ p. 6-51

heating system
1 Regulator for heating temperature
up: cold
down: warm
2 Regulator for recirculated air / fresh air
mode
up: fresh air mode
down: recirculated air mode
3 Regulator for air distribution on the
driver’s side
up: windscreen vents and air vent on the
instrument panel
down: cab floor
4 Regulator for air distribution on the
passenger’s side
up: windscreen vents and air vent on the
instrument panel
down: cab floor
5 Passenger side heater fan knob
off: as far as possible to the left
on: to the right, engages in three notches
6 Driver’s side heater fan knob
off: as far as possible to the left
on: to the right, engages in three notches
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Operating Instructions GMK 6300 2 084 548 en 4 - 35
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Air vent with air flow regulator

1 Adjustable ventilation louvre
1 2 2 Air flow regulator

➠ p. 6-52
C0009

Roof ventilator rocker switch (additional equipment)

~ Remove air: Press rocker switch up
Off: Rocker switch in mid-position
Air in: Press rocker switch down;
➠ p. 6-53

Roof fan handwheel (additional equipment)

Closing the roof ventilator: Turn handwheel to the left
Opening roof ventilator: Turn handwheel to the right;
➠ p. 6-53

Rocker switch with indicator lamp for additional heating system

0 (additional equipment)
To switch on: Press rocker switch down.
The indicator lamp in the rocker switch only indicates that
the switch has been activated. It does not indicate
whether the heating system ignited.
To switch off: Press rocker switch up.
The indicator lamp in the rocker switch goes out;
➠ p. 6-54.

Indicator lamp for additional heating system (additional equipment)

0 Illuminates when the heating system has ignited; ➠ p. 6-54.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Air conditioning The air-conditioning system is located on the roof of the driver’s cab.
system (additio- There are two different designs which are distinguished by the location of
nal equipment) the operating instruments. The function of the operating instruments is
the same with both versions; ➠ p. 6-59.

Version A
1 1 Air exit vents
2 Knob switch for fan
3 Knob switch for thermostat
4 Air exit vents, adjustable for air quantity
and direction
2

4
C0720

Version B
1 Air exit vents
2 Knob switch for thermostat
3 Knob switch for fan
4 Air exit vents

Fan knob
0 Fan and air-conditioning system off
1 Low output level
2 Medium output level
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3 High output level

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Operating Instructions GMK 6300 2 084 548 en 4 - 37
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Knob switch for thermostat

Turning the knob switch to the right increases the cooling output.

Cab lighting Cab lighting is fitted on the driver’s and passenger’s side of the driver’s cab.

1 Cab light
2 Switch for cab light pressed in forward:
on by door contact
central position: off
pressed in rearward: on
3 Switch for reading lamp
4 Reading lamp

4
3
2
1

C0721

Additional hea- Operating the additional heating system with timer; ➠ p. 6-56.
ting system with
timer (additional
equipment)
The operating instruments in the following section are in the plug-in mo-
dule of the additional heating system with the timer and are only present
with additional equipment.

Heating system display

Serves as a display for the time and selected storage places for the auto-
matic heating start and for the input of times.

Time display/set push-button

w This is used to display and set the current time.
01.02.2000

To set, also push the Forward or Reverse push-button.

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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Reservoir 1 push-button
M This is used to display and to switch an automatic heating start on and off
for reservoir 1.

Reservoir 2 push-button
N This is used to display and to switch an automatic heating start on and off
for reservoir 2.

Switching heating on/off push-button

L For switching the heating on and off manually.

Return push-button
J To enter the time for the automatic heating start and to set the current
time (in combination with the Display/set time push-button).

Flow push-button
K To enter the time for the automatic heating start and to set the current
time (in combination with the Display/set time push-button).

Heating system indicator lamp switched on

This lights up when the additional heating system is switched on.
It goes out when the additional heating system has been switched off.

Automatic heating start indicator lamp

This lights up when an automatic heating start has been activated.
It goes out when the automatic heating start been switched off.

Other operating
instruments
"Boom not set down warning" lamp (additional equipment)
3 This lights up when the ignition in the driver’s cab is on if the boom is not
in the boom support.
A warning buzzer sounds at the same time. The warning lamp and buzzer
indicated that the vehicle height given in the driver’s cab is exceeded at
on-the-road level; ➠ p. 6-10.
For additional equipment with telescopic swing-away lattice extension,
this lamp simultaneously takes on the function of the Collision danger
01.02.2000

warning lamp; ➠ GMK 6300 Lattice extension operating manual.

Operating Instructions GMK 6300 2 084 548 en 4 - 39

Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

4.2.2 Other operating instruments in the vehicle section

Keys, doors, The following keys belong to the truck crane carrier:
windows

1 Trip recorder lock

2 Door locks of the driver’s cab
3 Driver’s cab ignition lock
4 Key-operated switch for level adjustment
system
5 Carrier guards

The locks on the doors of the driver’s cab

may be locked from the outside using the
door key (1).

Open lock: Turn key to right.

Close lock: Turn key to left.
Open door: Press button (2).

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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

When the doors are closed, they can be locked from the inside with the
knob.

Open lock: Push button (3) up.

Close lock: Press button (3) down.
Open door: Pull (2) lever.
The sliding windows in the door may be
opened from the inside using release lever
(1) or (4).

The sliding window on the right-hand side

of the driver’s cab may also be opened using
release levers.

Access ladders Ladders and steps are fixed to the truck crane for access to the carrier.

A fixed ladder (2) is located on the right side

and another on the left side between the
fourth and fifth axle lines. There are two
hand holes (1) and a grip (3) above each
fixed ladder.

Two more fixed ladders are located on both

sides behind the 3rd axle line.
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Operating Instructions GMK 6300 2 084 548 en 4 - 41
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Ladders There is a ladder fixed to the rear right of the carrier platform. Furthermo-
re an extendible ladder is supplied for rigging work; Extendible ladder,
➠ p. 4-43.
The ladder (1) for accessing the crane carrier
is secured in the holder (2).

G
Danger from ladder falling down!
Secure the ladder in the appropriate holder after each use. In this way,
you prevent the ladder from falling down during on-road driving which
could endanger vehicles behind you or people standing at the side of the
road.

The ladder for accessing the superstructure

is attached to either to the bore holes (2) to
the rear on the right on the carrier or in the
bore holes (1) at the height of the counter-
weight platform,

• Attach the ladder so that the plugs go as

far as possible in the bores.
• Fold out the spreader at the bottom of the
ladder so that you have a safe stopper on
the sheet metal panel or the tyres.
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 Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

The extendible ladder can be transported in

a foldable holder (1) at the front underneath
the truck crane.
The holder with the extendible ladder is fol-
ded up and the lock (2) engages for transport.

Vehicle engine The diagnostic plug enables the Mercedes-Benz service to connect mea-
diagnostic plug suring devices and may only be used by service personnel.

The diagnostic plug (1) is located on the

right next to the fuses and behind the cover.
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Operating Instructions GMK 6300 2 084 548 en 4 - 43
Description of the truck crane – vehicle section
4.2 Functional description of the display and operating instruments

Fire extinguisher The fire extinguisher (additional equipment) is on the cab floor between
(additional the driver and passenger seat.
equipment)
• Follow the instructions for use on the fire extinguisher.
• Have the fire extinguisher serviced in good time by trained personnel
before the service interval given on the label expires.
Proper functioning of the fire extinguisher is no longer guaranteed once
the service interval given on the label has expired.

Folding bunk The folding bunk is located in the driver’s cab on the rear wall.
(additional To fold out the folding bunk you must tilt the back rest of the passenger
equipment) seat (if necessary also the middle seat) completely forward.

Folding down folding bunk

• Release the locking device by pulling on
the loop (2) and fold the bunk (3) down-
wards.
• Fasten the two securing belts into the
brackets (4) on the cab roof.
Folding away folding bunk
• Remove the two securing belts from the
brackets (4) and lay the belts on the
folding bunk.
• Fold away the folding bunk and push it
into the rear wall of the cab so that the
securing pin audibly engages behind the
mounting bracket (1).

G
Risk of accident due to bunk folding down!
Always check after folding away that the bunk sits firmly in the locking
devide and put the back rest of the passenger seat back into the upright
position. By doing this you avoid the folding bunk folding down when
braking or when emergencies provoke uncontrolled manoeuvres.

Fold away the bunk before each journey!

When the bunk is folded down, the operating instruments on the side
instrument panel which are needed for driving are hidden.
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 _______________________________________________________________________________________ 5
5 Vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1 Starting / turning off vehicle engine . . . . . . . . . . . . . . . . . . . 5 - 1
5.1.1 CHECK LIST: Starting vehicle engine . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1.2 CHECKLIST: In winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
5.1.3 Checks before starting up vehicle engine . . . . . . . . . . . . . . . . . . . 5- 4
5.1.4 Starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
5.1.5 Inspections after the engine has been started . . . . . . . . . . . . . . . . . 5 - 13
5.1.6 Turning off the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
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Operating Instructions GMK 6300 2 084 548 en

 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 Vehicle engine
5.1 Starting / turning off vehicle engine

5 Vehicle engine

5.1 Starting / turning off vehicle engine

5.1.1 CHECK LIST: Starting vehicle engine

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Check the oil level in the vehicle engine; ➠ p. 5-4.

2. Carry out precheck on oil level in automatic gearbox; ➠ p. 5-6.

3. Check the coolant level of the vehicle engine; ➠ p. 5-7.

4. Check oil level in the hydraulic system; ➠ Checking hydraulic oil level,
p. 5-8.
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Operating Instructions GMK 6300 2 084 548 en 5-1
Vehicle engine
5.1 Starting / turning off vehicle engine

5. Check the position of the stop cocks in the hydraulic system;

➠ Checking stop cocks in the hydraulic system, p. 5-9.

C0750

6. Switch on the battery master switch; ➠ p. 5-8.

7. Check whether the parking brake is locked (parking brake lever points
toward the rear).

C0027

8. Turn on ignition and check instruments; ➠ p. 5-10.

9. Shift the automatic gearbox to neutral position N; ➠ Operating the

> automatic transmission, p. 6-17.

10. Wait until the indicator lamp flame start system (additional equipment)
z goes out.

11. Starting vehicle engine; ➠ Starting the vehicle engine, p. 5-11.

12. Check instruments when the vehicle engine is running; ➠ Checking the
01.02.2000

instruments, p. 5-13.

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 Vehicle engine
5.1 Starting / turning off vehicle engine

13. Check the oil level in the automatic gearbox when the gear oil is cold;
➠ Checking the automatic gearbox oil level, p. 5-6.

14. Also observe the In winter checklist when the temperatures are low;
➠ p. 5-3.

5.1.2 CHECKLIST: In winter

The following additional points must be observed when using the truck
crane in winter:

1. Fuel and engine oil must comply with the specifications given in the
supplied vehicle engine manufacturer operating manual for the re-
spective external temperatures.

2. The engine coolant must contain sufficient antifreeze (see supplied ve-
hicle engine manufacturer’s operating manual).

3. The vehicle engine can be pre-warmed by the engine-independent ad-

ditional water heating system. ➠ Auxiliary water heating system, p. 6-54.
01.02.2000

Operating Instructions GMK 6300 2 084 548 en 5-3

Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.3 Checks before starting up vehicle engine

Checking engine Check the oil level in the vehicle engine daily before commencing work.
oil level The dipstick has been marked to check drive motor when it is not running.

The dipstick (1) for the vehicle engine is on

the left side of the carrier (looking in the
direction of travel) behind the driver’s cab.

Prior to main check

• Check the oil level using the dipstick (1).

The oil level has to be at the max.-mark
(arrow marks).
• If necessary, fill the motor oil up to the
max.-mark.

Inspection

• Start the vehicle engine and let it run in idling speed. Observe the oil
01.02.2000

pressure display.

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 Vehicle engine
5.1 Starting / turning off vehicle engine

S
Damage may occur to the engine if the oil level is too low!
If no oil pressure is shown after 10 seconds, turn off the motor and deter-
mine the cause; ➠ Malfunctions of the vehicle engine, p. 7-21.

• Switch off the engine after approx.

1 minute.
• After about five minutes, check whether
the oil level on the dipstick is at the
max.-mark (arrow marks).
• If necessary, fill the motor oil up to the
max.-mark.

Adding engine oil Data concerning the prescribed oil specification may be found in the
Mercedes-Benz operating manual.
The oil filler-neck (1) for the vehicle engine is
on the left side of the carrier (looking in the
direction of travel) behind the driver’s cab,
next to the dipstick.

• Refill the motor oil over the fillplug (1).

S
Damage may occur to the engine if the oil level is too high!
Do not fill with too much engine oil; the oil level must not be higher than
the highest arrow marking (max).
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Operating Instructions GMK 6300 2 084 548 en 5-5
Vehicle engine
5.1 Starting / turning off vehicle engine

Check oil level in This check is carried out before the vehicle engine is started and helps to pre-
automatic gear- vent gear damage caused by undetected loss of oil. The exact oil level can
box only be established when the engine is running.

The dipstick (1) is located on the right side of

the carrier (looking in the direction of travel)
behind the vehicle engine.

Check the oil level in the automatic gearbox

daily before starting the vehicle engine. The
truck crane must be on a level surface when
the oil is checked.

S
Damage to gearbox may occur!
This check is a precheck. If the oil level is not clearly above the
“warm range”, the engine must not be started.

• Remove the dipstick from the dipstick tube.

• Check the oil level. It must be well above
the upper mark (1).
• As necessary top up the oil with the dip-
stick tube. Data concerning the prescribed
oil specification ➠ maintenance manual.
When you have topped up the oil, the oil
level must be checked when the oil is warm;
➠ Checking oil level in automatic gearbox, p. 5-14.
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 Vehicle engine
5.1 Starting / turning off vehicle engine

Checking the The coolant reservoir is located on the left-hand side of the carrier behind
coolant level the driver’s cab.

G
Risk of burning when vehicle engine is hot!
The hot cooler is pressurised. Be careful to avoid burns from the hot
cooler, with escaping steam or any escaping coolant if you remove the lid
of the cooler when the vehicle engine is hot.
Wear suitable protective gloves and cover the lid of the cooler with a
cloth before opening it.
Turn the cooler lid slowly to the first notch in order to allow the excess
pressure to be released.

Do not open the pressure relief valves (2) on

the sides of the coolant reservoir.

• Loosen (do not open!) the lid of the filling

hole (1) when the coolant is at operating
temperature so that the pressure decrea-
ses.
• Open the lid.
The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:

• Top up the coolant.

See the vehicle engine operating instruc-
tions for the composition of the coolant.
• Screw the lid of the filling hole back on un-
til it reaches end position.
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Operating Instructions GMK 6300 2 084 548 en 5-7
Vehicle engine
5.1 Starting / turning off vehicle engine

Switching on the
battery master
switch

The battery master switch (1) is located on

the right-hand side of the vehicle behind the
driver’s cab and is accessible through an
opening in the side plate.

• Switch on the battery master switch.

The battery master switch is activated when
the selector handle is pointing forwards and
cannot be removed.

Checking hydrau- Check the level of the hydraulic oil tank daily before commencing work.
lic oil level
This requires that:
– The truck crane is standing on a horizontal surface in on-the-road
mode,
– the support is retracted,
– the truck crane is at on-the-road level.

• Check the level of the hydraulic oil tank

through the inspection glass (1). The hy-
draulic oil should be visible in the centre
of the inspection glass when cold.
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 Vehicle engine
5.1 Starting / turning off vehicle engine

Checking the The 4 stop cocks in the hydraulic system suction lines must be open,
hydraulic system when the vehicle engine is started.
stop cocks

S
Damage may occur to the hydraulic pumps!
The vehicle engine may only be started if the four stop cocks in the
suction lines of the hydraulic pumps are open!
The stop cocks are open when the handles are parallel to the suction lines.

The stop cocks are located on the left side of

the vehicle and are accessible through a hole
in the side panelling.
• Check whether stop cocks (1) to (4) are
open.
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Operating Instructions GMK 6300 2 084 548 en 5-9

Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.4 Starting vehicle engine

Activating the
ignition
• Switch on the ignition. Insert the ignition key into the ignition lock as far
as it will go and turn the key to position 2.

S
When starting the ignition or the vehicle engine, indicator lamps which
serve as warning lamps for functions that fail during operation are tested.
Replace any defective lamps immediately!

The following indicator and warning lamps must illuminate:

Vehicle engine oil pressure
L Charge indicator lamp
q Vehicle parking brake
f
Steering circuit I and steering circuit II
de The indicator lamp flame start system (additional equipment) (additional equip-
z ment) lights up. The temperature of the vehicle engine determines when
the lamp will go out; ➠ Starting cold vehicleengine, p. 5-11.
If the supply pressure in the brake circuits decreases to below 5 bar, the
l Supply pressure brake circuits I and II warning lamp will also illuminate.

If the Suspension locking system indicator lamp is lit although the Suspension
u locking system rocker switch is pressed up (switched off), then the air pres-

H
sure in the secondary consumer circuit is too low.

The Suspension locking system indicator lamp does not show the switching
state of the Suspension locking system rocker switch, but rather the actual
status of the suspension locking system. For this reason, check the posi-
tion of the Suspension locking system rocker switch before starting the ve-
hicle engine,➠ p. 6-8.

Motor electronics
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 Vehicle engine
5.1 Starting / turning off vehicle engine

Starting the Refer to the enclosed operating manual for vehicle engine operation.
vehicle engine
• Check whether the vehicle parking brake is locked.
If the brake is locked, the parking brake lever will point to the rear.

C0027

• Shift the automatic gearbox into neutral (N); ➠ Driving range of the auto-
v matic gearbox, p. 6-17.
You can start the vehicle engine only in this position.
Starting the vehicle engine in low temperatures can be made easier by
preheating the coolant using the additional water heating system (additio-
nal equipment); ➠ Additional water heating system, p. 6-54.

Starting a cold vehicle engine with additional equipment with flame start
system
The vehicle engine with additional equipment has a thermostat-controlled
flame start system. If the temperature of the coolant is low, the flame start
system heats the suction air of the vehicle engine by burning fuel in the
suction line.

S
Danger of explosions when using starter fuel!
The vehicle engine may never be started with the aid of starter feul (e. g.,
starter spray). Any starter fuel sprayed into the suction unit may ignite on
the flame start system.

The flame start system is activated each time the ignition is switched on.
z The vehicle engine will be ready to run in up to 20 seconds depending on
the temperature of the coolant. The engine is ready when the Flame start
system indicator lamp goes off. The vehicle engine should be started

H
within the next 30 seconds.

If the flame-start device indicator lamp does not go out after ca. 20 se-
conds, there is a malfunction of the flame-start device; ➠ Malfunctions

H
with the vehicle engine, p. 7-21.

If the engine is cold and switched off but the ignition is switched on, you
must first switch off the ignition briefly and switch it back on again to reac-
tivate the flame start system before starting the engine.
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Operating Instructions GMK 6300 2 084 548 en 5 - 11
Vehicle engine
5.1 Starting / turning off vehicle engine

• Check whether the flame start system indicator lamp illuminates.

z • Wait until the flame start system indicator lamp goes out.
• Leave the vehicle engine on, as with vehicles without a flame start

H
system.

You should not attempt to start the vehicle engine until after the Flame
start system indicator lamp has gone out. If you start the engine before the
lamp goes out and the temperature of the coolant is low, the vehicle
engine will emit smoke for several minutes after start-up.

Starting a cold vehicle engine without flame start system

• Do not press the accelerator.
• Turn the ignition key to position 3 no later than 30 seconds after the
flame start system indicator lamp goes out.

• Release the ignition key and the accelerator once the vehicle engine has
started running.
If the vehicle engine does not start, abort the starting procedure after
15 seconds and wait 1 minute before attempting to start the engine once
more.

Starting a warm vehicle engine

• Do not press the accelerator.

S
Danger of explosions when using starter fuel!
A warm vehicle engine must never be started using starter fuel (e. g.
starter spray). Any starter fuel sprayed into the suction unit may ignite on
the flame start system.

zH For additional equipment with flame start system, the indicator lamp for the
flame start system lights up shortly (2 to 3 seconds) even with a warm ve-
hicle engine after the ignition has been started. You do not need to wait
until the indicator lamp goes out.
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 Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.5 Inspections after the engine has been started

Checking The following indicator and warning lamps must go out when the engine
instruments is running:

• Monitor the Vehicle engine oil pressure status display as soon as you have
L started the vehicle engine.
If the oil pressure does not increase after 10 seconds and the warning
light on the status display Vehicle engine oil pressure status display does not
go out, switch off the vehicle engine by turning the ignition key to
position 0.

H
Charge indicator lamp
q
If the Charge indicator warning lamp lights up when the vehicle engine is
running, switch off the vehicle engine and attempt to find the cause of the
problem; ➠ Malfunctions of the vehicle engine, p. 7-21.

de
eH
Steering circuit Iand steering circuit II

The warning lamp Steering circuit II goes out only when the truck crane is
moving at around 10 km/h.

G
If one or both of the warning lamps Steering circuit I or II do not go out,
observe the notes in the section Observing control instruments while driving;
➠ Vehicle engine malfunctions, p. 7-21.

Motor electronics
à If the motor electronics warning light does not go out when the crane engine
is running, there is a malfunction of the motor electronics. Switch off the ve-
hicle engine and inform GROVE Product Support or the vehicle engine ma-
nufacturer’s customer service.

Observe the following indicator lamps (also while driving):

Vehicle engine air filter

p Vehicle engine coolant level
t
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Hydraulic oil return flow filter

g
s
Operating Instructions GMK 6300 2 084 548 en 5 - 13
Vehicle engine
5.1 Starting / turning off vehicle engine

Automatic gearbox oil filter

m Flame start system (additional equipment)
z If one of these indicator lamps lights up: Refer to ➠ Malfunctions on
carrier, p. 7-1.

Checking oil level

in the automatic
gearbox
The dipstick (1) is on the right (as seen from
the driving direction) on the carrier behind
the vehicle engine and is accessible through
an opening in the covering.

S
The correct oil level must be maintained to ensure smooth operation of
the automatic gearbox:
– if the oil level is too low the gearbox will not function properly
– if the oil level is too high the gearbox will lose power and overheat.

Requirements:
To check the oil level:
– the truck crane must be on a level surface,
– the parking brake must be engaged,
– the automatic gearbox must be in neutral N,
– the vehicle engine must be running,
– the precheck of the oil level must have been carried out.

Two types of oil level check:

The oil check can be performed in two different ways, depending on
01.02.2000

certain conditions:
– when the gear oil is cold,
– when the gear oil is warm.

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 Vehicle engine
5.1 Starting / turning off vehicle engine

Checking the oil level when the gear oil is cold (16 – 50 °C)
This method is only for the daily check before the truck crane is used.

S
If during one of the checks the oil is not at the correct level when the oil is
cold (so that oil has to be topped up or drained), an oil level check must
always be carried out with the oil at operating temperature.

• Check the oil level with the dipstick. The

oil level must be well above the “warm
range” (1). If it is not, the engine must not
be started.
If the oil level is too low:

• Top up oil through the dipstick tube.

Information concerning the prescribed oil
specification ➠ Maintenance manual.
• Let the engine run for approx. 2 minutes in
neutral N.
• Press the service brake pedal down to the
floor, even if the parking brake is engaged,
and change briefly into driving ranges D
and R to bleed the air from the hydraulic
system.
• Change back into neutral N.
• Check the oil level again at an operating temperature of 16–50 °C (indica-
ted on front instrument panel). The oil level must be in cold range (2);
only then is the automatic gearbox ready for driving.
– If the oil level is too high, you must drain oil; ➠ Maintenance manual.
– If the oil level is too low (no oil can be seen on the dipstick or only at
the lower tip), you must top up oil via the dipstick tube.
Information concerning the prescribed oil specification; ➠ Maintenance
manual.
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s
Operating Instructions GMK 6300 2 084 548 en 5 - 15
Vehicle engine
5.1 Starting / turning off vehicle engine

Checking the oil level when the gear oil is warm (70–90 °C)
This oil check is carried out when the oil is at operating temperature (70 to
90 °C) and the engine is running (at idling speed). It must be carried out in
the following cases:
– after any correction of the oil level (topped up or drained),
– after an oil change,
– after the automatic gearbox has been repaired.

S
The warm oil check is definitive. It should be carried out whenever there
is any doubt that the oil is at the correct level!

• First check the oil level when the oil is cold and correct if necessary.
• Check the coolant temperature of the vehicle engine on the status
°C
display to see whether the operating temperature of 70 °C has been
40 120 reached. Drive the truck crane a short distance until the temperature
has risen to 70 °C, if necessary.

H
C0012

If the operating temperature of the vehicle engine has not been reached
and you warm up the automatic gearbox with the service brake activated,
the coolant is heated and comes out of the equalizing reservoir.

• Press the service brake pedal right down

and change into driving range D so that
the oil heats up past 70 °C more quickly.
• Check the oil level at an operating tempera-
ture of 70 to 90 °C (indicated on the front
instrument panel).
The oil must be in the hot area between
the marks (1) and (2).
• Top up oil through the dipstick tube or
bleed it off as required.
Information concerning the prescribed oil
specification; ➠ Maintenance manual.
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 Vehicle engine
5.1 Starting / turning off vehicle engine

5.1.6 Turning off the vehicle engine

G
Risk of accidents due to truck crane steering not functioning!
Only turn off the diesel engine when the truck crane is at a standstill.
When you remove the ignition key, the steering locks and you will loose
control of the truck crane if it is moving.

If the temperature of the coolant is still very high (e. g. after driving over
a pass), let the diesel engine run for another one or two minutes at increa-
sed idling speed.

• Turn the ignition key to position 0 and remove the ignition key.

H If you want to shut-down the truck crane, observe the additional steps
described in Turning off truck crane, p. 6-31.

In the case of an emergency or when the ve-

hicle engine does not turn off after the igni-
tion key has been turned to position 0, it is
also possible to shut-down the vehicle engi-
ne outside the driver’s cab.

The battery master switch (1) is located on

the left-hand side of the vehicle behind the
driver’s cab and is accessible through an
opening in the side plate.

• Switch the battery master switch off to do

this. The battery master switch is off when
the selector handle cannot be removed.
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Operating Instructions GMK 6300 2 084 548 en 5 - 17

Vehicle engine
5.1 Starting / turning off vehicle engine

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5 - 18 2 084 548 en Operating Instructions GMK 6300

 _______________________________________________________________________________________ 6
6 Driving the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
6.1 Checking the truck crane before driving . . . . . . . . . . . . . . . . . 6 - 1
6.1.1 CHECK LIST: Condition of the truck crane for on-road driving . . . . . . . . 6 - 1
6.1.2 Driving mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
6.1.3 Checks to be carried out before driving . . . . . . . . . . . . . . . . . . . . 6 - 7
6.2 General operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
6.2.1 Operating the automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
6.2.2 Monitoring the control instruments while driving . . . . . . . . . . . . . . 6 - 22
6.2.3 Driving on downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 26
6.2.4 Driving on uphill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
6.2.5 Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 28
6.2.6 Turning off the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31
6.2.7 Removing/putting on outrigger pads . . . . . . . . . . . . . . . . . . . . . 6 - 33
6.3 Off-the-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 35
6.3.1 Off-the-road gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36
6.3.2 Drive of the second axle line / longitudinal differential locks . . . . . . . . . 6 - 37
6.3.3 Transverse differential locks in all driven axle lines . . . . . . . . . . . . . 6 - 39
6.3.4 Level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 40
6.3.5 Freeing an immobilised truck crane . . . . . . . . . . . . . . . . . . . . . . 6 - 43
6.4 Separate steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 45
6.4.1 Switching on separate steering . . . . . . . . . . . . . . . . . . . . . . . . 6 - 46
6.4.2 Steering axle lines with separate steering . . . . . . . . . . . . . . . . . . . 6 - 47
6.4.3 Switching off separate steering and locking steering . . . . . . . . . . . . . 6 - 48
6.4.4 Matching steering angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 50
6.5 Heating and ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 51
6.5.1 Driver’s cab heating system . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 51
6.5.2 Roof blower (additional equipment) . . . . . . . . . . . . . . . . . . . . . . 6 - 53
6.5.3 Additional water heating system (additional equipment) . . . . . . . . . . 6 - 54
6.5.4 Additional heating system with timer (additional equipment) . . . . . . . . 6 - 56
6.6 Air-conditioning system (additional equipment) . . . . . . . . . . . 6 - 59
6.6.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 59
6.6.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 59
6.6.3 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 60
6.7 Towing a trailer (additional equipment) . . . . . . . . . . . . . . . . . 6 - 63
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2 084 548 en Operating Instructions GMK 6300

 Driving the truck crane
6.1 Checking the truck crane before driving

6 Driving the truck crane

6.1 Checking the truck crane before driving

6.1.1 CHECK LIST: Condition of the truck crane for on-road driving

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Carry out the required checks and tasks before starting the vehicle
engine; ➠ CHECK LIST: Starting vehicle engine, p. 5-1, Items 1-7.

2. Check the tyres; ➠ Checking the tyres, p. 6-11.

3. Check the fluid level of the windscreen washing system;

➠ Checking the windscreen washing system reservoir, p. 6-11.

4. Adjust the driver’s seat; ➠ Adjusting the driver’s seat, p. 6-13.

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Operating Instructions GMK 6300 2 084 548 en 6-1
Driving the truck crane
6.1 Checking the truck crane before driving

5. Adjust the steering column; ➠ Adjusting the steering column, p. 6-13.

6. Adjusting the mirror; ➠ Adjusting the mirrors, p. 6-14.

7. Insert the 24-hour disc in the trip recorder; ➠ Inserting the 24-hour disc
in the trip recorder, p. 6-14.

8. Start the vehicle engine and carry out all necessary inspections;
➠ CHECK LIST: Starting vehicle engine, p. 5-1, Items 8-12.

9. Check the electrical system; ➠ Functional test of the electrical system,

!DHk p. 6-7.

10. Check the suspension locking system. The Suspension locking system
u indicator lamp must not illuminate; ➠ Checking the suspension, p. 6-8.

11. Check the on-the-road level; ➠ Checking the on-the-road level, p. 6-8.
{
12. Check the transverse differential locks in all driven axle lines;
h ➠ Transverse differential locks in the axle lines, p. 6-9.
13. Check the drive of 2nd axle line / Longitudinal differential locks
c ➠ drive of 2nd axle line / Longitudinal differential locks, p. 6-9.
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14. Check the steering locks on the axle lines; ➠ Checking the steering locks,
b? p. 6-10.

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 Driving the truck crane
6.1 Checking the truck crane before driving

15. Check the level of the fuel tank; ➠ Refuelling, p. 6-12.

C0013

16. Check the compressed air and brake systems; ➠ Checking the
5
4 6 compressed air and brake systems, p. 6-7.
3 7
2 8

1 9
0 bar 10

C0005

17. Check whether the transfer case is in On-road position;

4 ➠ Checking transfer case, p. 6-9.
18. Superstructure is locked; ➠ Hydraulic superstructure lock, p. 12-6.
! 19. The boom is completely retracted and has been lowered onto the
boom support.
The telescoping cylinder is, depending on the driving mode, in telesco-
pic section I or IV; ➠ Driving mode, p. 6-5.

20. All four sliding beams are retracted and secured to prevent inadver-
tent extension;
Outrigger pads are retracted and secured; ➠ Outrigger, p. 13-13.

21. The warning plates for designation of the vehicle width are folded
down; ➠ Warning plates for vehicle width, p. 6-16.
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Operating Instructions GMK 6300 2 084 548 en 6-3
Driving the truck crane
6.1 Checking the truck crane before driving

22. The detachable equipment parts are stripped down so that they fulfill
the regulations in the country in which you are working.
Detachable equipment parts include:
– Counterweight sections, ➠ Counterweight, p. 13-37;
– Auxiliary hoist (additional equipment), ➠ Mounting/dismounting
– the auxiliary hoist, p. 14-1;
– Hook block, ➠ Picking up the hook blocks, p. 13-63;
– Boom extension (additional equipment), ➠ GMK 6300 Lattice
extension operating manual;
– Telescopic swing-away lattice extension (additional equipment),
➠ GMK 6300 Lattice extension operating manual;
– Outrigger pads, ➠ Removing / putting on, p. 6-33.
– Spare wheel.

To find out which equipment parts you need to take off for a driving
mode with a max. axle load of 12 t see Driving mode table, p. 6-5.

23. All loose parts such as blocks or lifting gear are lashed securely.

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 Driving the truck crane
6.1 Checking the truck crane before driving

6.1.2 Driving mode

Driving mode The laws and regulations of the country in which you are working are va-
table lid for driving on public streets. Driving mode of the truck crane on public
roads with a maximum axle load of 12 t:

Table for 14.00 R25 tyres

Equipment Driving mode

1 2 3 4 5 6
14.00 R 25 tyres X X X X X X
12 x 6 x 12 drive X X

A 12 x 8 x 12 drive X X X X
Eddy current retarder *) X X X
Trailer coupling *) X
Spare wheel in
spare wheel holder ●

32 t hook block
attached to front ● ● ● ● ●

12 t hook tackle
attached at the front ●

Outrigger pad installed ● ● ● ●

Telescoping cylinder
locked in telescopic ● ● ● ●
B section I
Telescoping cylinder
locked in telescopic ● ●
section IV
Counterweight completely
unrigged ● ● ● ● ● ●

Rope grab removed ● ● ● ● ● ●

Auxiliary hoist not
installed*) ● ● ● ● ● ●

*) Additional equipment
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Operating Instructions GMK 6300 2 084 548 en 6-5
Driving the truck crane
6.1 Checking the truck crane before driving

Table for 16.00 R25 tyres

Equipment Driving mode
1 2 3 4 5 6 7 8
16.00 R 25 tyres X X X X X X X X
12 x 6 x 12 drive X X X X

A 12 x 8 x 12 drive X X X X
Eddy current retarder *) X X X
Trailer coupling *) X
Spare wheel in
spare wheel holder ●

32-t hook block,

attached at the front ●

12-t hook tackle

attached at the front ● ● ●

Outrigger pad installed ● ●

B Telescoping cylinder locked in
telescoping cylinder I
Telescoping cylinder locked in
telescoping cylinder IV ● ● ● ● ● ● ● ●

Counterweight completely
unrigged ● ● ● ● ● ● ● ●

Rope grab not installed ● ● ● ● ● ● ● ●

Auxiliary hoist not installed*) ● ● ● ● ● ● ● ●
*) Additional equipment

How to use the table:

The driving mode of your truck crane depends on the equipment specified

H
at A. Determine which driving mode applies to your truck crane.

Each truck crane has only one driving mode.

Example for using the table for 16.00 R25 tyres:

Let us assume that your crane is equipped with 16.00 tyres, 12 x 6 x 12 drive
and without eddy current retarder. The driving mode under A is 1 or 8.

At B you will find the accessories that you may take along during on-road dri-
01.02.2000

ving with a maximum of 12 t axle load.

6-6 2 084 548 en Operating Instructions GMK 6300

 Driving the truck crane
6.1 Checking the truck crane before driving

For both driving modes, you may attach the 12 t hook tackle at the front on the
bumper, the telescoping cylinder has to be locked in telescopic section IV, the
counterweight has to be unrigged, and the rope grab and the auxiliary hoist
(additional equipment) cannot be installed.

For driving mode 1, the outrigger pad must remain installed; for driving mode 8, the
16.00 R25 spare wheel at the rear may be included.

6.1.3 Checks to be carried out before driving

Functional test of
the electrical
system • Check the function of
– the lighting and signalling devices,
– the hazard warning system,
k – the windscreen wipers,
D – the windscreen washing system.
H
Check the com- • Fill the compressed-air supply in neutral gear until it reaches a cut-out
pressed air and pressure of 8.1 bar.
brake systems
• The Supply pressure brake circuits I and II warning lamp will not go out un-
l til the pressure in the tanks has reached 5.5 bar (Supply pressure brake cir-
cuits I and II status display).
You may not begin driving until the air pressure in brake circuit III is
f sufficient to release the parking brake. The releasing pressure is approx.
5.4 bar. The Vehicle parking brake indicator lamp will not go out until the
wheel brakes have been released.

G
Accidents may occur due to the unchecked movement of the truck crane!
If the pressure is too low the parking brake will not be released, even if
the parking brake lever is in released position.
Use the service brake to maintain the truck crane when the parking brake
is released for a functional check!
Do not refill the compressed air unless the parking brake is locked!
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Operating Instructions GMK 6300 2 084 548 en 6-7
Driving the truck crane
6.1 Checking the truck crane before driving

Checking • Check whether the suspension locking system is switched off.

suspension
The Suspension locking system indicator lamp should illuminate when
u suspension is locked.
Press the Suspension locking system rocker switch upward when the
Suspension locking system indicator lamp illuminates.

If the air pressure in the secondary consumer circuit decreases below

u 5 bar, the suspension is locked even if the suspension locking system is
switched off and the Suspension locking system indicator lamp illuminates.

S
Damage may occur to the axle lines!
The suspension must not be locked during on-road driving! The steering
behaviour may also change when the suspension is locked.

H
Check the on-the-
The suspension is always locked when the ignition is switched off.

road level
• Insert the key into the Level adjustment system key switch. Turn the key to
the right, push it in and turn it back to the left.

C0018

The Not on-the-road level indicator lamp must not illuminate during on-road
{ driving.
If the Not on-the-road-level indicator lamp does illuminate, you must move the

H
truck crane into On-the-road-level position; ➠ Level adjustment system, p. 6-43.

Leave on the key-operated switch Level adjustment system for further checks
of transverse differential locks, drive of the second axle line and longitudi-
nal differential locks.
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 Driving the truck crane
6.1 Checking the truck crane before driving

Checking the
transverse diffe-
rential locks
• Check the Transverse differential locks in all driven axle lines indicator lamp.
h All differential locks must be switched off. Operation of the differential
lock ➠ Transverse differential lock in the axle lines, p. 6-39.

Check the drive

of the second
axle line / longitu-
dinal differential
locks
• Check the Drive of second axle line / longitudinal differential locks indicator
c lamp. The drive and the longitudinal differential locks must be switched
off. Operation; ➠ Drive of the second axle line / longitudinal differential locks,
p. 6-37.

• Once you have checked the on-the-road level, the longitudinal and trans-
verse differential locks and the drive of the second axle line / longitu-
dinal differential locks, switch off the Level adjustment system key switch
and pull out the key.

C0018

Checking the
transfer case

• Check if the on-the-road gear indicator lamp is illuminating. The indicator

4 lamp illuminates if the on-the-road gear is switched on. Switching on
the on-the-road gear; ➠ Switching off the off-the-road gear, p. 6-36.
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Operating Instructions GMK 6300 2 084 548 en 6-9
Driving the truck crane
6.1 Checking the truck crane before driving

Checking the Operating the separate steering; ➠ Separate steering, p. 6-45.

steering locks

The Separate steering rocker switch must be pressed upward.

b The warning lamp (Steering unlocked) must not light up during on-road
? driving.
If the warning lamp lights up, the drag rods between the third and
fifth axle lines are not locked.

The Separate steering indicator lamp must not be off. If the indicator lamp is
b lit, either the steering of the fourth axle line and/or the manual steering of
the third axle line are/is not locked.

G
Risk of accidents during on-road driving with unlocked steering!
For on-road driving, the following must be locked:
– The steering of the fourth axle line,
– The manual steering of the third axle line,
– The drag rods between the third and fifth axle lines,
The warning and indicator lamps mentioned above must not be lit.

Checking the The Boom not set down warning lamp is additional equipment. Currently, it
Boom not set is only standard equipment for those cranes in use in Great Britain.
down warning Additional function as Kollisionsgefahr warning lamp;
lamp ➠ GMK 6300 Lattice extension operating manual.
(additional equip-
ment)
The Boom not set down warning lamp shows that the boom is not set down
3 correctly in the boom support and thus the specified vehicle height is ex-
ceeded at on-the-road level.
The vehicle height is specified on an adhesive label in the driver’s cab.

S
Risk of damage to the truck crane!
If the Boom not set down warning lamp is lit, the vehicle is higher than spe-
cified. If you drive under a bridge or through a place with low headroom
(tunnel), an accident may occur which could cause damage to the truck
crane, the bridge or the tunnel.
Set the boom down correctly in the boom support and ensure that on-the-
road level is set.

• Check the on-the-road level. The Not on-the-road level indicator lamp must
{ not be lit; ➠ p. 6-8.
• Check whether the Boom not set down warning lamp is out. If the warning
3 lamp is lit, the boom is not set correctly in the boom support. Thus the
01.02.2000

vehicle height specified in the driver’s cab is exceeded.

• Lower the boom until it is correctly situated in the boom support.

6 - 10 2 084 548 en Operating Instructions GMK 6300

 Driving the truck crane
6.1 Checking the truck crane before driving

Checking • Check the air pressure when the tyres are cold; ➠ Air pressure of the tyres,
the tyres p. 8-11.

S
Risk of damage to the tyres!
The air pressure increases when the tyres become hot during driving.
Never let out the increased air pressure of tyres that are warm from
driving!

• Check the condition of the tyres including

tread depth (1) and possible damage.

Checking the The reservoir of the windscreen washing system is locate on the right
reservoir of the side under the driver’s cab and can be reached through an opening above
windscreen the steps.
washing system

• Pull the cover (1) from the opening.

Keep the reservoir (2) full at all times and
add a cleaning agent and, if necessary,
antifreeze to the water.
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Operating Instructions GMK 6300 2 084 548 en 6 - 11
Driving the truck crane
6.1 Checking the truck crane before driving

Refuelling

Monitor the fuel gauge. Refuel with diesel whenever necessary.

C0013

G
Fires may occur due to flammable gases!
Switch off the vehicle engine, driver’s cab heater and all additional
heating devices before refuelling.

G
Danger of accident if the fuel tank is not closed!
Screw the sealing cover back on after each refueling. This helps prevent
vehicles behind you from being endangered by the sealing cover falling
off or fuel escaping.

• Always use a funnel and filter when

refuelling.
The fuel tank (1) contains about 500 litres.
• Use the extendible ladder supplied (2)
when refuelling; it is attached below the
driver’s cab; ➠ Extendible ladder, p. 4-43.
You can find information about the prescri-
bed fuel specifications in the supplied ve-
hicle engine operating manual.
• Close the fuel tank with the sealing cover
after each refueling.
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 Driving the truck crane
6.1 Checking the truck crane before driving

Adjusting the • Adjust the hydraulically spring-loaded seat to your height and weight.
driver’s seat The longitudinal direction, the stiffness of the suspension and angle of
the seat and back rest are adjustable.
1 Adjustment of the suspension stiffness
to your weight in kg

2 Seat height on the front edge of the seat

3 Seat height on the rear edge of the seat

4 Angle of the back rest

5 Longitudinal adjustment of the entire

seat

6 Inclination limiter

Adjusting the You can adjust the steering column for height and inclination.
steering column

G
Danger of accident when the steering column is unlocked!
Always stop the vehicle and activate the parking brake before you unlock
the steering column.
When the steering column is unlocked, you no longer properly steer the
vehicle.

You may adjust the angle and height of the

steering column by unscrewing the adjusting
screws (1) on the left and right-hand side of
the steering column.
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Operating Instructions GMK 6300 2 084 548 en 6 - 13
Driving the truck crane
6.1 Checking the truck crane before driving

Adjusting the The crane is equipped with several wing mirrors. Adjust the mirror to
mirrors your respective sitting position.

• Adjust the wide-angled wing mirror (2) on

the right-hand side of the vehicle and the
wing mirror (3) for the field of view on the
1 right-hand side of the crane.
• Adjust the starting mirror (1) on the right-
2 hand side of the vehicle to the height of
the driver’s seat for the field of view right
next to the vehicle.
• Also adjust the wing mirror on the driver’s
door.

C0930

Inserting the • Insert a new 24 hour disc in the trip recorder before driving.
24 hour disc in

S
the trip recorder
The trip recorder may only be opened and closed when the truck crane is
switched off, as the mechanical components of the recorder or the record-
ing stylus may otherwise be damaged!

• Once you have inserted a new 24 hour disc, close the trip recorder and

H
remove the key.

The key may not be left in the lock of the trip recorder while driving.

The trip recorder has not been locked properly if the warning lamp in the
recorder illuminates.
Open the trip recorder while the truck crane is stationary and check that
the 24 hour disc has been properly inserted.
The journey will not be recorded correctly if the warning lamp is on!
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 Driving the truck crane
6.1 Checking the truck crane before driving

Setting the trip recorder

As the crane operator, you are obliged to set

the trip recorder for the respective activities
using group control switches (1) and (2).

Set time group switch (2) to the symbol

corresponding to the activities of the first
driver. The time group switch (1) is used for
the activities of the second driver.

(1) Working hours: Corresponds to the same

activities as those in (2). The settings for
time groups (1) and (2) are different
depending on the regulations of the
respective country.

The steering time is no longer defined.

The trip recorder automatically switches
over to the steering range as soon as the
vehicle begins to move. This change-
over takes place regardless of which
activity range has been set for the time
group switch of the driver.
(2) Periods during which the driver was
present: Crane operation
(3) Breaks and resting periods:
These periods are defined by law and

H
must be observed.

When the drivers change over, the 24 hour discs in the trip recorder must
also be changed. The steering time is only recorded for the first driver.
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Operating Instructions GMK 6300 2 084 548 en 6 - 15
Driving the truck crane
6.1 Checking the truck crane before driving

Warning plates
for vehicle width

Because of the overall width of the truck

crane, the warning plates (1) (front right and
left) marking the vehicle width must be
folded down for on-road driving.

For off-the-road driving the warning plates

can be folded up and fastened with the
spring latch (2).

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 Driving the truck crane
6.2 General operation

6.2 General operation

G
Risk of accidents due to truck crane steering not functioning!
Never switch off the ignition and remove the ignition key while the truck
crane is moving.
This precaution prevents the steering from locking and loss of control of
the moving truck crane.

6.2.1 Operating the automatic gearbox

Driving range of You may choose between the various driving ranges of the automatic
the automatic gearbox using the selector switches.
gearbox

S
Damage to gearbox may occur!
Only switch between the driving ranges D and R when the truck crane is
stationary!
Never shift into driving range N (neutral) while driving. Otherwise, you
could lose control of the truck crane!
Do not drive long distances in reverse. When travelling in reverse the oil
pump in the transfer case does not function.

When the diaphragm pushbutton is depressed, a light engagement of the

button should be felt. The indicator lamp in the button lights up and an
acoustic signal indicates that the gearbox has switched to the selected

H
range.

Each time the carrier engine is started, all indicator lamps in the selector
switch panel illuminate for a few seconds. Replace any defective lamps
immediately!

Switch for neutral position N of automatic gearbox = neutral gear

> Switch the automatic gearbox into neutral position to start the vehicle
engine. Only in this position can the vehicle engine be started.
The parking brake or service brake must be used to brake the truck crane
in neutral position, as the crane could otherwise start to roll.

S
Gearbox damage may occur if the truck crane is allowed to roll!
Never switch the automatic gearbox into neutral position while driving.
This could damage the automatic gearbox. Moreover, the retarder does
not work in neutral position.
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Operating Instructions GMK 6300 2 084 548 en 6 - 17
Driving the truck crane
6.2 General operation

Switch for driving range D of the automatic gearbox = normal automatic

< driving range
The automatic gearbox automatically selects the appropriate forward gear
from gears 2 to 5 in driving range D.
The automatic gearbox begins driving in second gear and automatically
upshifts and downshifts via the hydraulic torque converter.
The torque converter is overridden and purely mechanical power is gene-
rated by the vehicle engine and transmitted to the gearbox in all forward
gears and every driving range when the respective number of revolutions
and speed have been reached.

The gearbox electronics establishes gear selection and shifting point

using the travelling speed, the position of the accelerator and the load
condition.

Switch for limited driving range 4 automatic gearbox

ô In driving range 4 the gearbox begins in second gear and only switches
between second, third and fourth gears.

Switch for limited driving range 3 automatic gearbox

Æ In driving range 3 the gearbox begins in second gear and only switches
between second and third gears.

Switch for limited driving range 2 automatic gearbox

Å The gearbox always stays in first gear in driving range 2. This driving
range is suitable for driving off-the-road.

Switch for limited driving range 1 automatic gearbox

Ä The gearbox always stays in first gear in driving range 1. In this gear you
can use the full braking power of the engine when travelling downhill.
This driving range 1 is also suitable for manoeuvring and for driving off-
the-road.

Switch for driving range R of the automatic gearbox

= The truck crane drives backwards in driving range R.

Shift lock warning lamp

# If a malfunction occurs in the automatic gearbox, the Automatic gearbox
shift lock warning lamp will illuminate, an acoustic signal will sound for ten
seconds and the gearbox will be in locked position.
When the gearbox is locked into position, the gearbox control shifts to a
safe gear and opens the converter override coupling to allow you to park
the truck crane; ➠ Troubleshooting for automatic gearbox functions, p. 7-29.
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 Driving the truck crane
6.2 General operation

Automatic
gearbox
diagnosis switch
If the automatic gearbox is not working perfectly, the warning lamp in the
. diagnosis switch illuminates. A continuation of gearbox operation is still
actually possible, however you should immediately consult a specialist
workshop or GROVE Product Support at the respective location.
Qualified repair personnel can use the diagnosis switch to check for an
error code. For this the switch must be kept pushed in. The warning lamp
then flashes with a certain frequency. The error code can determined
from the frequency of flashing. When the warning lamp stops flashing,
the switch can be released.

Automatic gear- You may select one of two driving modes:

box driving
modes In driving mode E (= Economy), the gearbox shifts to the next highest
gear at low engine speeds. This allows you to drive at a low engine speed
and thus consume less fuel than in driving mode P.
Use driving mode E when driving on flat, even surfaces.
In driving mode P (= Power), the gearbox shifts to the next gear at higher
speeds. The acceleration power and speed on inclining routes is higher
than that of driving mode E.
Use driving mode P when driving up inclines and on rough terrain.

S
You may only switch between driving modes E and P when the truck
crane is stationary and the automatic gearbox is in neutral position N.

Driving mode E (road): Driving modes of the automatic gearbox

î rocker switch pushed upward.

Driving mode P (hills): Driving mode of the automatic gearbox

î rocker switch pushed downward.

The rocker switch can only be switched over when the release button in
the upper section of the rocker switch is pressed simultaneously.
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Operating Instructions GMK 6300 2 084 548 en 6 - 19
Driving the truck crane
6.2 General operation

Starting and A safety circuit in the automatic gearbox delays the selection of the gear
stopping for about one to two seconds when a driving mode is selected while the
truck crane is stationary.

G
Accidents may occur due to the unchecked movement of the truck crane!
When starting the truck crane, use the service brake to stop the crane
from rolling until starting gear has been engaged!

If the truck crane is stationary, the automatic gearbox does not engage
the selected starting gear until the engine speed is under 900 rpm or the
accelerator is in neutral position.

If you switch from neutral position N to driving mode D or R and the

engine speed is too high, a warning signal will sound until the engine
speed has decreased to the correct speed.

You must carry out the following steps to begin driving with the parking
brake locked
– Release the accelerator (engine speed under 900 rpm),
– Select a driving mode (for on-road driving D or R, for off-the-road
driving in driving mode D select a lower gear first ➠ Off-the-road
driving, p. 6-35),
– Engage the service brake,
– Release the parking brake,
– Release the service brake after approx. 2 seconds and press the

H
accelerator.

Never press a driving range selector switch and the accelerator simultane-
ously when the truck crane is stationary! A warning signal will sound if
the engine speed is too high.

You must carry out the following steps to stop driving:

– Release the accelerator,
– engage the service brake.
When stopping briefly with the engine running you can stay in the
selected driving range.

G
Accidents may occur due to the unchecked movement of the truck crane!
The truck crane will begin to roll as soon as you release the service brake!
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 Driving the truck crane
6.2 General operation

For a longer stop when the vehicle engine is running you must
– release the accelerator,
– engage the service brake,
– lock the parking brake,
– shift the automatic gearbox to neutral position N.

Upshifting The position of the accelerator can be used to influence the time at which
the automatic the automatic gearbox upshifts.
gearbox
If you press the accelerator down completely, the automatic gearbox will
not shift until the engine speed is high. The automatic gearbox will only
shift at lower engine speeds when the accelerator is only partially pressed
down.
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Operating Instructions GMK 6300 2 084 548 en 6 - 21

Driving the truck crane
6.2 General operation

6.2.2 Monitoring the control instruments while driving

Test the service and parking brakes as soon as you begin driving.

While driving, monitor the following control and warning instruments:

Status display for supply pressure brake circuits I and II

4 5
6
3 7 The operating pressure is approx. 8 bar.
2 8

1 9 The pressure in both brake circuits must be over 5,5 bar while driving.
0 bar 10

C0005

Warning lamp for supply pressure brake circuits I and II

l A warning lamp illuminates if the pressure decreases to less than 5,5 bar.

G
Accidents may occur if one of the brake circuits fails!
The effectiveness of the service brake is reduced when one of the brake
circuits fails!
If the warning light illuminates, stop the truck crane immediately and
attempt to find the cause! You may only continue driving at a low travel-
ling speed until you reach the next workshop!

G
Accidents may occur if both brake circuits fail!
If the pressure in both brake circuits decreases to less than 5.5 bar,
the truck crane can only be stopped by the parking brake. Stop the truck
crane immediately and resume driving only after making the necessary
repairs.

ABS warning light for trailer (additional equipment)

y The warning lamp only functions when a trailer equipped with an ABS
system is attached correctly to the truck crane.
The warning lamp lights up when the truck crane is still; the warning lamp
goes out only when the truck crane and trailer drive at walking speed.
The warning lamp does not go out or it lights up when the crane is being
driven if the ABS system on the trailer is malfunctioning or fails. The ABS
system on the trailer is not ready for operation but the braking force of
the truck crane and the trailer are fully maintained.

Warning lamps for steering circuits I and II

de If the oil supply has fallen in a steering circuit the relevant warning light
will illuminate.
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 Driving the truck crane
6.2 General operation

H
d The warning lamp for steering circuit I illuminates at speeds of under
10 km/h. It must go out when the speed exceeds 10 km/h!

G
Accidents may occur if both steering circuits fail!
Stop the truck crane immediately if the both warning lamps remain
illuminated at a speed of over 10 km/h!
You must stop driving immediately, as the truck crane can no longer be
safely steered due to the high steering force!

G
Accidents may occur if one of the steering circuits fails!
If the one of two warning lamps remains on at a speed of over 10 km/h,
slowly reduce the speed of the truck crane and stop as soon as possible
and look for the cause!
If one of the steering circuits fails, you may only continue driving at a low
travelling speed until you reach the next workshop.

Status display with warning lamp for vehicle engine coolant temperature
°C
The temperature of the cooling water of the coolant may only increase to
40 120
95 °C on uphill routes.

H
C0012

Decrease the load on the engine if the temperature of the coolant exceeds
95 °C. Continue driving at a low speed and high engine speed!
Check whether the fan is functioning properly!

S
Stop the truck crane immediately if the temperature of the coolant in-
creases to over 100 °C and the warning lamp illuminates!
Switch the automatic gearbox to neutral position N and let the vehicle
engine run at increased idling speed to cool it down.
If the temperature does not decrease, turn off the vehicle engine and
attempt to find the cause!

Indicator lamp for vehicle engine coolant level

t If the Coolant level indicator lamp illuminates, the coolant level is too low.
Replenish immediately to prevent the vehicle engine overheating;
➠ Checking coolant level, p. 5-7.
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Operating Instructions GMK 6300 2 084 548 en 6 - 23
Driving the truck crane
6.2 General operation

Vehicle engine oil pressure warning lamp

L The oil pressure may not drop while driving.
The warning lamp goes on while the oil pressure drops below 0.4 bar.

S
If the indicator lamp illuminates, stop the truck crane immediately.
Turn off the vehicle engine and attempt to find the cause!
Never start the vehicle engine again before you have found the cause and
eliminated the error!
➠ Vehicle engine malfunctions, p. 7-21.

Engine electronics warning lamp

à If the Engine electronics warning lamp illuminates while driving, there is a
malfunction of the engine electronics. Switch off the vehicle engine and in-
form GROVE product support.

°C Status display for the automatic gearbox oil temperature

50 150 The maximum gear oil temperature during on-road driving is 110 °C.
With the converter not bypassed the gear oil temperature may rise briefly
to 130 °C.

C0008 The gearbox electronics blocks the higher gears if the oil temperature in-
creases to over 130 °C.

S
Danger of damage to the automatic transmission as a result
of overheating!
Switch the automatic gearbox to neutral position N and let the vehicle
engine run at increased speed. If the gear oil temperature does not
decrease within a few seconds, turn off the vehicle engine and attempt to
find the cause; ➠ Automatic gearbox malfunctions, p. 7-23.
If you cannot establish the cause of the oil temperature in the automatic
gearbox being too high, do not continue driving under any circumstances.

If the temperature of the gear oil is too high but the temperature of the
vehicle engine coolant is normal, check the oil level in the automatic gear-
box and add oil if necessary.

The increased temperature of the coolant in the vehicle engine could also
be responsible for the overheating of the automatic gearbox. Stop the
truck crane and check the cooling system of the vehicle engine. If the
cooling system is functioning properly, switch the automatic gearbox into
neutral position N and let the vehicle engine run at a speed of 1200 to
01.02.2000

1500 rpm. The temperature of the engine coolant and the gear oil should
return to normal within two to three minutes.

6 - 24 2 084 548 en Operating Instructions GMK 6300

 Driving the truck crane
6.2 General operation

Status display for the automatic gearbox oil pressure

bar
The oil pressure in the automatic gearbox must be between 10 and 12 bar
0 25
when driving and in neutral position N.

C0007

S
If the gear oil pressure in both brake circuits drops below 7 bar stop the
truck crane immediately. Switch the vehicle engine off and look for the
cause; ➠ Automatic gearbox malfunctions, p. 7-23.

Status display for hydraulic system oil temperature

The hydraulic oil temperature should not exceed 80 °C in normal driving
mode.

The radiator built into the oil circuit is switched thermostatically at

approx. 45 °C.

S
The hydraulic system is defective if the temperature of the hydraulic oil
increases to over 80 °C. Stop the truck crane as soon as possible and
attempt to find the cause.
Stop the truck crane immediately and turn off the vehicle engine if the
temperature of the hydraulic oil increases to over 100 °C!

Status display for fuel reserve

Monitor the status display Fuel reserve.
Never allow the fuel tank to run completely empty.

H
C0013

If the fuel tank is almost empty, accumulated dirt could clog the fuel filters.
The fuel system must be bled when air is taken in (refer to the Mercedes-
Benz operating manual).

If one of the following warning or indicator lamps illuminates:

Refer to ➠ Malfunctions on the carrier, p. 7-1.

Vehicle engine air filter

p Hydraulic oil return flow filter
g
01.02.2000

Automatic gearbox oil filter

m Flame start system (additioaal equipment)
z
Operating Instructions GMK 6300 2 084 548 en 6 - 25
Driving the truck crane
6.2 General operation

6.2.3 Driving on downhill slopes

You can brake the truck crane with the retarder and the increase the bra-
king force by a corresponding gear preselection while driving on downhill
slopes.
Additional braking with eddy current retarder (additional equipment)
➠ Eddy current retarder, p. 6-30.

Retarder An engine flap brake with constant throttle on the truck crane serves as
the retarder.

The retarder is activated using the footopera-

ted switch (1).

• Release the accelerator.

• Press down on the foot-operated switch (1).

1 The retarder is switched on, the gearbox can-

not shift upwards.

Release the foot-operated switch to switch

off the retarder.

H
C0961

If you press the accelerator while the retarder is switched on, the retarder
switches off and the gearbox can upshift again. Select a low driving range
for downhill stretches in order to be certain to avoid inadvertent upward
shifting.

G
Danger of overheating damage!
When driving downhill for long stretches with the retarder on, pay particu-
lar attention to the gear oil temperature; ➠ Status display for the automatic
gearbox oil temperature, p. 6-24.
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 Driving the truck crane
6.2 General operation

Preselecting gears To increase the braking force of the vehicle engine, you can select a lower
driving range and switch to driving mode P.

If the braking power of the engine on downhill slopes is insufficient and

the engine speed increases to an excessive speed, the automatic gearbox
shifts to the next speed for overspeed protection even though the enga-
ged speed was not previously selected.

If the automatic gearbox has already shifted to top gear and overspeed is
still reached, the motor electronics throttle the diesel engine until it
switches off.

If the diesel engine switches off before the truck crane has come to a
standstill:
• Keep calm.
• Do not remove the ignition key.
• Brake the truck crane using the foot brake until it comes to a standstill.
• Turn off the ignition.
• Start the diesel engine again.

G
Risk of accidents due to truck crane steering not functioning!
Never remove the ignition key as long as the truck crane is still driving af-
ter switching off the diesel engine.
If you remove the ignition key, the steering locks and you will lose control
of the truck crane if it is moving.
Only start the engine again once you have stopped the truck crane.

When driving on routes with varying gradients, you may avoid constant
upshifting and downshifting by preselecting the appropriate gears.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 6 - 27
Driving the truck crane
6.2 General operation

6.2.4 Driving on uphill slopes

The gearbox may switch between two gears at certain gradients.

Either release the accelerator a little or select a lower gear range.

When starting on slopes, the power in second gear (the starting gear in
driving range D) may not be sufficient for starting. If you wish to start in
first gear, you must start in driving range 1 and switch to a higher driving

H
range after moving off.

When starting on steep gradients and when manoeuvering, it can be

advantageous to operate the service brake with the left foot in order that
the brake and accelerator pedals can be operated simultaneously and
with sensitivity.
Switch to driving mode P when driving on uphill slopes (➠ Driving modes
of the automatic gearbox, p. 6-19).

G
Risk of accidents!
Always secure the vehicle on slopes with the service brake when releas-
ing the parking brake, because there is a gap of approx. 2 seconds be-
tween the driving range being selected and the gearbox engaging the
gear. The vehicle will roll immediately during this time if the brakes are
released on slopes. Do not depress the accelerator during this 2 second
period under any circumstances!

6.2.5 Cruise control

The truck crane is equipped with cruise control. This allows you to drive

H
at a speed which you determine.

Cruise control only works if you are driving at a speed of 30 km/h or more.

G
Risk of accidents!
You must remain alert and ready to brake when using the cruise control!
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 Driving the truck crane
6.2 General operation

Activating the
cruise control
• Press the Switch tempomat on/off rocker switch down when you have
è reached the desired speed.

To increase the speed, press the Set speed upwards and hold it there until
: the desired speed has been reached.

To decrease the speed, press the Set speed downwards and hold it there un-
: til the desired speed has been reached.

Driving with When driving with cruise control, you may release the accelerator without
cruise control changing the defined speed.

If you wish to increase the speed, e. g. in order to pass another vehicle,

you may press the accelerator and increase the speed of the vehicle
engine without erasing the predefined cruising speed. The truck crane will

H
return to the defined cruising speed when you release the accelerator.

The cruise control will be deactivated when you operate the service brake
or the engine brake.

G
Risk of accidents due to excessive speed!
Do not activate cruise control when you are driving on downhill slopes as
cruise control cannot cause your truck crane to brake. The driving speed
of your truck crane could be greater than the speed which you have set
on the cruise control.

H
Deactivating the
cruise control

The truck crane will brake if you deactivate the cruise control without first
pressing the accelerator.

• Press the accelerator until the truck crane accelerates.

• Press the Switch Tempomat on/off rocker switch up to delete the set speed
è again.
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Operating Instructions GMK 6300 2 084 548 en 6 - 29
Driving the truck crane
6.2 General operation

Cruise control is automatically deactivated if you activate the service bra-

ke, the retarder or the eddy current retarder.
➠ Driving on downhill slopes, p. 6-26.
The Cruise control indicator lamp then goes out.

Eddy current re- You can brake the vehicle with the eddy current retarder (additional equip-
tarder (additional ment) on downhill slopes. The eddy current retarder can be used for all
equipment) braking procedures as soon as the truck crane is in motion. This reduces
wear on the service brakes.

The eddy current retarder is operated with

the lever switch Eddy current retarder (1) on
the steering column.

H You cannot regulate the engine speed with the accelerator as long as the
eddy current retarder is in operation.

• Press the eddy current retarder switch from level 0 to one of the switch
levels from 1 to 4.
Level 0 = no braking power
Level 1 = 1⁄ braking power
4
Level 2 = 1⁄ braking power
2
Level 3 = 3⁄ braking power
4
Level 4 = full braking power
As soon as the eddy current retarder is activated, the indicator lamp eddy
ê

H
current retarder illuminates.

When switching over a number of levels, the switch must engage briefly in
each level in order to build up the power-supply connection of the retarder.
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 Driving the truck crane
6.2 General operation

The braking force of the eddy current retarder is dependent only on the
driving speed. In contrast to the retarder, the driving range engaged does
not influence the function of the eddy current retarder.
When driving down steep slopes, you can support the braking force of the
eddy current retarder by means of the retarder and the service brake.

For long downhill stretches, when you have stabilized your speed, you
should use the eddy current retarder at level 2.

G
Accidents may occur if the retarder is allowed to overheat!
As soon as the truck crane is stationary or the downhill stretch has
finished, you must switch the retarder back to level 0, in order to prevent
the retarder from overheating and consequently failing without you
noticing.

6.2.6 Turning off the truck crane

Locking the • Bring the truck crane to a halt using the service brake.
parking brake
• Lock the parking brake when the truck crane is switched off.

C0027

Automatic gear- • Put the automatic gearbox into neutral position N.

box in neutral
position

Turning off the • If the temperature of the coolant is still very high (e. g. after driving over
vehicle engine a pass), let the diesel vehicle engine run for another one or two minutes
at increased idling speed.
• Turn the ignition key to position 0 and remove the ignition key in order
to turn off the engine. All indicator lamps must go out.
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s
Operating Instructions GMK 6300 2 084 548 en 6 - 31
Driving the truck crane
6.2 General operation

Securing the
truck crane from
rolling

G
Accidents may occur due to the unchecked movement of the truck crane!
The truck crane cannot be prevented from rolling by selecting a driving
range!

• Secure the truck crane on uphill and downhill slopes using both the
parking brake and chocks. Two chocks are located under each of the
two rear lights.

Switch off the Always switch off the battery master switch if the truck crane is going to
battery master be inactive for over 8 hours.
switch if the
truck crane is idle
for a longer
period of time

S
When the vehicle engine is running you must never disconnect the cable
connection to the alternator!

• Switch off all current consumers.

• Turn off the vehicle engine and remove the ignition key.
• Switch off the main battery.

H You do not need to wait for the return water of the additional water
heating system (additional equipment).
However, you should always turn off the heater to prevent it from auto-
matically activating when the main battery is switched on.

Securing the Remove the ignition key and lock the driver’s cab to prevent unauthorised
truck crane use.
against un-
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authorised use

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 Driving the truck crane
6.2 General operation

6.2.7 Removing/putting on outrigger pads

Removing You must remove the outrigger pads from the outrigger cylinders for
outrigger pads some the driving modes.
Note the relatively high dead weight of the outrigger pads (approx. 90 kg)
and proceed as follows:
• Remove the holder (3) and pull the outrig-
ger pad from the holding rod (1) as far as
possible into the working position.
• Extend the outrigger cylinder until the
outrigger pad barely touches the ground
but is not yet under strain.
• Unscrew both retaining screws from the
bore holes (2).

• Push the outrigger pad from the cylinder

head (2) so that it lies on the ground.
• Screw both of the retaining screws (1) back
in.
• Insert the holder (3) back into the outrigger
pad and secure it with the retaining pin for
transport.
• Completely retract the outrigger cylinder.
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s
Operating Instructions GMK 6300 2 084 548 en 6 - 33
Driving the truck crane
6.2 General operation

Putting the Note the relatively high dead weight of the outrigger pads (approx. 90 kg)
outrigger pad on and proceed as follows:

• Extend the outrigger cylinder until it just

above the ground.
• Lay the outrigger pad behind the outrigger
cylinder, unscrew the retaining screws
from the bore holes (1) and remove the hol-
der.
• Correct the position of the outrigger cylin-
der if necessary. The bearing surface (2) on
the cylinder head must be under the guide
(3) on the outrigger pad.
• Pull the outrigger pad onto the outrigger
cylinder and screw in both retaining
screws.

If the truck crane is already at the work site, move the outrigger pad into
working position and secure it with the holder; ➠ Bring the outrigger pad
into work position, p. 13-28.
If you still have to drive the truck crane to the work site, retract the outrig-
ger cylinder and move the outrigger pad into transport position; ➠ Bring
the outrigger pad into driving position, p. 13-29.

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 Driving the truck crane
6.3 Off-the-road driving

6.3 Off-the-road driving

Switch to a lower driving range when there are difficulties obtaining
traction on swampy ground or on poorly compacted surfaces.
Shift the automatic gearbox to driving mode P, ➠ Driving modes of the
automatic gearbox, p. 6-19.
You may also perform the following steps in the order specified below:
– Switching from on-the-road gear to off-the-road gear
The off-the-road gear reduces the travelling speed in all gears and thus
increases the thrust of the driven wheels.
You may also use the off-the-road gear to shunt (driving slowly) on
solid ground.
– Drive of the second axle line
You can switch on the drive of the second axle line and the longitudinal
differential locks in the transfer case and in the fourth axle line for off-
the-road driving.
However you must not use the drive of the second axle line and the
longitudinal differential locks on firm ground.
– Transverse differential locks in all driven axle lines
The transverse differential locks in the driven axle lines prevent the
spinning of individual wheels on one axle line when driving on slippery
ground. (Must not be used on firm ground and when cornering!)
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Operating Instructions GMK 6300 2 084 548 en 6 - 35

Driving the truck crane
6.3 Off-the-road driving

6.3.1 Off-the-road gear

The off-the-road gear reduces the travelling speed in all gears and thus
increases the thrust of the driven wheels.
Speeds in off-the-road gear; ➠ Driving speeds, p. 8-12.

S
Danger of the transfer case not functioning properly!
Do not switch the off-the-road gear on or off unless the truck crane is
stationary and the automatic gearbox is in neutral position N!
Never press two of the three rocker switches Transfer case on-the-road gear,
Transfer case neutral position and Transfer case off-the-road gear simultaneously,
as this could cause improper shifting in the transfer case.

Engage the off- • Stop the truck crane.

the-road gear
• Switch the automatic gearbox into neutral position N.
> • Switch on the off-the-road gear with the rocker switch Off-the-road gear
5 transfer case. As soon as the off-the-road gear is engaged, the indicator
lamp Off-the-road gear illuminates.
The on-the-road gear is switched off and the indicator lamp On-the-road
4 gear goes out simultaneously.

The off-the-road gear is not engaged if the Off-the-road gear indicator lamp
5 does not illuminate.
• Switch the automatic gearbox briefly into position D and switch it back
to position N.
Press the Off-the-road gear transfer case rocker switch again.

Deactivating off- • Stop the truck crane.

the-road gear
• Switch the automatic gearbox into neutral position N.
> • Switch on the on-the-road gear with the rocker switch On-the-road gear
4 transfer case. As soon as the on-the-road gear is activated, the indicator
lamp On-the-road gear illuminates.
The off-the-road gear is switched off and the indicator lamp Off-the-road
5 gear goes out simultaneously.

The on-the-road gear is not engaged if the On-the-road gear indicator lamp
4 does not illuminate.
01.02.2000

• Switch the automatic gearbox briefly into position D and switch it back
to position N.
Press the On-the-road gear transfer case rocker switch again.

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 Driving the truck crane
6.3 Off-the-road driving

6.3.2 Drive of the second axle line / longitudinal differential locks

You can switch on the drive of the second axle line together with the lon-
gitudinal differential locks in the transfer case and the fourth axle line for
off-the-road driving.

The drive of the second axle line / longitudinal differential locks may only
be switched on if:

– The Level adjustment system key-operated switch is switched on

– The off-the-road gear is switched on and the Off-the-road gear indicator
lamp is lit.
The truck crane then drives in off-the-road gear only in the driving
ranges 1, 2 and R.

S
The drive of the second axle line / longitudinal differential lock may only
be switched on and off when the vehicle is stationary or is moving at a
speed of no more than 3 km/h. The drive of the second axle line / longitu-
dinal differential lock may not be switched on when driving on firm
ground.
Do not leave the drive of the second axle line / longitudinal differential
locks switched on longer than is absolutely necessary and always switch
it off before driving on firm ground.

Switching on • Stop the truck crane or let it roll with a maximum speed of 3 km/h.
drive / longitudi-
nal differential
locks
• Switch the automatic gearbox into neutral position N.
> • Position the steering straight ahead.
• Switch on the off-the-road gear.
5 • Turn on the level adjustment system with the key-operated switch.
• Press the Drive of the second axle line / longitudinal differential locks rocker
c switch down.
• Carefully start the truck crane until the Drive of the second axle line / longitu-

H
c dinal differential locks indicator lamp lights up.

When you turn on the Drive of second axle line/longitudinal differential locks
rocker switch, you trigger the mechanical gear changes for the drive of
the second axle line and the longitudinal differential locks. The Drive of the
second axle line/longitudinal differential locks indicator lamp will already light
up when one of the activation procedures is complete.
The indicator lamp also lights up when a further activation process is not
01.02.2000

carried out or completed mechanically (e. g. due to a malfunction).

s
Operating Instructions GMK 6300 2 084 548 en 6 - 37
Driving the truck crane
6.3 Off-the-road driving

Switching off dri-

ve / longitudinal
differential locks • Stop the truck crane or let it move at a maximum speed of 3 km/h.
• Switch the automatic gearbox into neutral position N.
> • Press the Longitudinal differential locks / drive of 2nd axle line rocker switch up.
c • Wait until the Longitudinal differential locks / drive of 2nd axle line indicator
c lamp goes out.
The indicator lamp only goes out once all deactivation procedures are

H
completed mechanically.

If the Drive of the second axle line / longitudinal differential locks indicator lamp
does not go out, assist the deactivation procedure by driving forward and
back slowly.

Once the indicator lamp has gone out, switch the level adjustment system
key-operated switch off again.

Switch off on-the-road gear or off-the-road gear when you no longer

5 need it.

S
Gearbox damage may occur due to the transfer case not functioning
properly!
Switch off the longitudinal differential locks / drive of 2nd axle line with
the Longitudinal differential locks / drive of 2nd axle line rocker switch!
Do not use the level adjustment system key switch!
This prevents improper shifting and possible damage in the axle centre
drive and transfer case.

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 Driving the truck crane
6.3 Off-the-road driving

6.3.3 Transverse differential locks in all driven axle lines

The transverse differential locks in the driven axle lines prevent the spin-
ning of individual wheels when driving on slippery ground.

The transverse differential locks can only be switched on if:

– the key-operated switch Level adjustment system is switched on and
– The off-the-road gear is switched on and the Off-the-road gear indicator
lamp is lit.
The truck crane then drives in off-the-road gear only in the driving ranges
1, 2 and R.

S
Switch the transverse differential locks on or off only when the vehicle is
stationary or moving at a maximum speed of 3 km/h. The transverse diffe-
rential locks may not be switched on when driving around corners on so-
lid ground. Do not leave the transverse differential locks switched on any
longer than necessary. It is imperative that you switch off the transverse
differential locks when driving on firm ground!

Activating trans-
verse differential
locks • Stop the vehicle or let it move at a maximum speed of 3 km/h.
• Switch the automatic gearbox into neutral position N.
> • Straighten the steering.
• Switch on the off-the-road gear.
5 • Turn on the level adjustment system with the key-operated switch.
• Press the rocker switch Transverse differential locks in all driven axle lines
h down.
• Carefully start the vehicle until the indicator lamp Transverse differential
h locks in all driven axle lines illuminates. The indicator lamp will flash if one
or more of the transverse differential locks has not been activated.
It will illuminate continuously only when the transverse differential
locks of all driven axle lines have been activated.
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Operating Instructions GMK 6300 2 084 548 en 6 - 39
Driving the truck crane
6.3 Off-the-road driving

Deactivating
transverse
differential locks • Stop the vehicle or let it roll with a maximum speed of 3 km/h.
• Switch the automatic gearbox into neutral position N.
> • Press the rocker switch Transverse differential locks in all driven axle lines up.
h The indicator lamp will flash if one or more of the transverse differential
locks have not been deactivated. It will not go out until the transverse

H
differentials in all axle lines have been deactivated.

One or more of the locks are still locked into place if the indicator lamp
flashes after the transverse differential locks have been deactivated. You
may expedite the disengaging of the locks by slowly driving forward and
backward while turning the steering slightly!

Once the indicator lamp has gone out, switch the level adjustment system
key-operated switch off again.

• Switch the on-the-road gear off again when you do not need it anymore.
5

S
Gearbox damage may occur due to the transfer case not functioning
properly!
Always switch off the transverse differential locks with the rocker switch
Transverse differential locks in all driven axle lines!
Do not use the level adjustment system key switch!
This prevents improper shifting and possible damage in the axle central
drive.

6.3.4 Level adjustment system

You may improve the off-the-road handling of the truck crane by in-
creasing its ground clearance and chassis angle with the level adjustment
system. Operation of the level adjustment system is inhibited by a key
switch.

Leave the key switch on when the truck crane is not at on-the-road level.
After a level change, return the truck crane to on-the-road level as soon as
possible.
Turn off the key switch and remove the key.
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 Driving the truck crane
6.3 Off-the-road driving

The rocker switches for the following functions are also activated using
this key switch:
– Transverse differential locks in all driven axle lines,
– Drive of the second axle line / longitudinal differential locks,
– Separate steering,
– Blocking gears 3, 4 and 5 in the automatic gearbox (only gears 1, 2 and
R may still be used).

Activating the
level adjustment
system

S
The suspension locking system of all axle lines must be switched off for
all level changes!
The transverse differential locks and the drive of the second axle line /
longitudinal differential locks must also be switched off!

• Insert the key into the Level adjustment system key-operated switch and
turn on the switch.
• Maintain the engine speed at between 1000 and 1300 rpm using the
accelerator during each level change.

C0018

Raising or lower-
ing the entire
truck crane
• Select the direction of movement of the level adjustment using the Raise /
: lower vehicle level rocker switch:
Raising the truck crane: Press rocker switch up.
Lowering the truck crane: Press rocker switch down.

The Raise vehicle level and Lower vehicle level indicator lamps show the selec-
98 ted direction of movement.

H
• Let the truck crane roll at approx. 3 km/h during the level change.

Applying the brakes during the level change increases tyre wear as well as
the load on the suspension cylinders. Therefore you should – if possible –
release the parking brake and allow the truck crane to roll during a level
change.
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Operating Instructions GMK 6300 2 084 548 en 6 - 41
Driving the truck crane
6.3 Off-the-road driving

Press the Raise / lower truck crane rocker switch down to raise or lower the
| entire truck crane.

The No on-the-road level indicator lamp will illuminate as soon as the truck
{ crane is no longer at on-the-road level.

S
Damage may occur to the suspension cylinders!
The distance the truck crane is raised or lowered changes the suspension
range accordingly. Drive carefully after changing the vehicle level in order
to prevent damage to the suspension cylinders!

Tilting the truck

crane lengthwise
or crosswise
• Select the direction of movement of the level adjustment using the Raise /
: lower vehicle level rocker switch:
Raising the truck crane: Press rocker switch up.
Lowering the truck crane: Press rocker switch down.

The Raise vehicle level and Lower vehicle level indicator lamps show the
89 selected direction of movement.

H
• Let the truck crane roll at approx. 3 km/h during the level change.

Applying the brakes during the level change increases tyre wear as well as
the load on the suspension cylinders. Therefore you should – if possible –
release the parking brake and allow the truck crane to roll during a level
change.

Using the rocker switches you may tilt the truck crane
6789 – forward or backward (longitudinal tilt) or
– to one side (diagonal tilt):

raise or lower at the front,

6 raise or lower at the rear,
7 raise or lower on the right-hand side,
8 raise or lower on the left-hand side.
9
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 Driving the truck crane
6.3 Off-the-road driving

The No on-the-road level indicator lamp will illuminate as soon as the truck
{ crane is no longer at on-the-road level.

S
Damage may occur to the suspension cylinders!
The distance the truck crane is raised or lowered changes the suspension
range accordingly. Drive carefully after changing the vehicle level in order
to prevent damage to the suspension cylinders!

Moving the truck • Park the truck crane on a flat, even surface.
crane into
• Straighten the steering.
position On-the-

H
road level • Let the truck crane roll at approx. 3 km/h during the level change.

Applying the brakes during the level change increases tyre wear as well as
the load on the suspension cylinders. Therefore you should – if possible –
release the parking brake and allow the truck crane to roll during a level
change.

• Press the On-the-road level rocker switch until the No on-the-road level
{ indicator lamp goes out.

Deactivating the • Turn the Level adjustment system key-operated switch to the right until it
level adjustment engages then remove the key.

S
system
Damage may occur to the suspension cylinders!
Do not turn off the level adjustment system until the truck crane is at
on-the-road level.

6.3.5 Freeing an immobilised truck crane

Freeing the truck If the crane is stuck in terrain, you can attempt to free it by changing
crane by oneself between forward and reverse driving (rocking free):

When rocking the vehicle free you should engage the off-the-road gear,
the transverse differential lock and the drive of the 2nd axle line.
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Operating Instructions GMK 6300 2 084 548 en 6 - 43
Driving the truck crane
6.3 Off-the-road driving

• Let the engine speed drop to idling speed.

• Select the limited driving range 1.
Ä • Press the accelerator until the truck crane comes to a halt.
• Press the service brake and release the accelerator.
• Let the engine speed drop to idling speed.
• Switch to neutral position N.
> • Select driving range R.
= • Release the service brake and press the accelerator until the truck crane
comes to a standstill.
• Press the service brake and release the accelerator.
• Let the engine speed drop to idling speed.
• Switch to neutral position N.
> Repeat the procedure until the truck crane has been freed.

Towing in reverse • Fasten a long steel rope to one of the towing eyes on the rear chassis
wall using a shackle. The towing eyes are located beside the tail lamps.
The towing eyes on the chassis rear wall are intended for a maximum
tractive force of 75 kN (7.6 t) if:
– The direction of pull runs out along the longitudinal axle toward the
rear or at an angle of 90° to the right or left from the longitudinal axle.
– The direction of pull runs along the longitudinal axis toward the rear
without diverting up or down.

S
Damage may occur to the chassis!
Only tow the truck crane free while observing the procedure given above
for the pulling direction. Otherwise the chassis can be damaged or the
towing eyes can bend off.

Towing free • Fasten a steel rope to the front towbar coupling.

S
forward
Damage may occur to the chassis!
The tractive force on the front towbar coupling may not exceed 98 kN
(10 t) to the front or at an angle of 45° to both sides from the longitudinal
axle of the truck crane. Support the towing manoeuvre with the engine
power of the truck crane. Pulling jerkily or at an angle is prohibited!
Pulling out the truck crane jerkily or at an angle may damage the chassis.
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 Driving the truck crane
6.4 Separate steering

6.4 Separate steering

Deutsche GROVE GmbH recommends switching to separate steering
when driving on the construction site at low speeds or when steering at a
standstill on the construction site.

When you switch on the separate steering, the wheels of the fourth axle
line are also steered. Prerequisites for this:
– The electronics are switched on for separate steering.
– The steering lock on the fourth axle line is unlocked.
– The drag rod joint between the third and fifth axle lines is separated.
– The manual steering of the third axle line is unlocked.
– The hydraulic system is switched over.
All locks are held by spring force for normal steering. For separate stee-
ring, this spring force is pneumatically opposed and thus the lock is re-
leased.

When separate steering is switched on:

– The first and second axle line are steered using the steering wheel.
– The fifth and sixth axle lines are steered with the Separate steering on the
b bottom left side of the driver’s seat.
– The steering of the third and fourth axle lines are electronically control-
led. The electronics register the current steering angle on the first, se-
cond, fifth and sixth axle lines and accordingly steers the wheels of the
third and fourth axle lines.
Operation of the separate steering is inhibited by the Level adjustment sys-
tem key switch. Leave the key-operated switch on as long as the aforemen-
tioned joints are unlocked or separate.
Reestablish the joints as soon as possible, switch the key-operated switch
off again and remove the key.
As long as the Level adjustment system key-operated switch is switched on,
C0018 only the gears 1 and 2 are active in driving range D.

You can drive with all-wheel steering as well as crab travel mode when
the separate steering is switched on.
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Operating Instructions GMK 6300 2 084 548 en 6 - 45
Driving the truck crane
6.4 Separate steering

All-wheel steering:
If you cramp the wheels of the first, second and third axle lines and the
wheels of the fourth, fifth, and sixth axle lines in opposite directions, the
turning circle of the truck crane becomes smaller.

C0931

Crab travel mode:

If you steer the wheels so that they are cramped in the same direction on
all axle lines, the truck crane drives diagonally and sideways.

G
Accidents may occur during on-road driving with unlocked steering!
After driving with separate steering, reestablish the normal driving mode
with locked steering on the fourth axle line, connected drag rods between
the third and fifth axle lines and locked manual steering of the third axle
line without delay.
The Steering unlocked warning lamp and the Separate steering indicator lamp
must not be lit.

6.4.1 Switching on separate steering

• Switch on the Level adjustment system key switch.

This switches on the electronics for separate steering.

C0018

• Press the Separate steering rocker switch down.

b This requires pressing the lock button.
The unlocking procedures will begin:
– The steering lock on the fourth axle line is unlocked.
– The manual steering of the third axle line is unlocked.
– The drag rod joint between the third and fifth axle lines is separated.

As soon as a lock is released, the Steering unlocked warning lamp lights up.
? When all joints are unlocked or separated, the hydraulic system is
01.02.2000

switched over for the separate steering.

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 Driving the truck crane
6.4 Separate steering

When these procedures have been finished and the electronics for separa-
b te steering are ready, the Separate steering indicator lamp also lights up.
The steering system is now in separate steering mode.

6.4.2 Steering axle lines with separate steering

H If you have activated the outrigger or the level adjustment system whilst
separate steering is switched on, the current steering angle must be re-
corded again by the control system and the steering angle of the third and
fourth axle lines must be adjusted before steering ensues for the next
time; ➠ Match steering angle, p. 6-10.

You can steer the wheels of the fifth and sixth axle lines with the Separate
b steering rocker switch when the separate steering is switched on.
The rocker switch is located on the bottom left side of the driver’s seat.

Cramping wheels to the left: Push rocker switch to the left

Cramping wheels to the right: Push rocker switch to the right

The steering angle changes until you release the rocker switch or until the
end position is reached.

The electronics register the current position of the first, second, fifth and
sixth axle lines and steers the wheels of the third and fourth axle lines in
the direction corresponding to the turning circle radius or crab travel
mode.

All-wheel steering If you turn the wheels of the fifth and sixth axle lines opposite to those
of the first and second, the electronics turn the wheels of the third and
fourth axle lines to correspond to the turning circle radius.

Crab travel mode If you turn the wheels of the fifth and sixth axle lines in the same direction
as those of the first and second, the electronics turn the wheels of the
third and fourth axle lines also in the same direction for crab travel mode.

The wheels of the first and second axle lines are steered with the steering

H
wheel.

The steering on the first and second axle lines are only supported by the
steering circuit I when separate steering is switched on. This means that
01.02.2000

the wheels on these axle lines cannot be moved as far in standstill as they
can be in the On-road driving setting.

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Operating Instructions GMK 6300 2 084 548 en 6 - 47
Driving the truck crane
6.4 Separate steering

G
Accidents may occur during on-road driving with unlocked steering!
After driving with separate steering, reestablish the normal driving mode
with locked steering on the fourth axle line, connected drag rods between
the third and fifth axle lines and locked manual steering of the third axle
line without delay; ➠ Switch off separate steering and lock steering, p. 6-48.

6.4.3 Switching off separate steering and locking steering

For on-road driving you must switch off the separate steering again and
the following prerequisites must be fulfilled:
– The steering of the fourth axle line is locked.
– The manual steering of the third axle line is locked.
– The drag rod is connected between the third and fifth axle lines.
Upon switching off the separate steering the locks are bled of air one after
the other and the spring force for locking is again established. The locks

H
can however only be engaged when the wheels are in the correct position.

If you switch off the separate steering, the locking of the steering will be-
gin right after. If the wheels are in the correct position, the locking proce-
dures are executed very quickly, one directly after the other, and the
warning and indicator lamps go out.
The correct position of the wheels can be most easily reached in the
straight forward position. But you can lock the steering in other positions
as well; ➠ Mechanically locking in another position, p. 6-49.

G
Accidents may occur during on-road driving with unlocked steering!
Always check the steering lock after switching off the separate steering,
as described in this section.
Only once the warning and indicator lamps below have gone out is the
truck crane in a safe condition for on-road driving.

• Release the Separate steering rocker switch and press it up.

b The locks on the third and fourth axle lines are first bled of air. But they
can only engage if the wheels are in the correct position.

• Steer the wheels of the first and second axle lines into the straight for-
ward position with the steering wheel.
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 Driving the truck crane
6.4 Separate steering

• Steer the wheels on the fifth and sixth axle lines into the straight for-
b ward position with the Separate steering rocker switch.
Once the correct position has been reached, the locks on the third and
b fourth axle lines engage and the indicator lamp Separate steering goes out.

The lock of the drag rod between the third and fifth axle lines is bled of air.
The joint engages audibly and the Steering unlocked warning lamp goes out.
? If the indicator lamp does not go out, steer the steering slowly over the
straight forward position a few times.

• Switch off the key switch Level adjustment system and remove the key.

C0018

Locking in other positions

You can lock the steering in every other position which corresponds to on-
road driving. For this you must turn the wheels of the fifth and sixth axle
lines opposite the steering angle of the first and second axle lines at the

H
corresponding spot in this section.

Always steer the wheels of the fifth and sixth axle lines to the correct posi-
tion for connecting.
If the wheels on the fifth and sixth axle lines are fully cramped, they do
not reach the necessary cramping angle for the engaging of the connec-
tion with the first, second, and third axle lines because of the reduced
steering force (only steering circuit I).
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Operating Instructions GMK 6300 2 084 548 en 6 - 49

Driving the truck crane
6.4 Separate steering

6.4.4 Matching steering angle

When separate steering is switched on and you activate the outrigger or

the level adjustment system, the separate steering control system no lon-
ger records the current steering angle.
If the steering angle changes (e. g. when relieving the load on the wheels
by raising the crane), the wheels of the third and fourth axle lines will not
automatically match the steering angle to the other axle lines.

You must therefore do the following after activating the outrigger or level
adjustment system:

• Press the Separate steering rocker switch and hold it down.

b The separate steering now records the steering angles on the axle lines
and matches the steering angles of the third and fourth axle lines.

• Wait until no more wheels are steered and let the Separate steering rocker
b switch go.
By letting go of the rocker switch, the control unit switches back into sepa-
rate steering mode and you can control the axle lines again with separate
steering.

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 Driving the truck crane
6.5 Heating and ventilation

6.5 Heating and ventilation

6.5.1 Driver’s cab heating system

A heat exchanger heats the driver’s cab with the heat from the engine
coolant.

Fresh air, recirculated air or mixed air can be

used as the suction air of the heating system.
The air is controlled using the Recirculated air /
fresh air mode regulator (1):

1 Fresh air: Push regulator up.

Mixed air: Regulator in mid-position.

Recircu-
lated air: Push regulator down.

C0758

The regulator Heater temperature regulator (1)

is used to set the desired air temperature:

Warm: Push regulator down.

Cold: Push regulator up.

1 The blower is switched on with knobs (2)

and (3):

Knob (2): Driver’s side

Knob (3): Passenger side

2 3
C0759

The fans have three levels (low, medium, high).

01.02.2000

To switch on, turn the knob to the right; the three levels engage one after
the other.
To switch off, turn the knob as far as possible to the left.

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Operating Instructions GMK 6300 2 084 548 en 6 - 51
Driving the truck crane
6.5 Heating and ventilation

Air distribution in the driver’s cab can be set

using the regulators Air distribution (1 and 2):
Regulator (1): on the driver’s side
Regulator (2): on the passenger side

12 Windscreen and in-

strument panel: Push regulator up.
All vents: Regulator in
mid-position.
Cab floor: Push regulator down.

C0760

You may control the air flow of the air vents

(1) on the instrument panel using the ad-
justing knob (2). You may adjust all vents
individually using the regulator (3):

1 Vent open: Regulator pushed to the

blue area.
Vent closed: Regulator pushed to the
white area.
2
3

H
C0033

If the windscreen becomes foggy in damp weather, push the regulators

Fresh air mode / circulation air operation and Air distribution up and the regu-
lator Temperature of the heating system down.
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 Driving the truck crane
6.5 Heating and ventilation

Ventilating the
driver’s cab
• Push the regulator heater temperature (1) up
as far as it will go and turn on the blower
using the knobs (3) and (4).
• Push the regulator Circulation air operation /
2 fresh air mode (2) up.

3 4
C0761

6.5.2 Roof blower (additional equipment)

The blower used to ventilate the driver’s cab is installed in the ceiling of
the cab.

You may determine the direction of the air flow (in or out) using the
~ Roof fan rocker switch located on the front instrument panel.

Remove air: switch pressed up

Off: mid-position
Air in: switch pressed down

You can regulate the volume of air with the

handwheel (1).
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Operating Instructions GMK 6300 2 084 548 en 6 - 53

Driving the truck crane
6.5 Heating and ventilation

6.5.3 Additional water heating system (additional equipment)

Preheating the The vehicle engine may be preheated using the additional heating
vehicle engine system. The regulator for the Temperature of the heating system in the

H
driver’s cab must be set to Warm and the blower should be off.

If you operate the additional heating system with the engine off, the
batteries will run down. If you use the additional heating system frequent-
ly, you must recharge the batteries in shorter intervals!

When the vehicle engine is running, the additional heating system supple-
ments the engine’s heating output when the outside temperature is low
and the engine has not sufficiently warmed up the coolant.

When the operating temperature of the vehicle engine has been reached,
a thermostat turns off the heater, while the pump of the heating system
remains on.

Once the heater has been turned off, the additional heating system should
be turned off manually to prevent it from starting up again.

Preheating the If you turn on the blower as described in the section Heating the driver’s

H
driver’s cab cab, p. 6-51, the driver’s cab will be heated simultaneously.

If you heat the driver’s cab simultaneously, the amount of time required
to preheat the vehicle engine will increase significantly.

Switching on
the additional
heating system
• Push the regulator Heating air temperature
(1) downwards into the Warm position.

1
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C0813

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 Driving the truck crane
6.5 Heating and ventilation

• Press the Additional heating system rocker switch down to turn on the
0 additional heating system. The indicator lamp in the rocker switch
illuminates.
After a preheating period of approx. 15 seconds, automatic ignition takes
place. If the heating system does not trigger after 30 seconds, ignition is

H
aborted.

The indicator lamp in the rocker switch merely indicates that the switch
has been operated and that the heating system has been switched on or
off. It does not indicate whether the heating system has been triggered.

The heating system has triggered if:

– the Additional heating system indicator lamp illuminates, and
0 – the air flowing from the blower vents is warming up (cab heating), or
– the engine temperature rises (preheating vehicle engine).
Once the heating system has triggered, a thermostat in the heater takes

H
over control of the heating system.

If a malfunction of approx. 10 seconds occurs while the heating is on, the

heating system will automatically shut down.

If you wish to restart the heating system, you must turn off the Additional
0 heating system rocker switch and turn it back on again.

Deactivating
the additional
heating system
• Press the Additional heating system rocker switch up to turn off the
0 additional heating system. The Additional heating system indicator lamp
will go out.
The heating pump will continue to run for approx. 3 minutes to cool

H
down the heater.

Turning off the battery master switch while the heater is cooling down
will not interrupt the cooling of the heater.
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Operating Instructions GMK 6300 2 084 548 en 6 - 55

Driving the truck crane
6.5 Heating and ventilation

6.5.4 Additional heating system with timer (additional equipment)

Preheating the The vehicle engine may be preheated using the additional heating sy-
vehicle engine stem. During additional heating the heating air temperature regulator in the

H
driver’s cab must be set at Warm and the fan must be switched off.

If you operate the additional heating system with the engine off, the batte-
ries will run down. If you use the additional heating system frequently,
you must recharge the batteries in shorter intervals!

When the vehicle engine is running, the additional heating system supple-
ments the engine’s heating output when the outside temperature is low
and the engine has not sufficiently warmed up the coolant.
When the operating temperature of the vehicle engine has been reached,
a thermostat turns off the heater, while the pump of the heating system
remains on.
Once the heater has been turned off, the additional heating system should
be turned off manually to prevent it from starting up again.

Preheating the If you turn on the blower as described in the section Heating the driver’s

H
driver’s cab cab, p. 6-51, the driver’s cab will be heated simultaneously.

If you heat the driver’s cab simultaneously, the amount of time required
to preheat the vehicle engine will increase significantly.

Switching the • Turn the diesel engine ignition on.

heating system
on/off
• To switch on, press the switch heating on/off pushbutton once.
L The heating switches on and the display and switch light up. The fan
starts.
The heating system turns on and the Heating system on indicator lamp
lights up.

H You can also store the switch-on point and have the heating turned on
automatically; ➠ Save automatic heating start, p. 6-57.
01.02.2000

• To switch off press the switch heating on/off pushbutton once.

L The heating switches off immediately.

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 Driving the truck crane
6.5 Heating and ventilation

Displaying and It is always possible to display and set the current time on the Heating sys-
setting the cur- tem display.
rent time

• Press and hold down the Display/set time push-button.

w As long as you press on the push-button, the current time will be shown
on the Heating system display.

• To set the time, also press one of the two Backwards or Forwards push-
J K buttons.
The longer you keep one of the push-buttons depressed, the faster the
time will go backwards or forwards.
• When the correct time is shown, let go of all the push-buttons.
The status display goes out after about 20 seconds, and the new time will
be saved.

Switching on The heating system can be set so that it switches on automatically. There
and saving auto- are two storage locations at which you can save different heating starts
matic heating and which then can then be switched on as you wish.
start

Switching on automatic heating start

• Press the respective push-button for the desired storage location; that
M N is, Storage location 1 or Storage location 2.
In the Heating display the called up storage location will be shown (e. g.
2 bottom left) along with the time of the last heating start to be saved
(e. g. 16.30).

• If the heating system is to be switched on at the set time wait about

20 seconds until the time in the display goes out.
Now the automatic heating start is switched on and the Automatic heating
start indicator lamp lights up.

The heating system switches itself on at the time which is set at storage
location 2.
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Operating Instructions GMK 6300 2 084 548 en 6 - 57
Driving the truck crane
6.5 Heating and ventilation

Storing automatic heating start

Press the respective push-button once for the storage location where you
M N want to save a new time; that is, Storage location 1 or Storage location 2.

In the Heating display the called up storage location will be shown (e. g.
2 bottom left) along with the time of the last heating start to be saved
(e. g. 16.30).

• Use the Backwards or Forward push-buttons to set the time for the new
J K heating start (e. g. 8.00).

• The new time will be saved. After 20 seconds the time will go out and
only the storage location will be shown.

Now the automatic heating start is switched on and the Automatic heating
start indicator lamp lights up.

The heating system switches on at the time saved at storage location 2.

Switching off The Automatic heating start indicator lamp lights up and the activated sto-
automatic hea- rage location will be shown on the Heating system display.
ting start

• For the storage location that is shown, press the respective push-button
M N once; i.e. Storage location 1 or Storage location 2.
The storage location will not be shown any more, and the Automatic
heating start indicator lamp goes out.

The automatic heating start is switched off.

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6.6 Air-conditioning system (additional equipment)

6.6 Air-conditioning system (additional equipment)

The air-conditioning system is located on the roof of the driver’s cab. It
only works in recirculated air mode. The refrigerant compressor is driven
via V-belts by the vehicle engine.
Further information on the crane cabin air conditioning can be found in
section Air conditioning, p. 6-60.

6.6.1 Switching on

• Turn the Blower knob to level 1, 2 or 3 depending on the output desired.

• Set the desired temperature with the thermostat knob switch.

• Adjust the air outlet jets so that the cool air is mixed well with
the cabin air.

6.6.2 Switching off

• Turn the Blower knob to the 0 position.

• Turn the Thermostat knob switch to the left as far as possible.

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Operating Instructions GMK 6300 2 084 548 en 6 - 59

Driving the truck crane
6.6 Air-conditioning system (additional equipment)

6.6.3 Air conditioning

How to ensure Avoid excessive cooling of the air in the cab.

pleasant air- For example, with an outside temperature of 40 °C the temperature inside
conditioning the cab should lie between 26 °C and 30 °C; in other words, the difference
in temperature should not exceed 10 °C to 14 °C. When the external tem-
perature is low, you should select a correspondingly lower temperature
difference. Excessive cooling frequently results in physical discomfort,
mostly after you have left the cab.

Avoid exposing your body directly to cold air. Direct the air stream from
the nozzles in the cab floor so that the cold air mixes thoroughly with the
warm air in the cab. This produces an even temperature throughout the
cab and ensures cooling without a draught.

In the mixed air mode, operate the air-conditioning system with a low
proportion of fresh air in order to dehumidify the driver’s cab, while at the
same time ensuring a fresh supply of oxygen.

Keep adjusting the cooling system as needed:

Initially, if the truck crane has e. g. been parked in strong sunlight for a
long time, the cooling system should be operated at maximum cooling
capacity and with the blower on setting 3 with the vehicle’s engine running.
The driver’s cab doors or at least the windows should be kept open for a
time to ventilate the cab.
The cooling-down process can be accelerated by increasing the engine
speed.

If you then continue to run the air-conditioning system, close the windows
and other air vents to ensure that the driver’s cab can be cooled adequately.

Once the desired inside temperature has been reached, set the blower to
level 2 again and reduce the cooling output on the air conditioner tempe-
rature regulator correspondingly. If only a low level of cooling is required,
blower level 1 will be sufficient.
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6.6 Air-conditioning system (additional equipment)

Dehumidifying On humid days at the turn of the season you can dehumidify the air in the
the air in the crane operator’s cab by operating the air-conditioning system in the com-
driver’s cab bined heating and cooling mode. Operation of the heating system is

H
described in section Heating and Ventilation, p. 6-51.

As this involves the heating and air-conditioning system functioning

“in opposition to each other” dehumidifying produces little or no heat.

• Set the knob Driver / passenger side heater fan and the knob switch Thermostat
of the air-conditioning system to approximately the same output.

H
• Switch on the blower.

The air in the cab will be dehumidified more thoroughly the higher the
heating and cooling settings are set.
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Operating Instructions GMK 6300 2 084 548 en 6 - 61

Driving the truck crane
6.6 Air-conditioning system (additional equipment)

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6.7 Towing a trailer (additional equipment)

6.7 Towing a trailer (additional equipment)

A towbar coupling has been installed on the rear side of the chassis to
facilitate towing a trailer.

Please observe the permissible trailer load of your truck crane.

G
Accidents may occur if the trailer rolls away!
Before coupling or uncoupling the trailer, it must be secured with the
trailer parking brake as well as chocks on the rear axle to prevent it from
rolling away. Ensure that it still possible to swivel the unbraked front axle
of the trailer.

H Before coupling the trailer, adjust the towbar to the height of the towbar
coupling.

G
Accidents may occur when coupling the trailer!
No one may stand between the truck crane and the trailer when coupling
the two vehicles.

H Please observe the professional trade association regulations regarding

the coupling and uncoupling of the trailer.

Effects on the Observe the effects on the axle loads when towing a trailer. The axle
axle loads loads of your truck crane change in the following manner when operating
with central axle trailers:

– For every 100 kg drawbar load, the axle loads on the first and second
axle lines decreases by 37 kg each.
– For every 100 kg drawbar load, the axle loads on the third, fourth, fifth
and sixth axle line increases by 44 kg each.
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Operating Instructions GMK 6300 2 084 548 en 6 - 63
Driving the truck crane
6.7 Towing a trailer (additional equipment)

Coupling the
trailer

G
Risk of injury if the automatic closing device is actuated!
Do not put your hand into the coupling jaw when the trailer coupling is
open.
This can actuate the automatic closing device, make the cotter pin move
down with great force and seriously injure your hand.

• Open the trailer coupling.

To do this, push the hand lever (1) up.
The lever locks into the uppermost position.
• Check that the coupling jaw (2) is stable.
It must not be allowed to move to the left
or the right when the towbar coupling is
open.
• Adjust the towbar of your trailer to the
height of the towbar coupling and carefully
drive the truck crane in reverse towards the
towbar.
The towbar coupling automatically locks
when the eyes of the towbar and towbar
coupling are correctly aligned. The hand
lever (1) disengages from the uppermost
position and drops down.

H Make sure that you check the prescribed condition of the coupling after
every coupling process.

The control pin (1) must not protrude from

the guide bushing after the trailer has been
coupled. 01.02.2000

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6.7 Towing a trailer (additional equipment)

G
Accidents may occur if the trailer is incorrectly coupled!
If the control pin is protruding from the guide bushing (this can also be
established in the dark by touch), the trailer is not correctly coupled and
could be disengaged from the towbar coupling when you are driving.

Connecting
supply cables

• Insert the plug of the trailer’s electrical

system into the socket (5). Also insert the
ABS connecting cable into the socket (3) if
necessary (additional equipment).
• First connect the hose of the brake cable to
the yellow coupling head (4).
• Subsequently connect the hose of the
supply cable to the red coupling head (1).
Another cable is connected to the socket (2)
(additional equipment) for special equipment
of the trailer.

G
Accidents may occur if the hoses are too short or incorrectly positioned!
The hose lines must not come off when driving around corners. When
connecting the hoses, ensure that the length is sufficient and that the
hoses have enough clearance.

• Check the function of the trailer’s direction indicators and light system.
• Test the service brake and the parking brake immediately after setting
off.
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Operating Instructions GMK 6300 2 084 548 en 6 - 65
Driving the truck crane
6.7 Towing a trailer (additional equipment)

Removing the
supply lines

G
Accidents may occur if these steps are not carried out in the proper
order!
It is imperative that the hoses be disconnected in the order specified
below.
It is imperative that the hoses be disconnected in the order specified be-
low. If the hose for the brake line is disconnected first, the trailer brake
will be released and the trailer will begin to roll.

• First disconnect the hose of the supply line

from the red coupling head (1). The trailer
brakes automatically.
• Then disconnect the hose of the brake line
from the yellow coupling head (4).
• Pull the plugs of the trailer’s electrical sys-
tem out of the sockets (2), (3) and (5).
Pull the ABS connection cable (if one is at-
tached) out of the appropriate socket.

Uncoupling the
trailer

G
Risk of injury if the automatic closing device is actuated!
Do not put your hand into the coupling jaw when the trailer coupling is
open. This can actuate the automatic closing device, which moves the cot-
ter pin down with great force and may seriously injure your hand.
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6.7 Towing a trailer (additional equipment)

• Use the trailer service brake and chocks as

prescribed to prevent the trailer from
rolling.
• Open the trailer coupling.
To do this, push the hand lever (1) up. The
lever locks in the uppermost position.
• Drive the truck crane carefully away from
the trailer.

G
Risk of injury when closing the trailer coupling by hand!
When closing, the hand lever moves down with great force in the direc-
tion of the coupling jaw. Therefore start the closing process only by
moving the lever briefly in the direction of the coupling jaw with the hand
balls.
If you hold the hand lever and move it down, it may carry your hand with
it and crush it.

If no trailer is connected you must close the

trailer coupling by hand. Proceed in the
following manner:

• Move the hand lever knob (1) briefly in

the direction of the coupling jaw (observe
direction of arrow).

G
Always close the coupling when no trailer is connected. This prevents
people being injured by the automatic closing device being activated un-
01.02.2000

intentionally.

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Operating Instructions GMK 6300 2 084 548 en 6 - 67
Driving the truck crane
6.7 Towing a trailer (additional equipment)

Test position of When driving the truck crane with a trailer attached, you can check
the parking brake whether the braking force of the truck crane suffices to brake both the
when towing a truck crane and trailer on downhill and uphill slopes.
trailer
• When the parking brake is shut, push the parking brake lever down-
ward, pull it backward and hold it in this position.
This releases the parking brake on the trailer; the parking brake on the
truck crane remains engaged.
In this way, in the event of a defect to the trailer’s parking brake system
(e. g. a burst brake hose), you can check if the braking force of the truck
crane’s parking brake system alone is sufficient to brake the truck crane
and trailer.
• Release the parking brake lever again. The parking brake lever snaps
back into the parking brake engaged position and the trailer’s parking brake
is again engaged.

S
Accidents may occur if the truck crane is allowed to roll!
In addition to the parking brake, always secure the trailer with chocks
when parked on uphill or downhill slopes in order to prevent rolling. Do
this even if the parking brake functioned perfectly when you checked it.

H Wheel chocks are supplied only when they are included in the package for
the specific country.

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 _______________________________________________________________________________________ 7
7 Malfunctions on the carrier . . . . . . . . . . . . . . . . . . . . . . 7- 1
7.1 Emergency stop device on carrier . . . . . . . . . . . . . . . . . . . . . 7- 1
7.2 Breakdown in road traffic . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 3
7.3 Towing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 5
7.4 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
7.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.5.1 Plug-in modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.5.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.6 Troubleshooting and malfunction correction . . . . . . . . . . . . . . 7 - 21
7.6.1 Vehicle engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 21
7.6.2 Automatic gearbox malfunctions . . . . . . . . . . . . . . . . . . . . . . . 7 - 23
7.6.3 Transfer case malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 24
7.6.4 Differential lock malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 25
7.6.5 Service brake malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
7.6.6 Steering system malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
7.6.7 Outrigger malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 27
7.6.8 Suspension locking system malfunctions . . . . . . . . . . . . . . . . . . . 7 - 28
7.6.9 Level adjustment system malfunctions . . . . . . . . . . . . . . . . . . . . 7 - 28
7.7 Procedure in the event of malfunctions . . . . . . . . . . . . . . . . . 7 - 29
7.7.1 Switching the fan thermostat to emergency operation . . . . . . . . . . . . 7 - 29
7.7.2 Troubleshooting for malfunctions in the automatic gearbox . . . . . . . . 7 - 30
7.7.3 Emergency operation of the solenoid valves for the outriggers . . . . . . . 7 - 31
7.8 Separate steering emergency operation . . . . . . . . . . . . . . . . . 7 - 35
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2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the carrier
7.1 Emergency stop device on carrier

7 Malfunctions on the carrier

7.1 Emergency stop device on carrier

With the GMK 6300, you can also turn off the vehicle engine from outside
of the crane cab in an emergency (e.g. if the truck cranes rolls unintentio-
nally or if the ignition locks malfunctions).

Turning off the You can turn off the truck crane from ouside of the driver’s cab by
vehicle engine switching off the battery master switch.

The battery master switch (1) is located on

the left side behind the driver’s cab. It can be
reached through an opening in the panels.

• Switch off the main battery. Turn the selec-

tor handle so that it can be pulled off.
The crane engine switches off.
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Operating Instructions GMK 6300 2 084 548 en 7-1
Malfunctions on the carrier
7.1 Emergency stop device on carrier

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 Malfunctions on the carrier
7.2 Breakdown in road traffic

7.2 Breakdown in road traffic

Road traffic regulations require that a vehicle which has stopped in the
traffic lane, or on the verge or hard shoulder of a public highway due to a
breakdown or for any other reason be marked using the prescribed traffic
markers.

Please observe the following if a breakdown occurs:

• Keep calm!
• Brake the vehicle. Watch the traffic behind you when braking!
• Stop at a location that is safe for you, your vehicle and those behind you!

G
Risk of accidents if visibility is poor!
If possible, do not stop in a tunnel or directly after a curve.

• Secure the vehicle!

• Turn on the hazard warning lights!
• Secure the breakdown area:
– Set up a warning triangle.
– Set up a signal lamp or torch.

G
Risk of accidents if visibility is poor!
Warning triangles, signal lamps and torches must be set up in front of the
breakdown area in such a way as – to prevent rear end collisions, particu-
larly in curves!

Try to repair the damage yourself. If this is not possible, inform the local
GROVE Product Support or have the vehicle towed away; ➠ Towing the
truck crane, p. 7-5.

G
Risk of accidents when repair work is carried out in the danger area!
In danger area (e. g. tunnel, intersection, highway bridge), even repairs
which are easy to carry out are dangerous.
When in a danger area, only carry out the repair work which is required
to leave the area.
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Malfunctions on the carrier
7.2 Breakdown in road traffic

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 Malfunctions on the carrier
7.3 Towing the truck crane

7.3 Towing the truck crane

Observe the following when towing the truck crane:
– The truck crane may only be towed with a tow-rod. Attach the tow-rod
on the tow-rod coupling on the front bumper of the truck crane and the
towbar coupling of the towing vehicle.
– The statutory regulations concerning the overall length of the towing
and towed vehicle, including the tow-rod must be observed.
– If the vehicle engine, the steering and the service brake still work, you
may tow the truck crane with a truck.
– If the vehicle engine, the steering or the service brake no longer
function properly, the truck crane must be towed with a special
breakdown truck.
– Maximum towing speed is 25 km/h.
– The front towing coupling is for a maximum tractive force of 10 t.

Towing with If the compressed-air supply system is damaged, the filler connection of
running vehicle the truck crane must be connected to the Supply coupling head of the
engine towing vehicle; ➠ Compressed-air supply for vehicle engine breakdown in this
section, p. 7-7.

G
Accidents may occur if the brakes fail!
If the service brake system of the truck crane is damaged, the crane can
only be braked by the towing vehicle. You should therefore use extreme
caution when towing. Observe the mass of the towed vehicle and adjust
the speed and driving style accordingly.

• Let the vehicle engine run in neutral gear when towing.

• Select neutral on the automatic transmission; ➠ Driving ranges of the
automatic gearbox, p. 6-17.
• Switch the transfer case into neutral position; ➠ Gearbox in this section,
p. 7-8.
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Operating Instructions GMK 6300 2 084 548 en 7-5
Malfunctions on the carrier
7.3 Towing the truck crane

Towing when the To provide compressed air supply, connect the filler connection of the
vehicle engine is truck crane to the Supply coupling head of the towing vehicle;
off ➠ Compressed-air supply for vehicle engine breakdown in this section, p. 7-7.

G
Accidents may occur if the brakes fail!
If the service brake system of the truck crane is damaged, the crane can
only be braked by the towing vehicle. You should therefore use extreme
caution when towing. Observe the mass of the towed vehicle and adjust
the speed and driving style accordingly.

• When towing, switch the automatic gearbox and the transfer case to
neutral position.
The engine-dependent power steering is only supported by the emer-

H
gency steering pump of the transfer case during engine failure.

The emergency steering pump only pumps oil if the truck crane is rolling
at least 2 km/h.

S
Steering will become difficult if the power steering is only supplied by the
emergency steering pump!

S
If the truck crane is to be towed over a distance of more than 30 km, the
cardan shaft between the transfer case and the automatic gearbox on the
transfer case must be disconnected and secured.
The automatic gearbox must be in neutral position and the transfer case
in on-the-road gear when the crane is being towed.

S
Be careful not to damage the cardan shaft!
The vehicle engine must not be started while the cardan shaft is discon-
nected from the transfer case!
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 Malfunctions on the carrier
7.3 Towing the truck crane

Compressed-air
supply in the
event of engine
failure
The filler connection (1) of the truck crane
must be connected to the Supply coupling
head of the towing vehicle to supply the
truck crane with compressed air.
The filler connection (1) is located at the
front on the inside of the sheet metal
paneling between the steps and can be
reached from below.

Monitor the supply pressure on the Supply pressure brake circuits I and II
5
4 6 status display during towing.
3 7
The supply pressure must be at least 6 bar for towing!
2 8

1 9
0 bar 10

C0005

The Supply pressure brake circuits I and II warning lamp must not light up!
l
Power supply

• Switch on the battery master switch.

• Switch on the ignition.

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Operating Instructions GMK 6300 2 084 548 en 7-7
Malfunctions on the carrier
7.3 Towing the truck crane

z H For additional equipment with flame start system, the flame start system
is activated every time the ignition is started. If the vehicle engine is not
started it switches itself off after a certain interval, which depends on the
temperature of the coolant.

Gearbox Deactivate all differential locks. Switch the transfer case into neutral
position N.

• To do this, press down the Transfer case neutral position rocker switch.
v45 The On-road driving and Off-road driving indicator lamps must go out.
• Switch the automatic gearbox into neutral position N.
v
If the automatic gearbox is damaged, the cardan shaft between the trans-
fer case and the automatic gearbox on the transfer case must be discon-
nected and tied up.

Vehicle engine

Start the vehicle engine if it is operable.

H Please note that the flame start system (additional equipment) is only
active for a certain interval after the ignition is switched on; ➠ Starting
the vehicle engine; p. 5-10.

Parking brake

• Release the parking brake.

C0107

The Parking brake indicator lamp goes out.

f
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 Malfunctions on the carrier
7.3 Towing the truck crane

H The supply pressure in brake circuit 3 is not high enough if the indicator
lamp does not go out.
Increase the supply pressure by waiting a few minutes with the vehicle
engine running or with the filling connector in place and the towing
vehicle engine running.
If the indicator lamp still does not go out, the parking brake system is
damaged and the parking brake must be mechanically released before
towing; ➠ Releasing the parking brake mechanically, p. 7-9.

Mechanically
releasing the
parking brake

S
The parking brake should only be released mechanically if it can no
longer be pneumatically released. It should only be released mechanical-
ly if the truck crane must be towed but must thereafter be immediately re-
activated!

G
Accidents may occur due to the unchecked movement of the truck crane!
The movement of the truck crane can no longer be stopped by means of
the parking brake when the parking brake is mechanically released.
Secure the vehicle with wheel chocks before mechanically releasing the
parking brake.

Open all spring accumulators

(two each on the second to fifth axle lines)
as follows:

• Unscrew the hexagon screw (1) (spanner

size 27) until it is touching the preloaded
spring.
• Continue to unscrew the hexagon screw
(1) until the wheel brake is released
(torque 5 to 15 Nm).

G
Accidents may occur due to released parking brake!
The spring-loaded brake cylinder must be unblocked immediately after
01.02.2000

towing. This may be carried out by trained, qualified personnel only as

the operational safety and roadworthy condition of the truck crane could
otherwise be impaired!

Operating Instructions GMK 6300 2 084 548 en 7-9

Malfunctions on the carrier
7.3 Towing the truck crane

Towing procedure The towing vehicle must start driving slowly.

S
Damage may occur to the chassis!
Starting to tow too quickly or in jolts can damage the chassis!

Removing the
mechanical
locking from all
spring-loaded
brake cylinders • Use chocks to prevent the vehicle from rolling.
• Fill the compressed-air supply completely (the Supply pressure brake
l circuits I and II warning lamp must not light up).
• Do not operate the service brake.

Gf
Accidents may occur if the brakes are improperly adjusted!
The removal of the mechanical locking on the brake cylinders may be
carried out by trained, qualified personnel only.

• Release the vehicle parking brake (Vehicle parking brake indicator lamp
must not be lit)

• Screw in the hexagon screw (1) completely.

• Tighten the hexagon screw with
40 + 10 Nm.
-0

• Perform a functional test on the service

brake and the parking brake.

Tow starting The vehicle engine cannot be started by tow starting the truck crane.
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 Malfunctions on the carrier
7.4 Wheel change

7.4 Wheel change

If a tyre puncture occurs while driving:

H
• Watch the traffic behind you and stop when it is safe.

Keep in mind that the steering wheel may jolt! Hold the steering wheel
with both hands!

• Choose the flattest possible location to change the tyres. The chosen
location should not impede traffic or pose danger to you or the vehicle!
• Protect the vehicle and the breakdown area; ➠ Breakdown in road traffic,
p. 7-3.

G
Danger of accidents from overturning wheel!
If you temporarily lean a wheel against the truck crane when changing a
wheel secure it against falling over with a rope!
Only move the outriggers if there is no wheel leaning against the truck
crane.

Removing a • Engage the vehicle parking brake.

damaged tyre
• Lock the suspension system.
• Lift the truck crane with the outrigger until the tyre that is to be changed
leaves the ground.
• Unscrew the wheel nuts.

G
Danger of accidents from overturning wheel!
When unscrewing the last wheel nuts the wheel can slip off the hub and
tip in your direction.
Move back quickly if the wheel threatens to tip.

• Remove the pressure plate.

• Pull the wheel off the wheel bolts (shake it off if necessary). Ensure that
the thread of the wheel bolts is not damaged.
• Secure the wheel against falling over if you temporarily lean it against
the vehicle.
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Operating Instructions GMK 6300 2 084 548 en 7 - 11
Malfunctions on the carrier
7.4 Wheel change

Removing the You can lift the spare wheel with a spur-wheel chain hoist or with the
wheel from the truck crane itself.
spare wheel
holder You should first of all support the truck crane if you wish to lift the spare
wheel using the truck crane.

G
Risk of overturning with a rigged outrigger span of 8.70 x 2.68 m!
If you have supported the truck crane for lifting the spare wheel with the
outrigger span of 8.70 x 2.68 metres, you must first of all raise the main
boom to an angle permitted in the operating area (about 60 to 82°). With
angles less than those permitted in the operating area, the truck crane
can overturn during turning.

G
Danger of accidents from overturning wheel!
Changing the tyres without the appropriate lifting equipment for the
spare wheel is dangerous!
Have someone help you change the tyre whenever possible!

• Attach the wheel; ➠ Weight of wheels,

p. 8-9.
• Remove the four nuts (1).
• Raise the wheel from the spare wheel
holder.
• Secure the wheel against falling over by
temporarily putting it down.

Mounting a da- If you lift the wheel with the truck crane onto the spare wheel holder, ob-
maged wheel on serve the safety instruction Risk of overturning with a rigged outrigger span of
the spare wheel 8.70 x 2.68 m! in the previous section before turning.
holder
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• Raise the wheel onto the spare wheel holder.

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 Malfunctions on the carrier
7.4 Wheel change

• Screw the wheel onto the spare wheel hol-

der using the four nuts (1).
Tightening torque: 500 Nm in each case.

Mounting the

G
spare wheel
Risk of accidents!
Check the wheel rim, the tyres, the wheel nuts and the wheel bolts for da-
mage before mounting the spare wheel.
Never mount damaged parts!
Use only the original spare wheel provided by the manufacturer!

• Check whether the surface of the wheel rim and the hub are clean
(no paint, grease or oil).
• Grease the wheel bolts slightly.
• Put the wheel on the hub vertically.
• Extend or retract the outrigger cylinders until the holes in the wheel
rims align with the wheel bolts.
• Push the wheel – shaking the wheel if necessary – onto the wheel bolts.
Ensure that the thread of the wheel bolts is not damaged.
• Place a pressure plate on the upper and lower wheel bolts respectively,
and screw the wheel nuts tight by hand.
• Place the remaining pressure plates on the wheel bolts and screw the
other wheel nuts tight with your hand.
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Operating Instructions GMK 6300 2 084 548 en 7 - 13
Malfunctions on the carrier
7.4 Wheel change

• Tighten the wheel nuts crosswise in

three stages in the order shown in the
diagram using a torque wrench.
First level: 200 Nm

Second level: 400 Nm

Third level: 650 Nm

• Tighten the wheel nuts again after driving

50 km and again after 150 km!

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 Malfunctions on the carrier
7.5 Electrical system

7.5 Electrical system

7.5.1 Plug-in modules

Front plug-in
module

Pos. Designation of plug-in Function

module in the electronic
circuit diagram

1 1.2 D Display for automatic gearbox oil tempe-

rature and pressure, hydraulic system,
braking circuit/ steering circuit monito-
ring, hydraulic system, driving direction
indicator, suspension locking system

2 4.1 D Speed indicator with revolution

counter and trip recorder

3 5.3 D Vehicle engine temperature and oil

pressure display/ vehicle engine
monitoring, transfer case, coolant level,
differential locks, lighting, cruise
control

4 Heating plug-in module Heating and ventilation on driver and

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passenger side

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Operating Instructions GMK 6300 2 084 548 en 7 - 15
Malfunctions on the carrier
7.5 Electrical system

Side plug-in
module

Pos. Designation of plug-in Function

module in the electronic
circuit diagram

1 6D Operation and monitoring of transfer

case,
transverse differential locks, drive of
2nd axle line/longitudinal differential
locks,
separate steering, additional heating
system,
automatic gearbox, suspension system

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 Malfunctions on the carrier
7.5 Electrical system

7.5.2 Fuses

S
Risk of fire!
Never repair a defective safety device with a nail, wire or aluminium foil.
Always replace defective safety devices with safety devices of the indi-
cated ratings.

The fuses are divided into 9 groups F 1 to F 9.

Group F 1 to F 6
The groups F 1 to F 6 are located under the
cover at the right next to the front instru-
ment panel and become accessible if you
remove the covering which is shaped into a
placement surface.

Each group consists of 8 fuses.

The following tables show the designations

of the individual fuses, their strength and
function.
The designations 1 to 8 in the tables corres-
pond to the order from top to bottom
(fuse 1 is always the top fuse).

Name in circuit Rating (A) Function

diagram: F 1

1 20 E control vehicle engine

2 10 Diagnostics plug for the vehicle engine /

engine control system

3 10 Flame start system

(additional equipment)
4 15 Hazard warning system

5 10 Braking lights

6 10 No function
7 10 Driver’s cab ceiling lighting /
cigarette lighter
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8 15 No function

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Operating Instructions GMK 6300 2 084 548 en 7 - 17
Malfunctions on the carrier
7.5 Electrical system

Name in circuit Rating (A) Function

diagram: F 2

1 10 E control vehicle engine

2 10 Diagnostics plug for the vehicle engine /

engine control system

3 10 Flame start system

(additional equipment)
4 10 Constant throttle for motor brake

5 10 Level adjustment system / axle spring

accumulator

6 10 Suspension locking system / steering

circuit display I + II / separate steering

7 10 Differential locks / transfer case

8 10 Outriggers / electronic level
(inclination indicator) / outrigger
pressure display

Name in circuit Rating (A) Function

diagram: F 3

1 10 Automatic gearbox shifting field /

display for oil pressure and automatic
gearbox temperature / hydraulic oil
temperature display

2 5 Speedometer

3 15 Heater fan
4 10 Mirror heating / air dryer

5 15 Windshield wiper and washing pump /

roof ventilator (additional equipment) /
horn
6 10 Back-up light

7 20 Rotating warning lights

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8 15 Turn indicators

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 Malfunctions on the carrier
7.5 Electrical system

Name in circuit Rating (A) Function

diagram: F 4

1 15 Heating system

2 10 Radio,
Mobile phone (additional equipment)

3 5 Diagnostic plug for transfer case

4 10 No function

5 10 No function

6 10 No function
7 10 No function

8 10 Fog lights/rear fog lights

Name in circuit Rating (A) Function

diagram: F 5

1 5 Position lamps left superstructure /

left parking light
2 5 Position lamps right superstructure /
right parking light
3 10 Left rear circumference lamps /
instrument lighting

4 5 Right rear profile lamps

5 10 Left fog lamp / left headlight –
high-beam

6 10 Right fog lamp / Right high-beam

7 10 Left low-beam headlight

8 10 Right low-beam headlight

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Operating Instructions GMK 6300 2 084 548 en 7 - 19
Malfunctions on the carrier
7.5 Electrical system

Name in circuit Rating (A) Function

diagram: F 6

1 20 Hydraulic oil cooler

2 5 Speed control

3 15 Retarder (additional equipment)

4 10 No function

5 5 Central lubrication

6 10 Voltage transformer 24 V/12 V

7 5 Trip recorder

8 15 Additional heating system (additional

equipment)

Group F 6 to F 9
Fuses F 6, F7 and F 8 are also in the battery
box.

• Open the lid of the battery box.

Ther are two terminal boxes on the inside at
the right:

– The two fuses F 7 and F 8 are in terminal

box (1).
– The fuse F 9 is located in the terminal
box (2).

Terminal Designation in Rating (A) Function

box circuit diagram:

1 F7 50 Superstructure
central fuse
F8 50

For all consumer

equipment which is still
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26.06.2000

2 F9 20 supplied with power

when the battery master
switch is switched off.

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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6 Troubleshooting and malfunction correction

7.6.1 Vehicle engine malfunctions

Malfunction
H Also see the vehicle engine operating manual for malfunctions in the ve-
hicle engine.

Cause Action

Engine does not start Battery master switch not Switch battery master switch
(starter does not turn over) switched on on; ➠ p. 5-8.
Ignition switched off Switch on ignition;
➠ p. 5-10.
Automatic gearbox not in Switch automatic gearbox to
neutral position N; ➠ p. 5-10.
Parking brake not engaged Engage parking brake;
➠ p. 5-10.
Fuse F7/1 Carrier or F7/4 Check fuse, replace if
Carrier defective necessary; ➠ p. 7-17.
Engine does not start Batteries flat Charge batteries; ➠ also
(starter motor turns over) Maintenance Manual.
Fuel tank empty 1. Fill fuel tank;
➠ p. 6-12
2. Ventilate fuel tank;
➠ Vehicle engine
operating manual
Flame-start device indicator Fuse F1/3 Carrier or F2/3 Check fuses and replace if
lamp (additional equipment) Carrier faulty necessary; ➠ p. 7-17.
does not go on during igni-
tion of the motor when cold
Vehicle engine air filter war- Air filter is clogged Replace dry-type air filter
ning lamp is on (➠ Maintenance manual)
Vehicle engine coolant level Coolant level too low Top up coolant;
warning lamp is on ➠ p. 5-7
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Operating Instructions GMK 6300 2 084 548 en 7 - 21

Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Malfunction Cause Action

Engine coolant temperature Coolant level too low Fill coolant; ➠ p. 5-7.
too high (warning lamp illuminates)
Oil level in automatic gearbox Check oil level, fill if
too low necessary; ➠ p. 5-6
Maintenance Manual
Outside of heat exchanger Clean outside of heat
dirty exchanger
V-belt of the coolant pump on Tighten V-belt;
the engine loose ➠ Vehicle engine operating
manual
Fan wheel at the heat Switch fan thermostat to
exchanger does not turn emergency mode;
➠ p. 7-29
Engine oil pressure too low Engine oil level too low Check oil level, fill if
necessary; ➠ p. 5-4 and
Maintenance Manual
Motor cannot be switched off Malfunction of the electronics Switch of the engine with
with the ignition key emergency stop device;
➠ p. 7-1.
Check fuses, replace if
necessary; ➠ p. 7-17.
Motor brake (retarder) Fuse F2/4 Carrier defective Check fuses, replace if
does not switch on necessary; ➠ p. 7-17.

Vehicle engine diagnostic Fuse F2/2 Carrier or F1/2 Check fuses, replace if
plug no function Carrier faulty necessary; ➠ p. 7-17.

Power drop and abnormal If the charge air temperature ➠Malfunctions in the
exhaust gas opacity is too high, the fault can be in Mercedes-Benz Operating
the charge air thermostat (fan Instruction manual. Function
wheel is not turning). in the charge air thermostat
switch the thermostat to
Emergency operation; ➠ p. 7-29.
The motor electronics warning In the event of engine electronics malfunctions the performan-
lamp is on during driving, the ce of the engine reduces continously. The engine does not
engine performance gets wor- switch off, however, and you can therefore continue driving
se and worse until you get an opportunity to stop.
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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Malfunction Cause Action

The motor electronics warning Cooling water level too low, Cooling water level; ➠ p. 5-7;
lamp is on during driving, oil level too low, Oil level; ➠ p. 5-5;
the engine performance gets air filter dirty. Air filter; ➠ Maintenance
worse and worse manual
V-belt too loose Check V-belt tension;
➠ Vehicle engine operating manl
Plug or cable on the control Check the plug on the control
unit loose unit (on the right next to the
fuses); ➠ p. 7-17
Cabling behind the Check cable, if damaged, in-
accelerator pedal is damaged form GROVE Product Support

7.6.2 Automatic gearbox malfunctions

Malfunction Cause Action

Warning lamp for gear oil Gear oil filter dirty Replace filter;
filter illuminates ➠ Maintenance manual
Gear oil pressure display Oil level in automatic gearbox Check oil level, fill if necessary;
during driving less than 7 bar too low ➠ p. 5-6 and Maintenace
Manual.
If the oil pressure remains
under 7 bar, the gearbox is
defective.
Do not continue to drive!
Gear oil pressure and tempe- Fuse F 3/1 Carrier defective Check fuse, replace if
rature gauge do not display necessary; ➠ p. 7-17.
Gear oil temperature too high Long drive downhill with Stop and let oil cool down;
retarder switched on ➠ gear oil temperature gauge,
p. 6-24.
Oil level in automatic gearbox Check oil level, fill if necessary;
too low ➠ p. 5-6 Maintenance Manual
Engine coolant temperature ➠ Malfunction of vehicle engine
too high p. 7-21.
Gearbox does not switch up Level adjustment system Switch off level adjustment
to 2nd gear switched on system; ➠ p. 6-40.
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Operating Instructions GMK 6300 2 084 548 en 7 - 23

Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Retarder cannot be switched Fuse F6/3 Carrier defective Check fuse, replace if
off necessary; ➠ p. 7-17.
Gearbox does not react when Fuse F3/5 Carrier defective Check fuse, replace if
the selector switch for the necessary; ➠ p. 7-17.
driving ranges is operated
Converter override coupling Oil level in the automatic Check oil level, fill if necessary;
slides out, engine races du- gearbox too low ➠ p. 5-6 and Maintenance
ring driving Manual
Diagnosis plug with display Fuse F3/5 Carrier defective Check fuse, replace if
lamp (➠ p. 6-19) does not necessary; ➠ p. 7-17.
work

7.6.3 Transfer case malfunctions

Malfunctions of the longitudinal differential lock of the transfer case;

➠ Malfunctions of the differential locks, p. 7-25.
Malfunction Cause Action

On-the-road gear, off-the- Compressed air system is not Let engine run in neutral.
road gear or neutral position filled sufficiently Approx. 10 minutes after the
cannot be engaged indicator lamp for the air
pressure in circuit 3 goes out,
the 4th circuit is filled for the
secondary consumers;
➠ p. 6-7. Test the switch.
Fuse F2/7 Carrier defective Check fuse, replace if
necessary; ➠ p. 7-17.

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 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.4 Differential lock malfunctions

This section applies to malfunctions of all differential locks:

– transverse differential locks of the driven axle lines
– drive of the 2nd axle line/longitudinal differential locks (in the transfer
case and in the 4th axle line)

Malfunction Cause Action

Differential locks cannot be Off-the-road gear not Switch on off-the-road gear;

switched on switched on ➠ p. 6-36.
Level adjustment system Switch on level adjustment
switched off system key switch
Suspension locking system Switch off suspension locking
switched on system
Stress in transmission system Switch the automatic gearbox
to neutral position
Compressed-air system not Let engine run until pressure
filled sufficiently has built up. The circuit for
secondary consumers takes a
few minutes to fill after the
indicator lamp goes out.
Fuse F2/7 Carrier defective Check fuse, replace if
necessary; ➠ p. 7-17.
Differential locks cannot be Stress in transmission system Drive truck crane backwards
switched off and forwards slowly with the
steering straight
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Operating Instructions GMK 6300 2 084 548 en 7 - 25

Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.5 Service brake malfunctions

Malfunction Cause Action

Supply pressure brake cir- Air pressure in one of the two Vehicle can be driven slowly
cuits I and II warning lamp circuits has dropped below as far as the next workshop.
lights up during driving or 5,5 bar, check pressure gauge
does not go out after the for compressed air supply.
engine has started
Air pressure in both circuits 1. Fill compressed-air supply
below 5,5 bar, check pressure at connection for external
gauge for compressed-air filling.
supply.
2. Tow truck crane
using a tow-rod.
Parking brake does not disen- Air pressure in circuit 3 is too Let the engine run in neutral
gage, “Parking brake” indica- low. with the parking brake
tor lamp does not go out, engaged until the air pressure
Supply pressure brake in circuit 3 is high enough.
circuits I and II warning lamp
is off
ABS warning lamp (additional ABS-brake system has broken Drive to nearest workshop;
equipment) lights up even down. braking without ABS support
with speeds over 6 km/h is still possible.

7.6.6 Steering system malfunctions

Malfunction Cause Action

Steering wheel stiff, creaking Oil level in hydraulic oil tank 1. Check the level of the
noises during steering too low. hydraulic oil and top up if
necessary.
2. Vehicle can be driven
slowly to the
nearest workshop.
One warning lamp for Oil level in hydraulic oil tank 1. Check the level of the
steering circuit I or II is on too low. hydraulic oil and top up if
necessary.
2. Vehicle can be driven
slowly to the
nearest workshop.
01.02.2000

Failure of steering circuit, e. g. Vehicle can be driven slowly

defective pump as far as the next workshop.

7 - 26 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

Malfunction Cause Action

Both warning lamps for Both steering circuits have Vehicle cannot be driven, as it
steering circuits I and II failed cannot be steered!
are on
Hydraulic oil temperature Oil level in hydraulic oil tank Check hydraulic oil level and
too high too low top up if necessary
Hydraulic oil cooler does not Check fuse, replace if
switch on, fuses F 6/1 necessary; ➠ p. 7-17.
defective
Warning lamp for hydraulic Hydraulic oil return flow filter Change hydraulic oil return
oil return filter I and II contaminated filter I and II
lights up
The Separate steering indicator Malfunction in the separate Decode the error code and
lamp flashes steering inform GROVE Product
Support and, if need be, put
the steering into street driving
mode with the emergency
operation;
➠ Separate steering emergency
operation, p. 7-35.

7.6.7 Outrigger malfunctions

Malfunction Cause Action

Strut cylinder and outrigger Fuse F 2/8 Carrier defective Check fuse, replace if
beams cannot be extended or necessary; ➠ p. 7-17.
retracted and the electronic Solenoid valves jammed Operate solenoid valves by
level does not display hand; ➠ Emergency operation
of the solenoid valves for the
outriggers, p. 7-31.
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Operating Instructions GMK 6300 2 084 548 en 7 - 27

Malfunctions on the carrier
7.6 Troubleshooting and malfunction correction

7.6.8 Suspension locking system malfunctions

Malfunction Cause Action

Suspension lock cannot be Compressed-air system not Let the engine run in neutral.
switced off filled sufficiently Approx. 10 minutes after the
indicator lamp for the air
pressure in circuit 3 goes out,
the 4th circuit is filled for the
secondary consumers.
Fuse F2/6 Carrier defective Check fuse, replace if necessary

7.6.9 Level adjustment system malfunctions

Malfunction Cause Action

Level adjustment system Level adjustment system key Switch on level adjustment
does not function switch switched off system key switch
Automatic gearbox not in Move gear lever to neutral N
neutral position
Suspension locking system Switch off suspension locking
switched on system
Fuse F2/5 Carrier defective Check fuse, replace if
necessary; ➠ p. 7-17.

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

7.7 Procedure in the event of malfunctions

7.7.1 Switching the fan thermostat to emergency operation

A temperature-controlled hydraulic valve controls the speed of the fan for

the coolant water cooler. The respective valve can be switched manually
in the event of a thermostat malfunction.

G
Accidents may occur due to turning fan wheel!
If you switch a fan to emergency operation the fan wheel immediately
begins to turn very quickly. Objects or loose clothing can sucked in.
Make sure that there are no people or objects in the vicinity of the fan
when switching to emergency operation.

The coolant water cooler is located on the left side of the vehicle above
the first and second axle lines.

The tap (1) is under the cooling water cooler,

under the sheet metal.
• Close tap (1) for emergency operation. The
grip must be at right angles to the pipe
line. Close the tap slowly!

H After installing a new thermostat, the corresponding tap must be opened

again!
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Operating Instructions GMK 6300 2 084 548 en 7 - 29

Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

7.7.2 Troubleshooting for malfunctions in the automatic gearbox

In the event of a malfunction of the automatic gearbox, the gearbox con-

trol attempts to establish the most secure gearbox operating condition
possible in order that the crane may be driven to a safe place.
The gearbox control locks the last gear selected (gearbox in locked
position) and opens the converter override coupling.
The warning lamp Shift lock for automatic gearbox in the selector switch
# panel of the gearbox control illuminates and an acoustic signal sounds for

H
10 seconds.

When the Shift lock for automatic gearbox warning lamp lights up, the gear-
box control no longer responds to the selector switch being actuated. You
can no longer shift from neutral position N into another gear. The driving
direction can therefore not be changed!

G
Risk of accidents!
With the gearbox in locked position, the stationary vehicle must be
secured against rolling away. Engage the parking brake and secure the
vehicle using chocks.

Resetting the When the warning lamp Shift lock in automatic gearbox indicates a gear
gearbox control malfunction, you can reset the gearbox control to its original position.

• Stop the truck crane at a safe place.

• Turn off the vehicle engine.
• Turn off the ignition.
• Wait for at least ten seconds before turning on the ignition again and
restarting the vehicle engine.
The warning lamp Shift lock in the automatic gearbox will not light up again in
# the event of a temporary malfunction and the gearbox operates normally.

The warning lamp Shift lock in the automatic gearbox lights up again if the
malfunction is permanent.

In this case the functioning of the gearbox is dependent on the mal-

function:
– The gearbox appears to function normally;
– the gearbox only operates in the lower gears;
01.02.2000

– the gearbox remains in neutral position. In this case, driving cannot be

continued.

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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

7.7.3 Emergency operation of the solenoid valves for the outriggers

The truck crane has four groups of solenoid

valves for emergency operation of the out-
rigger beams and the outrigger cylinders.
A solenoid valve group (1) is located over
each outrigger beam.

Each solenoid valve group has four switches

(2). With the switches of a solenoid valve
group you can only move the outrigger
beams and outrigger cylinders on the side
opposite to them (➠ diagram p. 7-32).

The switches are only active when a second

person operates the pressure build-up valve
47-Y9 at the same time.

• Remove the rearmost covering on the

carrier.
The pressure build-up valve 47-Y9 (1) is loca-
ted on the left-hand side of the crane carrier
behind the automatic gearbox.

• Press in the button (2) with a pointed

object.

Valve 47-Y9 is now activated and you can

move the outrigger with the buttons on the
solenoid valve groups.

The diagram on the next page shows you the position and designation of
the individual solenoid valves on the mobile crane. Which button to press
for the desired motion of the outrigger beam or supporting cylinder can
be found in the accompanying table.
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s
Operating Instructions GMK 6300 2 084 548 en 7 - 31
Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

G
Danger of accidents when outrigger movements are performed outside
of your field of view!
You will not be able to monitor the movement of the outrigger beams as
you are on the opposite side of the truck crane. Have a helper monitor the
movements of the outrigger beams and ensure you have visual contact
with him.

All the switches are numbered in the following diagram. Which switch
you must push for the desired motion (extending or retracting) of the
outrigger beams and the outrigger cylinders can be found in the table on
the next page.

VR HR

SR
1 2 1 2
V H
3 4 3 4

5 6 5 6
V H
7 8 7 8
SL

VL HL

C0523

H The front left valve block (V5 to 8) is installed on edge. Therefore the
switches are not all on a level but rather in pairs over each other. The
switches 6 and 8 on the truck crane are over the switches 5 and 7.
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 Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

Front emergency operation Switch Valve designation in

V hydraulic circuit
diagram

left 2 44 Y 1
retract
Support cylinder right 8 44 Y 2
front
left 4 44 Y 5
extend
right 6 44 Y 6

left 1 44 Y 51
retract
Outrigger beam right 7 44 Y 61
front
left 3 44 Y 11
extend
right 5 44 Y 21

Rear emergency operation Switch Valve designation in

V hydraulic circuit
diagram

left 1 44 Y 3
retract
Support cylinder right 8 44 Y 4
rear
left 3 44 Y 7
extend
right 6 44 Y 8

left 4 44 Y 31
retract
Outrigger beam right 5 44 Y 41
rear
left 2 44 Y 71
extend
right 7 44 Y 81
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Operating Instructions GMK 6300 2 084 548 en 7 - 33

Malfunctions on the carrier
7.7 Procedure in the event of malfunctions

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 Malfunctions on the carrier
7.8 Separate steering emergency operation

7.8 Separate steering emergency operation

If the Separate steering indicator lamp flashes while driving with separate
b steering, there is a malfunction of the separate steering.

• Stop the truck crane.

• Switch the ignition off and then on again.

Now the Separate steering indicator lamp displays an error code by

flashing. The error codes consist of one to three digits. The digits are dis-
played by the frequency of the flashing. The lamp between the individual
digits goes out briefly. When the error code output is finished, the indica-
tor lamp flashes several times in a row very quickly.

Example of error output

• Wait until the indicator lamp flashes quickly several times in a row.
After that, the indicator lamp continues to flash at a slower rate (ca. one
time per second).

• Count how often the indicator lamp flashes and note the value (e. g. 3).
b The indicator lamp goes out now for a brief period of time and then
flashes again with a low frequency.

• Count how often the indicator lamp flashes and note the value (e. g. 4).
b When the error code output is finished, the indicator lamp flashes several
times in a row very quickly. Then the error code output is repeated.

You have the error code when you write down the digits in the sequence
of its output from left to right.
In this example, the error code 34 was displayed.

The responsible GROVE Product Support team can establish the cause of
error with the error code and provide further assistance.

If the cause of the error cannot be rectified immediately, you can move
the steering into the on-the-road mode again with the help of the emer-
gency operation.
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s
Operating Instructions GMK 6300 2 084 548 en 7 - 35
Malfunctions on the carrier
7.8 Separate steering emergency operation

Moving the stee- For on-the-road mode, you must:

ring into on-road
driving
– Connect the drag rod between the third and fifth axle lines.
– Lock the manual steering of the third axle line.
– Lock the steering of the fourth axle line.
When a fault occurs air is automatically removed from the locking devices
which are held by spring force. To lock the numbered positions, the
wheels must be brought successively to the straight forward position so
that the locks engage.

• Let the engine run and steer the front wheels to the straight forward
position with the steering wheel.
• Switch on the Level adjustment system key-operated switch and leave it
on for all of the following procedures.

C0018

First you must steer the fifth and sixth axle lines to the straight forward
position. You can steer these axle lines with the steering wheel if the front
axle lines have more of a load on them than the rear axle lines.

• Extend both rear outrigger cylinders until the wheels of the sixth axle
line are just above the ground; ➠ Extend/retract support cylinder, p. 13-30.
Now the front axle lines are under a load and you can steer the rear axle
lines with the steering wheel.

• Steer the fifth and sixth axle lines to the straight forward position until
the lock audibly snaps into place.

S
Danger of damage to the steering linkage!
Do not continue to steer after the locks have snapped into place. After
continued steering with unequally loaded wheels, very high stresses in
the steering linkage can cause eventual damage.

Now you can move the wheels of the third and fourth axle lines to the
straight ahead position. To do this you have to first build up the necessary
pressure in the corresponding hydraulic circuit. Then a second person can
steer the axle lines via valves.
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 Malfunctions on the carrier
7.8 Separate steering emergency operation

• Move an outrigger cylinder or outrigger beam against the stop and

keep the toggle switch pressed to build up pressure.
There is a valve block on the left side behind
the steps, under the Operating the outriggers
control box.

• Press the valve 47Y10 (5) here for pressure

build-up.
You must also press the following valves to
steer the third and fourth axle lines:

Third axle line to the left: 47Y5 (4)

Third axle line to the right: 47Y6 (1)

Fourth axle line to the left: 47Y7 (3)

Fourth axle line to the right: 47Y8 (2)

• Steer the third axle line to the straight forward position with the corre-
sponding valves first. The axle line is locked when it can no longer be
steered by pressing the valve.
• Then steer the fourth axle line to the straight forward position with the
corresponding valves. The axle line is locked when it can no longer be
steered by pressing the valve.
• Retract both rear outrigger cylinders again.
• Switch off the Level adjustment system key-operated switch.

C0018

• Check whether the steering is in the on-road driving status.

– All wheels must be in the straight forward position.
– The indicator lamp for the separate steering must be off.
b? – When steering with the steering wheel, the wheels of the first, second,
and third axle lines have to move together in the same direction. At the
same time, the wheels of the fifth and sixth axle lines have to move in
the opposite direction. The wheels of the fourth axle line always have
to be in the straight ahead position.
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Operating Instructions GMK 6300 2 084 548 en 7 - 37

Malfunctions on the carrier
7.8 Separate steering emergency operation

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7 - 38 2 084 548 en Operating Instructions GMK 6300

 _______________________________________________________________________________________ 8
8 Technical specifications carrier . . . . . . . . . . . . . . . . . . . 8- 1
8.1 Technical description of the carrier . . . . . . . . . . . . . . . . . . . . 8 - 1
8.1.1 Crane carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1.2 Driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1.3 Drive units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2
8.1.4 Engine and gearbox cooling system . . . . . . . . . . . . . . . . . . . . . . 8- 2
8.1.5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 2
8.1.6 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
8.1.7 Suspension system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
8.1.8 Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
8.1.9 Compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4
8.1.10 Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.11 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.12 Retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.13 Secondary consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
8.1.14 Towing the crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.15 Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.16 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.17 Slewing duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7
8.2.1 Measurements and weights of the truck crane . . . . . . . . . . . . . . . . 8 - 8
8.2.2 Dimensions and weights of removable parts . . . . . . . . . . . . . . . . . 8 - 9
8.2.3 Carrier technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10
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Operating Instructions GMK 6300 2 084 548 en

 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 Technical specifications carrier
8.1 Technical description of the carrier

8 Technical specifications carrier

8.1 Technical description of the carrier

8.1.1 Crane carrier

The following parts are screwed to the crane carrier:

– The travel drive units,
– the axle lines,
– the suspension system,
– the steering,
– the driver’s cab,
– the outriggers,
– the ball bearing slewing for the crane superstructure
– the ball bearing connection to the crane superstructure.

8.1.2 Driver’s cab

The 2+1 man aluminium driver’s cab is equipped with safety glass. The
operator’s and second mans seat are hydraulically damped. As additional
equipment, the driver’s cab can be equipped with a third seat and a fol-
ding bed.

All operating and control equipment for driving the truck crane is located
in the driver’s cab, which is heated by a heat exchanger with the engine
coolant.
The coolant used to preheat the engine and to heat the driver’s cab can
be heated with an additional warm water heating system.
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s
Operating Instructions GMK 6300 2 084 548 en 8-1
Technical specifications carrier
8.1 Technical description of the carrier

8.1.3 Drive units

The truck crane is powered by a water-cooled Cummins diesel engine

with exhaust gas turbocharger.

The axle lines are driven by a power shift gear with secondary transfer
case. The electronically operated power shift gear can be switched to an
E programme (economy) for driving on flat, even surfaces and a P pro-
gramme (power) for driving uphill. The transverse differential locks can
be activated on all driven axle lines. For off-road driving, the drive of the
second axle line can be connected together with the longitudinal differen-
tial locks in the transfer case and on the fourth axle line.

8.1.4 Engine and gearbox cooling system

The engine is equipped with thermostat-controlled circulating cooling and

a charge cooling. A heat exchanger is installed in the coolant circulation
system to cool the oil in the automatic gearbox. A viscous fan on the
diesel engine and a hydraulically driven fan on the radiator on the left
side of the carrier are switched on by a thermostat.

8.1.5 Hydraulic system

The diesel engine drives the hydraulic pumps. The hydraulic pumps are
fed from the hydraulic tank on the left side of the carrier. Two return flow
filters on the hydraulic tank clean the hydraulic oil as it flows back.

A combination pump with three pumps is connected to a power take-off

of the diesel engine. The hydraulic pumps supply the outriggers, the fan
for engine and gearbox cooling, the suspension and both steering circuits.

Another hydraulic pump is flanged onto the transfer case as an emergen-

cy steering pump, and it supplies the steering circuit I during towing.

Two return flow filters on the hydraulic tank clean the hydraulic oil as it
flows back.
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 Technical specifications carrier
8.1 Technical description of the carrier

8.1.6 Steering

The steering gear is mechanically connected to the first, second, third,

fifth and sixth axle lines. The dual-circuit hydraulic steering supports the
steering movement through hydraulic cylinders on all steerable axle lines.

The steering is divided into two steering circuits which are supplied by
different hydraulic pumps. If both steering pumps malfunction, an emer-
gency steering pump flanged onto the transfer case is switched on auto-
matically.

The steering system can be switched from normal steering mode to

separate steering for slow manouvering. This switches on the steering of
the 4th axle line. The wheels of the fourth, fifth and sixth axle lines are
then turned regardless of the steering direction of the front wheels.
With separate steering, the wheels of the first, second, fifth, and sixth axle
lines are steered with the steering wheel or with a rocker switch. The stee-
ring of the third and fourth axle lines is electronically controlled. If you
switch to separate steering, you can drive with either all-wheel steering or
with crab travel mode:

– The size of the turning circle decreases with all-wheel steering.

The front and rear axle lines turn in opposite directions.
– The truck crane moves diagonally sideways in crab travel mode.
The front and rear axle lines now turn in the same direction.

8.1.7 Suspension system

All wheels are individually suspended from the crane carrier with hydro-
pneumatic suspension cylinders. The hydraulic system of the suspension
system is separated from the carrier’s hydraulic system by solenoid
valves.
The suspension system is adjusted by control signals of the gearbox
control and the level adjustment system by the various driving modes
(e. g. driving off-the-road).
The axle lines are interconnected respectively to suspension groups. The
wheel load is transferred equally between all axle lines of a suspension
group. The oil displaced when the suspension cylinders are compressed
is stored in pressure accumulators.
The suspension groups must be locked for various driving modes on the
site and during crane work. The suspension cylinders are separated from
the pressure accumulators by pneumatically operated blocking valves.
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Operating Instructions GMK 6300 2 084 548 en 8-3
Technical specifications carrier
8.1 Technical description of the carrier

The overall level of the vehicle can be adjusted by extending and re-
tracting the suspension cylinders, if necessary in longitudinal and lateral
direction. If the level of the vehicle is on-the-road level, the solenoid
valves are controlled by sensors on the suspension cylinders.

8.1.8 Outrigger

The outrigger, like the suspension system, is supplied with hydraulic oil
from the carrier’s hydraulic system. The cylinders in the outrigger beams
and the outrigger cylinders are controlled separately via solenoid valves
from both sides of the carrier.

The outrigger beams can be operated from the carrier side only, from
where the movement may be observed. The outrigger cylinders can be
operated from both sides.

Each of the four outrigger beams consists of 2 beams, one of which is con-
tained in the other, which can be telescoped in and out using tackle lines.

An electronic inclination indicator (electronic level) on the carrier detects

the alignment of the truck crane and displays it in display fields in the
control boxes on each side of the carrier. Another display is located in the
crane cab on the front instrument panel.

8.1.9 Compressed air system

The compressed air system comprises the air compression system,

the service brake, the parking brake and the control for the secondary
consumer.
The vehicle engine drives the compressor directly. The compressor takes
in dust-free air from the engine’s air intake system and conveys the com-
pacted air through the air drier with pressure regulator and conditioning
unit via the four-circuit protection valve in the tank.
When pumping up, the air in the air drier is conveyed by a highly porous
drying agent. The dry air flows into the consumer system and into the
conditioning unit. When blowing off, the dry conditioned air flows back
through the air drier, extracts moisture from the drying agent and is
released outside. A cartridge heater supports the drying process if the air
temperature is low. The compressed air system can be backfilled (e. g.
when towing) through the connection for independent ventilation. The
tyres can be filled with the compressed air system using the tyre inflation
01.02.2000

hose.

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 Technical specifications carrier
8.1 Technical description of the carrier

8.1.10 Service brake

The service brake (foot brake) is divided into two circuits for increased
road safety. Circuit I (brake circuit 1) effects the first, second and third axle
line and circuit II (brake circuit 2) effects the third to sixth axle line.
All wheels are braked pneumatically via directly controlled diaphragm
cylinders. The wheels on the first axle line have duplex wedge brakes and
the wheels on the second to fifth axle line have simplex wedge brakes.
If a brake circuit should fail, a warning lamp lights up in the driver’s cab.
An ABS system can be installed as aditional equipment.

8.1.11 Parking brake

The parking brake (handbrake) is supplied by brake circuit 3. It has an

indirect effect on the 2nd, 4th, 5th and 6th axle lines via the spring-loaded
brake cylinder.

The parking brake can also be used as an auxiliary brake. The braking
force can be continuously adjusted with the parking brake lever.

8.1.12 Retarder

A motor flap brake is switch on as a retarder.

The truck crane can also be equipped with an eddy current retarder as
additional equipment.

8.1.13 Secondary consumers

A 4th compressed-air circuit supplies all pneumatic secondary consumers

of the truck crane (e. g. activation of longitudinal and transverse differential
locks, drive of second axle line, gear change of transfer case, etc.).
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Operating Instructions GMK 6300 2 084 548 en 8-5

Technical specifications carrier
8.1 Technical description of the carrier

8.1.14 Towing the crane

The truck crane (additional equipment) is equipped with a towing coup-

ling for towing operation. The air reservoirs of all truck crane compressed-
air circuits can be filled by the towing vehicle via a filler connection.

8.1.15 Towing a trailer

The truck crane is equipped with a trailer coupling for towing a trailer
(additional equipment). The trailer brake valve is supplied by a coupling
from compressed-air circuit 3. The marker lights of the trailer are supplied
by the electrical system of the carrier via a plug connection.

8.1.16 Electrical system

The carrier’s 24 V on-board network is supplied by the alternator on the

vehicle engine and two batteries in the battery box at the left behind the
driver’s cab.

The electrical system includes the vehicle system of the carrier and the
limitation, position and rotating warning lights of the superstructure.

8.1.17 Slewing duct

The slewing duct allows an electrical connection between the carrier and
the superstructure via a slip ring contact even during crane operation. The
slewing duct is, for example, used to connect the display of the electronic
level and the outrigger pressure display (additional equipment) in the
crane cab to the measurement units on the carrier. During on-road dri-
ving, the marker lights, position lights, and rotating warning lights on the
superstructure are also supplied via the slewing duct.
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 Technical specifications carrier
8.2 Technical specifications

8.2 Technical specifications

GROVE truck crane GMK 6300

Permissible temperature range: –25 °C to +40 °C

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Technical specifications carrier
8.2 Technical specifications

8.2.1 Measurements and weights of the truck crane

Dimensions for Length: 18,05 m (without auxiliary hoist)

driving on public Width: 3.00 m
roads
Height at on-the- 3.95 m –130 / +170 mm suspension range
road level: with tyres 14.00 R 25

4.00 m –130 / +170 mm suspension range

with tyres 16.00 R 25

Angle of negotiable
banks, front: approx. 16° at on-the-road level

total weight: 72.0 t

axle load each 12.0 t on-the-road mode

Permissible driving mode during on-road driving; ➠ Section Driving

mode, p. 6-5.
Dimensions and weights of the parts which must be transported on a
separate vehicle during on-road driving; ➠ Dimensions and weights of
removable parts, p. 8-9.
all measurements in mm

375 15460
4730
2600
+170
-130
3950

16°

14°

400
2400 1700 3200 1650 2400 1650 1500 870
2370 15370 310
18050

*) max. 3 000 with 16.00 R25 tyres

01.02.2000

2548 **)max. 3 100 with 20.50 R25 tyres

2990

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 Technical specifications carrier
8.2 Technical specifications

8.2.2 Dimensions and weights of removable parts

This section contains the transport dimensions and weights of those parts
which can be transported on separate vehicles during on-road driving.

Spare wheel

Name Length x width x Weight (kg)

height (m)

Spare wheel with rim 14.00 R 25 1.50 x 1.50 x 0.40 300

Spare wheel with rim 16.00 R 25 1.50 x 1.50 x 0.45 350
(additional equipement)
Spare wheel with rim 20.50 R 25 1.50 x 1.50 x 0.60 450
(additional equipement)
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Technical specifications carrier
8.2 Technical specifications

8.2.3 Carrier technical data

Vehicle engine Make: Mercedes-Benz

Type: OM 502 LA
Performance: 420 kW (571 PS) with 1800 rpm
(80/1269/EEC, fan slack)
Fuel tank: capacity ≈ 500 l

Power shift gear Allison CLT 755 automatic gearbox with 2 driving programs, 5 forward
gears and 1 reverse gear.

Transfer case Kessler transfer case VG 2600, in 2 stages with lockable longitudinal differ-
ential; switching and differential lock are pneumatically actuated.

Axle lines Drive: 12 x 8 x 10,

First axle line: steered axle line
Second axle line: steered and driven axle line (drive can be switched on)
Third axle line: steered axle line
Fourth axle line: steered and driven axle line
Fifth axle line: steered and driven axle line
Sixth axle line: steered axle line

Steering Make: ZF
Type: dual-circuit hydraulic steering with emergency
steering pump
The wheels of the 4th, 5th and 6th axle lines are steered separately when
the separate steering is switched on.

Tyres 12 x 14.00 R 25, single rear wheels on disk wheels 9.50-25

(12 x 16.00 R 25 on disk wheels 11.00-25 as additional equipment)
(12 x 20.50 R 25 on disk wheels 17.00-25 as additional equipment)
Spare wheel 14.00 R-25 with holder (16.00 R-25, or 02.50 R 25 as additio-
nal equipment)
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 Technical specifications carrier
8.2 Technical specifications

Air pressure:

Tyres Air pressure (bar)

14.00 R 25 10.0

16.00 R 25 19.0

20.50 R 25 (Michelin) 17.0

20.50 R 25 (Bridgestone) 18.0

Outrigger Design: 4-point telescoping outrigger system,

doubly telescopable

Control Can be controlled individually from

either side of the carrier.

Outrigger spans: 8.70 x 8.50 m

8.70 x 6,00 m
8.70 x 2.68 m
8.70 x 8.50 / 2.84 m

Outrigger pad size: 810 x 750 mm

outrigger pad surface area: 6075 cm2

Maximum Outrigger span Outrigger pressure

outrigger
pressure:

8.70 x 8.30 m 115 t ( ≅ 1 128 kN)

8.70 x 6.00 m 125 t ( ≅ 1 125 kN)

8.70 x 2.68 m 35 t ( ≅ 1 343 kN)

8.70 x 8.50 / 2.84 m 137 t ( ≅ 11 344 kN)

Stroke of outrigger 500 mm backward

cylinders: 500 mm forward

Inclination indicator: Electronic inclination indicator on the

crane carrier (electrical spirit level)
with displays on carrier and in the crane cab.

Outrigger pressure Integrated in the outrigger, with digital

01.02.2000

indicator: display in the switch box on the carrier

and in the crane cab.

s
Operating Instructions GMK 6300 2 084 548 en 8 - 11
Technical specifications carrier
8.2 Technical specifications

Vehicle’s Alternator: 28 V / 100 A

electrical
system Batteries: 2, each 12 V / 170 Ah
On-board voltage: 24 V

Tools 1 tool kit in tool box,

Wheel chocks (number according to country package)

Driving speeds Driving speed at an engine speed of 2000 rpm:

Gear in automatic gearbox

Switch position
tyres 1 2 3 4 5 R
of transfer case

Driving speeds in km/h approx.

14.00 13,7 22,2 35,1 51,2 70,9 15,0

On-the-road gear 16.00 14,9 24,2 38,2 55,8 77,1 16,3

20.50 14,9 24,1 38,1 55,7 77,0 16,3

14.00 6,1 9,9 15,7 22,9 31,7 6,7

Off-the-road gear 16.00 6,7 10,8 17,1 24,9 34,5 7,3

20.50 6,6 10,8 17,0 24,9 34,4 7,3

Climbing ability Climbing ability in the fixed brake point of the converter with 72 t trans-
port weight:

Switch position Climbing ability in %

transfer case Tyres 14.00 Tyres 16.00

On-the-road gear 50 46

Off-the-road gear 45 41
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 Technical specifications carrier
8.2 Technical specifications

Turning radiuses

– For normal steering mode, with 14.00 tyres

– For separate steering mode, with 14.00 tyres

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Technical specifications carrier
8.2 Technical specifications

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 _______________________________________________________________________________________ 9
9 Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1
01.02.2000

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 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 9 Alphabetical index

H How to use the alphabetical index; ➠ p.1-16.

To avoid making the index unnecessarily long and unclear,
we have not included every single element from the instrument panel.
These elements, such as rocker switches, warning and indicator lamps, as
well as status displays are described and named in detail in the overviews
of chapter 4 and 7 Description of the truck crane .
From there, you will be referred to more detailed descriptions of these
elements.
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Operating Instructions GMK 6300 2 084 548 en 9-1

 Blank page

01.02.2000

9-2 2 084 548 en Operating Instructions GMK 6300

 Alphabetical Index

A Access ladders to the superstructure . . . . . . . . . . . . . . . . . . 4-41

Activating the ignition
carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Adding oil
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Additional heating system . . . . . . . . . . . . . . . . . . . . . 4-36, 6-54
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
time, displaying, setting . . . . . . . . . . . . . . . . . . . . . . . 4-38
Additional heating system with timer . . . . . . . . . . . . . . . . . . 6-56
automatic heating start, switching off . . . . . . . . . . . . . . . . 6-58
automatic heating start, switching on and saving . . . . . . . . . 6-57
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
time, displaying/setting . . . . . . . . . . . . . . . . . . . . . . . 6-57
Additional water heating system
see Additional heating system
Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
on the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Adjusting the seat
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Air-conditioning system
in the crane cab . . . . . . . . . . . . . . . . . 10-55, 12-105 to 12-108
in the driver’s cab . . . . . . . . . . . . . . . . . . . . 4-37, 6-59 to 6-62
Anemometer
installing on the main boom . . . . . . . . . . . . . . . . . . . . 13-79
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
behaviour when upshifted . . . . . . . . . . . . . . . . . . . . . . 6-21
checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
diagnosis switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
driving modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
driving ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
operation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
procedure in the event of malfunctions . . . . . . . . . . . . . . . 7-30
starting and stopping . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Automatic gearbox diagnosis switch . . . . . . . . . . . . . . . . . . 6-19
Automatic gearbox driving modes . . . . . . . . . . . . . . . . . . . . 6-19
Auxiliary hoist
assembly/disassembly . . . . . . . . . . . . . . . . . . . 14-1 to 14-32
01.02.2000

malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
transport dimensions and weight . . . . . . . . . . . . . . . . . 16-10
working with the auxiliary hoist . . . . . . . . . . . . . . . . . . 12-39

Operating Instructions GMK 6300 2 084 548 en 9-3

 Auxiliary hoist gear
display and operating instruments . . . . . . . . . . . . . . . . 10-33
Axle drive
display and operating instruments in the driver’s cab . . . . . . . 4-27

B Battery master switch

Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Brakes
auxiliary brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
checking the brakes system . . . . . . . . . . . . . . . . . . . . . . 6-7
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
display and operating instruments in the driver’s cab . . . . . . . 4-28
see also Eddy current retarder
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Breakdown
towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-10
Breakdown
procedure in road traffic . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4

C Carrier hydraulic system

check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
checking the position of the stop cocks . . . . . . . . . . . . . . . . 5-9
Charge indicator lamp
after ignition has been switched on . . . . . . . . . . . . . 5-10, 11-11
after the engine has been started . . . . . . . . . . . . . . . . . 11-14
after the vehicle engine has been started . . . . . . . . . . . . . . 5-13
warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
CHECK LIST
condition of the truck crane for on-road driving . . . . . . . . . . . 6-1
extending the outriggers . . . . . . . . . . . . . . . . . . . . . . 13-13
retracting the outriggers . . . . . . . . . . . . . . . . . . . . . . 13-15
rigging for crane operation with main boom . . . . . . . . . . . . 13-1
rigging mode when truck crane is rigged . . . . . . . . . . . . . . 12-1
starting the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-1
starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
unrigging for crane operation with main boom . . . . . . . . . . 13-4
Check the oil level
in the carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . 5-8
in the superstructure hydraulic system . . . . . . . . . . . . . . . 11-6
Checking the coolant level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
01.02.2000

in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

9-4 2 084 548 en Operating Instructions GMK 6300

 Checking the oil level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
checking the oil level;in the automatic gearbox . . . . . . . . . . . . . . 5-6
Checking the steering lock . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Checking the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Checking the windscreen washing system
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
checklist
mounting/dismounting the auxiliary hoist with
auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . 14-3 to 14-8
before starting crane work in winter . . . . . . . . . . . . . . . 5-3, 11-3
rigging the counterweight . . . . . . . . . . . . . . . . . . . . . 13-42
unrigging the counterweight . . . . . . . . . . . . . . . . . . . . 13-45
CHECKLIST: Mounting/dismounting the auxiliary hoist with
counterweight lifting gear . . . . . . . . . . . . . . . . . . . 14-9 to 14-14
Checks
"boom not set down" warning lamp . . . . . . . . . . . . . . . . . 6-10
after starting the crane engine . . . . . . . . . . . . . . . . . . . 11-14
after the engine has been started . . . . . . . . . . . . . . . . . . 5-13
before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
before starting the crane engine . . . . . . . . . . . . . . . . . . . 11-4
of the safety equipment . . . . . . . . . . . . . . . . . . . . . . 12-10
prior to starting vehicle engine . . . . . . . . . . . . . . . . . . . . 5-4
while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Choosing the site . . . . . . . . . . . . . . . . . . . . . . . . 13-7 to 13-12
clock
setting time in the crane cab . . . . . . . . . . . . . . . . . . . . . 4-38
Compressed air system
see Brakes
Constant engine speed . . . . . . . . . . . . . . . . . . . . . . . . . 12-89
constant speed
see Tempostat
Control lever emergency program . . . . . . . . . . . . . . . . . . . 15-72
counterweight
checklist: rigging the counterweight . . . . . . . . . . . . . . . . 13-42
Crane cab
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52, 12-101
inclining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-91
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-104
Crane cab windscreen wipers . . . . . . . . . . . . . . . . . . . . . 10-49
Crane control
see acknowledging error messages
display and operating instruments . . . . . . . . . . . . . . . . 10-30
display of an error message . . . . . . . . . . . . . . . . . . . . 12-87
01.02.2000

emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . 15-2

enter telescope status menu . . . . . . . . . . . . . . . . . . . . 15-80
entering power unit speeds menu . . . . . . . . . . . . . . . . . 12-83
error memory sub-menu . . . . . . . . . . . . . . . . . . . . . . 12-81

Operating Instructions GMK 6300 2 084 548 en 9-5

 error messages . . . . . . . . . . . . . . . . . . . . . . 15-61 to 15-82
menu Display states . . . . . . . . . . . . . . . . . . . . . . . . 12-79
menu Display telescoping status . . . . . . . . . . . . . . . . . 12-83
menus on the display . . . . . . . . . . . . . . . . . . . . . . . . 12-79
Crane control emergency stop switch . . . . . . . . . . . . . . . . . . 15-2
Crane control error messages . . . . . . . . . . . . . . . . 15-61 to 15-82
Crane engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . 11-4

display and operating instruments . . . . . . . . . . . . . . . . 10-25

inspections after starting . . . . . . . . . . . . . . . . . . . . . . 11-14
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
setting a constant engine speed . . . . . . . . . . . . . . . . . . 12-89
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
starting - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
VDO electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
crane work
critical load control . . . . . . . . . . . . . . . . . . . . . . . . . 12-90
in winter - checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-3, 11-3
permissible slewing ranges . . . . . . . . . . . . . . . . . . . . 12-35
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
troubleshooting for malfunctions . . . . . . . . . . . . . . 15-3 to 15-4
Crane work with main boom
rigging - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
unrigging - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 13-4
Critical load control . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-90
Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
driving with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

D dead man’s switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62

Derricking gear
display and operating instruments . . . . . . . . . . . . . 10-35, 10-53
lowering the main boom for maintenance . . . . . . . . . . . . 12-77
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21
working with the derricking gear . . . . . . . . . . . . . . . . . 12-41
Differential locks
see Transverse differential locks
Door
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
01.02.2000

drive of second axle line / longitudinal differential locks

check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

9-6 2 084 548 en Operating Instructions GMK 6300

 switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Driver’s cab
adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
adjusting the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Driving
breakdown procedure . . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4
checks before driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
checks while driving . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
off-road . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 to 6-44
on downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
on uphill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
with a rigged crane . . . . . . . . . . . . . . . . . . . . 12-93 to 12-98
Driving direction indicator . . . . . . . . . . . . . . . . . . . . . . . . 4-32
driving mode
equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

E Earthing
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
Earthing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
Eddy current retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Electrical system
display and operating instruments in the crane cab . . . . . . . 10-49
display and operating instruments in the driver’s cab . . . . . . . 4-32
fuses in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
fuses in the superstructure . . . . . . . . . . . . . . . . . . . . . . 15-7
plug-in modules and consoles in the crane cab . . . . . . . . . . 15-5
plug-in modules in the driver’s cab . . . . . . . . . . . . . . . . . 7-15
SLI fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Electronic level
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
Emergency operation
solenoid valves for the outriggers . . . . . . . . . . . . . . . . . . 7-31
Emergency operation submenu on the Crane control display) . . . . 15-79
Emergency stop device
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 to 7-2
on the superstructure . . . . . . . . . . . . . . . . . . . . . 15-1 to 15-2
Enlarging the surface area of the outrigger . . . . . . . . . . . . . . . 13-9
Error messages
control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-61
01.02.2000

power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-62

SLI, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30

Operating Instructions GMK 6300 2 084 548 en 9-7

F Fast speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-78
Fire extinguisher
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Flame start system
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fuel tank
crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Fuses
in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
in the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
of the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13

H Hazard warning system . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Heating system
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52, 12-101
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35, 6-51
Hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67
checking the position . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
reeving on the main boom . . . . . . . . . . . . . . . . . . . . . 13-70
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Hook block
on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . . . 13-65
on the bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
Hydraulic system
display and control instruments . . . . . . . . . . . . . . . . . . . 4-30

I Identification
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
Instrument panels
in the crane cab - overview . . . . . . . . . . . . . . . . . . . . . . 10-6
in the driver’s cab - overview . . . . . . . . . . . . . . . . . . . . . 4-8

K Keys
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
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9-8 2 084 548 en Operating Instructions GMK 6300

 L Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Lamp test SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
display and operating instruments . . . . . . . . . . . . . . . . . 4-34
moving the truck crane into on-road driving position . . . . . . . 6-43
raising or lowering the entire truck crane . . . . . . . . . . . . . . 6-41
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
tilting the truck crane lengthwise or crosswise . . . . . . . . . . . 6-42
Level of on-road driving
see On-the-road level
Lifting limit switch
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-38
Lifting limit switch weight . . . . . . . . . . . . . . . . . . . . . . . 13-74
Load bearing capacity of the ground . . . . . . . . . . . . . . . . . . . 13-7
table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Locking the superstructure . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60

M Main boom
lower the boom for maintenance purposes . . . . . . . . . . . . 12-77
rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
Main hoist
display and operating instruments . . . . . . . . . . . . . . . . 10-32
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
working with the main hoist . . . . . . . . . . . . . . . . . . . . 12-36
Main rope, possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-75
Malfunctions
automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
differential locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
procedure in the event of malfunctions . . . . . . . . . . . 7-29 to 7-34
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
sevel adjustment system . . . . . . . . . . . . . . . . . . . . . . . 7-28
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
suspension locking system . . . . . . . . . . . . . . . . . . . . . . 7-28
transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
when working with the crane . . . . . . . . . . . . . . . . . . . . 15-3
Malfunctions on
counterweight lifting gear / lock . . . . . . . . . . . . . . . . . . 15-26
crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-28
01.02.2000

hydraulic oil cooler for superstructure . . . . . . . . . . . . . . 15-27

Mirror heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Mounting wheel
on the spare wheel holder . . . . . . . . . . . . . . . . . . . . . . 7-12

Operating Instructions GMK 6300 2 084 548 en 9-9

 on the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
movements combinations
for operation with the main boom . . . . . . . . . . . . . . . . . 12-92
Multipurpose switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

O Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 to 6-44

Off-the-road gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
On-the-road level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
moving the crane into on-the-road level . . . . . . . . . . . . . . 6-43
Operating hour counter
see crane control, display status menu
Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-36
actuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
display and operating instruments . . . . . . . . . . . . . . . . 10-26
extending - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . 13-13
see also Level adjustment system
preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
retracting - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . 13-15
variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Outrigger beams
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
Outrigger cylinders
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
Outrigger pads
moving into driving position . . . . . . . . . . . . . . . . . . . . 13-29
moving into working position . . . . . . . . . . . . . . . . . . . 13-28
Outrigger pressure displays
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35
Outrigger spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Overview
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
crane section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
display and operating instruments . . . . . . . . . . . . . 4-1 to 4-21
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
of display and operating instruments . . . . . . . . . . . 10-1 to 10-24
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

P Parking brake
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display and operating instruments . . . . . . . . . . . . . . . . . 4-28

releasing mechanically . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
removing the mechanical lock . . . . . . . . . . . . . . . . . . . . 7-10

9 - 10 2 084 548 en Operating Instructions GMK 6300

 while towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-75
Power unit speed
see crane control, entering power unit speeds

R Refuelling
fuel for the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-9
fuel for the vehicle engine . . . . . . . . . . . . . . . . . . . . . . 6-12
Removing the tyre
from the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Removing the wheel
from the spare wheel holder . . . . . . . . . . . . . . . . . . . . . 7-12
Rigging mode
before starting work - CHECK LIST . . . . . . . . . . . . . . . . . 12-1
setting on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Rigging work
main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-36
rigging for crane operation - CHECK LIST . . . . . . . . . . . . . . 13-1
unrigging after crane work - CHECK LIST . . . . . . . . . . . . . . 13-4
Roof ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Rope end clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67
Rotating warning light . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

S Safe distance
from banks and pits . . . . . . . . . . . . . . . . . . . . . . . . 13-10
from electrical lines . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Safe load indicator
see SLI
Safety equipment
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
functional description . . . . . . . . . . . . . . . . . . 10-59 to 10-62
Sensor/indicator
releasing shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 15-39
switch off during malfunction . . . . . . . . . . . . . . . . . . . 15-39
Separate steering
checking the steering lock . . . . . . . . . . . . . . . . . . . . . . 6-10
general . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 to 6-50
steering with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
switching off axle lines and locking steering . . . . . . . . . . . . 6-48
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Operating Instructions GMK 6300 2 084 548 en 9 - 11

 witching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
display and operating instruments . . . . . . . . . . . . . . . . 10-34
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25
slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
slewing gear permanent brake . . . . . . . . . . . . . . . . . . . 12-43
tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44
SLI
display and operating instruments . . . . . . . . . . . . . . . . 10-40
during crane work . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
functional description . . . . . . . . . . . . . . . . . . . . . . . 10-59
fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
input of values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
setting rigging mode . . . . . . . . . . . . . . . . . . . . . . . . 12-16
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
SLI error message table . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Spotlight for working area . . . . . . . . . . . . . . . . . . . . . . . 10-49
Steering
display and operating instruments in the driver’s cab . . . . . . . 4-30
Stop engine cable
see emergency stop device
Superstructure hydraulic system
Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
checking the position of the stop cock . . . . . . . . . . . . . . . 11-7
cooling the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 12-92
display and control instruments . . . . . . . . . . . . . . . . . . 10-48
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
Superstructure lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Superstructure, access ladder . . . . . . . . . . . . . . . . . . . . . . 4-41
Suspension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Switching off the
crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Switching the fan thermostat to emergency operation . . . . . . . . . 7-29
Symbols in the operating instructions, explanation . . . . . . . . . . . 2-1

T Technical data
superstructure . . . . . . . . . . . . . . . . . . . . . . . . 16-7 to 16-16
Technical description of the carrier . . . . . . . . . . . . . . . . 8-1 to 8-6
01.02.2000

Technical description of the truck crane

superstructure . . . . . . . . . . . . . . . . . . . . . . . . 16-1 to 16-6

9 - 12 2 084 548 en Operating Instructions GMK 6300

 Technical specifications . . . . . . . . . . . . . . . . . . . . . . 8-7 to 8-14
Telescoping gear
display and operating instruments . . . . . . . . . . . . . . . . 10-36
example of procedures when telescoping . . . . . . . . . . . . 12-56
function of the control lever . . . . . . . . . . . . . . . . . . . . 12-54
functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
main boom fixed length . . . . . . . . . . . . . . . . . . . . . . 12-49
main boom intermediate length . . . . . . . . . . . . . . . . . . 12-50
main boom telescoping length . . . . . . . . . . . . . . . . . . 12-50
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-22
telescope status, status display on the SLI . . . . . . . . . . . . 12-50
telescoping sequence . . . . . . . . . . . . . . . . . . . . . . . 12-53
telescoping, indicated on the crane control display. . . . . . . . 12-83
Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-10
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
when the diesel engine is off . . . . . . . . . . . . . . . . . . . . . 7-6
with diesel engine running . . . . . . . . . . . . . . . . . . . . . . . 7-5
Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 to 6-68
towing free
backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Transfer case
display and operating instruments in the driver’s cab . . . . . . . 4-26
while towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Transverse differential locks
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Transverse differential locks in all driven axle lines . . . . . . . . . . . 6-39
Trip recorder
inserting the 24-hour disc . . . . . . . . . . . . . . . . . . . . . . 6-14
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Truck crane
checking horizontal alignment . . . . . . . . . . . . . . . . . . . 12-31
earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
freeing the crane by oneself . . . . . . . . . . . . . . . . . . . . . 6-43
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
in on-road driving position . . . . . . . . . . . . . . . . . . . . . . 6-43
overview of the crane section . . . . . . . . . . . . . . . . . . . . 10-1
overview of the vehicle section . . . . . . . . . . . . . . . . . . . . 4-1
raising or lowering . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
safe distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
securing the truck crane from rolling . . . . . . . . . . . . . . . . 6-32
tilting the crane lengthwise or crosswise . . . . . . . . . . . . . . 6-42
01.02.2000

towing free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Tyre change
see Wheel change

Operating Instructions GMK 6300 2 084 548 en 9 - 13

 V Vehicle engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
diagnostic plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
display and operating instruments . . . . . . . . . . . . . . . . . 4-22
inspections after starting . . . . . . . . . . . . . . . . . . . . . . . 5-13
preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54, 6-56
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10, 11-10
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
starting - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
starting a warm engine . . . . . . . . . . . . . . . . . . . . . . . . 5-12
starting cold vehicle engine . . . . . . . . . . . . . . . . . . . . . 5-11
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Ventilation
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-104
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35, 6-53

W Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 to 7-14

Wind
influence of wind on crane work . . . . . . . . . . . . . . . . . . 12-32
permissible wind load . . . . . . . . . . . . . . . . . . . . . . . 12-34
wind speed table . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-99 to 12-100
for work breaks lasting more than 8 hours . . . . . . . . . . . . 12-100
short work break . . . . . . . . . . . . . . . . . . . . . . . . . . 12-99

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9 - 14 2 084 548 en Operating Instructions GMK 6300

01.02.2000

Operating Instructions GMK 6300 2 084 548 en 9 - 15

Operating Instructions Part 2 Superstructure

Vehicle serial number: 2 084 548 en

26.06.2000
(01.02.2000)
 Important note

Duplications of any kind and excerpts from this

document are not subject to the alterations
service. Original documents of Deutsche GROVE
GmbH are marked with the blue serial number of
the truck crane on the cover page.

Duplications and print-outs of data carriers on

which Deutsche GROVE GmbH has delivered this
document are also not subject to the alterations
service.

©
Copyright reserved by Deutsche GROVE GmbH
01.02.2000

The passing on or duplication of this document as well as the use and disclosure of its contents are prohibited
unless expressly permitted. Offenders will be liable for damages. All rights pertaining to registration of patent or utility mo-
del are reserved.
 These operating instructions consist of two parts:
– Part 1 – Carrier

– Part 2 – Superstructure

Part 2 comprises the following chapters:

10 Description of the truck crane – crane section

11 Crane engine

12 Crane operation

13 Rigging work

14 Auxiliary hoist assembly/disassembly

15 Malfunctions on the superstructure

16 Technical information for superstructure

17 Alphabetical index

Chapters 1 to 9 are in part 1 – Carrier

This section is not equivalent to complete

operating instructions. The basic safety
information for working with the crane can be
found in Section 1, Chapter 2.
01.02.2000

Operating Instructions GMK 6300 2 084 548 en

 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 ____________________________________________________________________________________ 10
10 Description of the truck crane – crane section . . . . . . . 10 - 1
10.1 Overview of the operating and display instruments . . . . . . . . 10 - 1
10.1.1 Overview of crane section . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
10.1.2 Crane cab overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 4
10.1.3 Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 6
10.1.4 Left control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 20
10.1.5 Right control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 21
10.1.6 Control box for operating the outriggers . . . . . . . . . . . . . . . . . . 10 - 22
10.1.7 Counterweight lifting gear switch unit . . . . . . . . . . . . . . . . . . . . 10 - 23
10.1.8 Electronic level control box . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 24
10.2 Functional description of the display and operating instruments 10 - 25
10.2.1 Crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 25
10.2.2 Other operating instruments on the crane cab . . . . . . . . . . . . . . . 10 - 56
10.3 Functional description of the safety devices . . . . . . . . . . . . . 10 - 59
10.3.1 Safe load indicator (SLI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 59
10.3.2 Lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 60
10.3.3 Lifting limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 61
10.3.4 Dead man’s and seat contact switches . . . . . . . . . . . . . . . . . . . 10 - 62
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 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10 Description of the truck crane – crane section

10.1 Overview of the operating and display instruments

This section deals only with display and operating instruments for crane
operations which are located on the outside of the mobile crane and in
the crane cab.

10.1.1 Overview of crane section

The figure on the following page shows the position of the operating and
control instruments on the outside of the truck crane which are necessary
for crane work.
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Operating Instructions GMK 6300 2 084 548 en 10 - 1
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

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10 - 2 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Main hoist ➠ p. 10-32

2 Auxiliary hoist (additional equipment) (disassembled) ➠ p. 10-33
3 Counterweight lifting gear switch unit ➠ p. 10-23
4 Counterweight (dismounted) ➠ p. 13-37
5 Hydraulic oil cooler ➠ p. 12-92
(second hydraulic oil cooler)

6 Rear support (outrigger beam, outrigger pad) ➠ p. 13-13

7 Hydraulic oil tank, inspection glass ➠ p. 11-6
8 Storage box and access ladder

9 Crane cab (can be inclined) ➠ p. 10-4

➠ p. 10-20
10 Switch box for operating the outriggers and ➠ p. 10-22
switch box for electronic level ➠ p. 10-24
outrigger pressure display (additional equipment) ➠ p. 10-24
11 Working headlights ➠ p. 10-49
12 Front support (outrigger beam, outrigger pad) ➠ p. 13-13
13 Hook block ➠ p. 13-63
14 Data transmitter

15 Crane engine fuel tank filler pipe ➠ p. 11-9

16 Slewing gear ➠ p. 12-43
17 Central lubrication system Maintenance
manual

18 Crane engine ➠ p. 11-1

19 Mirror for monitoring rope running ➠ p. 12-8
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Operating Instructions GMK 6300 2 084 548 en 10 - 3

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.2 Crane cab overview

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10 - 4 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Front instrument panel ➠ p. 10-6

2 Accelerator

3 Right control console ➠ p. 10-21

4 Crane operator’s seat with dead man’s switch ➠ p. 10-62
➠ p. 10-58
5 Crane control ➠ p. 10-30
6 Air-conditioning system ➠ p. 10-55
7 Crane engine diagnostic plug ➠ p. 10-58
8 Fire extinguisher (additional equipment) ➠ p. 10-57
9 Left control console ➠ p. 10-20
10 Foot-operated switch for fast speed derricking ➠ p. 10-35
gear/telescoping gear ➠ p. 10-40
11 Foot-operated switch for fast speed hoisting gear ➠ p. 10-32
12 Foot-operated switch for free movement of the ➠ p. 10-35
slewing gear

13 Ignition lock ➠ p. 10-49

14 Heater fan knob ➠ p. 10-52
15 Regulator for windscreen / cab floor air distribution ➠ p. 10-52
16 Recirculated air / fresh air regulator ➠ p. 10-52
17 Temperature regulator ➠ p. 10-52
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Operating Instructions GMK 6300 2 084 548 en 10 - 5

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.3 Instrument panel

Front instrument
panel

H For additional equipment with item 22, the position of 16 changes.

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10 - 6 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Hydraulic system oil temperature display ➠ p. 10-48

2 Crane engine coolant temperature display ➠ p. 10-25
3 Status display for fuel reserve ➠ p. 10-26
4 Warning lamp for charge indicator ➠ p. 10-49
5 Indicator lamp for crane motor air filter ➠ p. 10-25
6 Crane engine oil pressure warning lamp ➠ p. 10-26
7 Engine electronics warning lamp ➠ p. 10-26
8 Warning lamp for crane engine coolant level ➠ p. 10-25
9 Indicator lamp for flame start system ➠ p. 10-25
(additional equipment)

10 Warning lamp for control circuit hydraulic oil filter ➠ p. 10-48

11 Warning lamp for feed circuit hydraulic oil filter ➠ p. 10-48
12 Hydraulic oil return fine filter warning lamp ➠ p. 10-48
13 Warning lamp for hydraulic oil return filter ➠ p. 10-48
14 Rocker switch for left working lights socket ➠ p. 10-49
15 Rocker switch for right working lights socket ➠ p. 10-49
(additional equipment)

16 Rocker switch for hoist rope control spotlight ➠ p. 10-49

(additional equipment)

17 Rocker switch with indicator lamp for additional ➠ p. 10-53

heating system (additional equipment)

18 Rocker switch for windscreen wiper ➠ p. 10-49

19 Rocker switch for roof window wiper ➠ p. 10-50
20 Rocker switch for intermittent wiper operation, ➠ p. 10-50
windscreen and roof window

21 Rocker switch for windshield wiper/washing system ➠ p. 10-50

22 Additional heating system with timer *)

*) Either positions 17 or 22 is possible as additional equipment.

The operating instruments of the additional heating system with timer
(22) are identical to those for the additional heating system in the
01.02.2000

carrier; ➠ p. 6-56.

s
Operating Instructions GMK 6300 2 084 548 en 10 - 7
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

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10 - 8 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Crane control display ➠ p. 10-30

2 Membrane switch for view and entry display ➠ p. 10-30
3 Membrane switch to display states ➠ p. 10-31
4 Power unit speeds/critical load control ➠ p. 10-31
5 Control lever emergency program membrane switch ➠ p. 10-31
6 Membrane switch for displaying telescoping status and ➠ p. 10-31
teleautomatic

7 Enter telescope status after emergency operation

membrane switch
➠ p. 10-31
8 Indicator lamp for right control lever at telescoping
function
➠ p. 10-36
9 Indicator lamp for right control lever at derricking
function
➠ p. 10-35
10 Telescoping ram in foot section I position light ➠ p. 10-37
11 Telescoping ram in foot section II position light ➠ p. 10-37
12 Telescoping ram in foot section III position light ➠ p. 10-37
13 Telescoping ram in foot section IV position light ➠ p. 10-37
14 Telscoping cylinder indicator lamp on the locking point ➠ p. 10-38
15 Telescope section locked indicator lamp ➠ p. 10-39
16 Telescope section unlocked indicator lamp ➠ p. 10-39
17 Telescoping cylinder locked indicator lamp ➠ p. 10-39
18 Telescoping cylinder unlocked indicator lamp ➠ p. 10-39
19 Select locking/unlocking rocker switch ➠ p. 10-38
20 Telescoping main boom blocked warning lamp *)

21 Crane control emergency stop switch ➠ p. 10-32

22 Slew lattice extension rocker switch *)

23 Lattice extension in driving position indicator lamp *)

*) ➠ GMK 6300 Lattice extension operating manual.

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Operating Instructions GMK 6300 2 084 548 en 10 - 9
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

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10 - 10 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Crane cab electronic level ➠ p. 10-51

2 Anemometer ➠ p. 12-32
3 Lifting limit switch shutdown warning lamp ➠ p. 10-33
4 Luffing control arm erected indicator lamp *)
(only for additional equipment with luffing jib)

5 Front left outrigger pressure (additional equipment) ➠ p. 10-54

6 Slewing gear permanent brake indicator lamp ➠ p. 10-34
7 Steepest position warning lamp *)
(only for additional equipment with luffing jib)

8 Front right outrigger pressure (additional equipment) ➠ p. 10-54

9 “Superstructure unlocked” indicator lamp ➠ p. 10-34
10 Telescoping range indicator lamp *)
(only for additional equipment with luffing jib)

11 Rear left outrigger pressure (additional equipment) ➠ p. 10-54

12 “Superstructure locked” indicator lamp ➠ p. 10-34
13 Working range indicator lamp *)
(only for additional equipment with luffing jib)

14 Rear right outrigger pressure (additional equipment) ➠ p. 10-54

15 Superstructure lock rocker switch ➠ p. 10-34
16 Rigging range indicator lamp *)
(only for additional equipment with luffing jib)

17 Operating mode selector lever

(only for additional equipment with luffing jib) *)

18 Rocker switch with level indicator measuring range ➠ p. 10-52

indicator lamp (crane cab)

19 Override key-operated switch

for safe load indicator (SLI) ➠ p. 10-51
for safe load indicator and lifting limit switch ➠ p. 10-61
20 Lowest position warning lamp *)
(only for additional equipment with luffing jib)

*) ➠ GMK 6300 Lattice extension operating manual.

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Operating Instructions GMK 6300 2 084 548 en 10 - 11

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 2 3 4

5
6
7
8

9
0

C0566
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10 - 12 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Display for current status of telescope section I ➠ p. 10-41

2 Display for current status of telescope section II ➠ p. 10-41
3 Display for current status of telescope section III ➠ p. 10-41
4 Display for current status of telescope section IV ➠ p. 10-41
5 Status display for lattice extension angle with ➠ p. 10-41
membrane switch

6 Indicator lamp for SLI shutdown ➠ p. 10-44

7 SLI early warning lamp ➠ p. 10-44
8 Status display for lattice extension length with ➠ p. 10-41
membrane switch

9 Display for maximum load ➠ p. 10-42

10 Display for degree of utilization ➠ p. 10-42
11 Display for actual load ➠ p. 10-42
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Operating Instructions GMK 6300 2 084 548 en 10 - 13
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 2 3 4
5

6 7 8 9
0 q w e

a btc d e
C0852 fghij
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10 - 14 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Membrane switch with warning lamp for error ➠ p. 10-42

information

2 Without function (in preparation)

3 Membrane switch with indicator lamp for permissible ➠ p. 10-42

slewing range

4 Membrane switch with indicator lamp for main boom ➠ p. 10-43

5 Information status display ➠ p. 10-44
6 Membrane switch with indicator lamp for main boom ➠ p. 10-43
length

7 Membrane switch with indicator lamp for height of ➠ p. 10-43

single-sheave boom top

8 Membrane switch with indicator lamp for angle of ➠ p. 10-43

lattice extension

9 Membrane switch with indicator lamp for degree of ➠ p. 10-43

utilization

10 Without function (in preparation)

11 Membrane switch with hydraulic oil pressure indicator ➠ p. 10-43

lamp for derricking cylinder lower chamber Sensor A

12 Membrane switch with hydraulic oil pressure indicator ➠ p. 10-44

lamp for derricking cylinder lower chamber Sensor B

13 Membrane switch with indicator lamp for hydraulic oil ➠ p. 10-44

pressure in derricking cylinder upper chamber

14 Outrigger span display with membrane switch ➠ p. 10-46

15 Numerical pad with membrane switches 1 to 0 ➠ p. 10-46
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Operating Instructions GMK 6300 2 084 548 en 10 - 15
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

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10 - 16 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Counterweight display with membrane switch ➠ p. 10-44

2 Hoist display lamps ➠ p. 10-45
3 Display for current main boom angle ➠ p. 10-41
4 Reeving display with membrane switch ➠ p. 10-45
5 Rigging mode display (SLI code) with membrane ➠ p. 10-45
switch

6 Display for current radius ➠ p. 10-41

7 Service key switch ➠ p. 10-45
8 Entry mode membrane switch ➠ p. 10-47
9 Lamp test membrane switch (2nd level assignment) ➠ p. 10-47
10 Dimmer brighter membrane switch ➠ p. 10-47
(2nd level assignment)

11 Dimmer darker membrane switch ➠ p. 10-47

(2nd level assignment)

12 Membrane switch to acknowledge ➠ p. 10-46

13 Membrane switch to switch to second level ➠ p. 10-47
14 Membrane switch to confirm entry ➠ p. 10-46
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Operating Instructions GMK 6300 2 084 548 en 10 - 17
Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

1 Rocker switch for constant engine speed ➠ p. 10-50 01.02.2000

10 - 18 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

Fittings
behind the
crane driver seat
1 Loudspeaker

2 Radio

3 Interior lighting

H The cab lighting is operated in the same way as in the driver’s cab;
➠ p. 4-38.
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Operating Instructions GMK 6300 2 084 548 en 10 - 19

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.4 Left control console

1 Control lever for slewing gear ➠ p. 10-34

and auxiliary hoist (additional equipment) ➠ p. 10-33
2 Horn button

3 Dead man’s switch ➠ p. 10-62

4 Hoist drum synchro for auxiliary hoist ➠ p. 12-38
(additional equipment)

5 Rocker switch for slewing gear permanent brake ➠ p. 10-34

6 Rocker switch for auxiliary hoist shutdown ➠ p. 10-33
(additional equipment)

7 Rocker switch to incline crane cab ➠ p. 10-51

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10 - 20 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.5 Right control console

1 Control lever for main hoist and derricking ➠ p. 10-32

gear/telescoping gear ➠ p. 10-35
2 Horn button

3 Dead man’s switch ➠ p. 10-62

4 Hoist drum synchro for main hoist ➠ p. 12-38
5 Rocker switch for main hoist shutdown ➠ p. 10-32
6 Rocker switch for shutdown derricking gear ➠ p. 10-35
7 Rocker switch for telescoping gear shutdown ➠ p. 10-36
8 Rocker switch for preselecting control lever function ➠ p. 10-35
derricking / telescoping ➠ p. 10-36
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Operating Instructions GMK 6300 2 084 548 en 10 - 21

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.6 Control box for operating the outriggers

2
6
3

5 4

C0117

1 Control box lighting

2 Toggle switch for preselection of outrigger cylinder / ➠ p. 10-26

outrigger beam

3 Toggle switch for front left outrigger ➠ p. 10-27

4 Toggle switch for front right outrigger ➠ p. 10-27
5 Toggle switch for rear right outrigger ➠ p. 10-27
6 Toggle switch for rear left outrigger ➠ p. 10-27
7 Toggle switch for preselection of direction of outrigger ➠ p. 10-26
movement

8 Central outrigger toggle switch with speed control ➠ p. 10-27

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10 - 22 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.7 Counterweight lifting gear switch unit

1 No function.

2 Locking counterweight switch ➠ p. 10-28

3 Counterweight locked indicator lamp ➠ p. 10-28
(in the lock counterweight switch)

4 Unlocking counterweight switch ➠ p. 10-28

5 Counterweight locked warning lamp ➠ p. 10-28
(in the unlock counterweight switch)

6 Extend counterweight lifting cylinder / ➠ p. 10-28

Lift counterweight

7 Switch to retract counterweight lifting ➠ p. 10-28

cylinders/lower counterweight

8 Release switch unit knob ➠ p. 10-28

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Operating Instructions GMK 6300 2 084 548 en 10 - 23

Description of the truck crane – crane section
10.1 Overview of the operating and display instruments

10.1.8 Electronic level control box

1 Toggle switch for changing measuring ➠ p. 10-52

ranges

2 Electronic level display ➠ p. 13-33

3 Outrigger pressure display for carrier ➠ p. 13-35
(additional equipment)

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10 - 24 2 084 548 en Operating Instructions GMK 6300

 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

10.2 Functional description of the display and operating

instruments
Definition of direction information for using operating elements;
➠ p. 1-16.

10.2.1 Crane work

Crane engine

Ignition lock
To switch on the ignition and to start the crane engine;
➠ Starting the crane engine, p. 11-10.

Indicator lamp for flame start system

z Illuminates when the ignition is switched on and the crane engine is cold.
Goes out when the crane engine is ready to start;
➠ Starting crane engine, p. 11-12.
Warning lamp for crane engine coolant level
t Illuminates if the fluid level in the coolant water circuit of the crane engine
is too low; ➠ Checking the instruments, p. 11-14.

Status display for coolant temperature in crane engine

The temperature of the coolant should not exceed 95 °C.
When the maximum permissible temperature of the coolant is exceeded,
a warning buzzer sounds; ➠ Crane engine malfunctions, p. 15-15.

Indicator lamp for crane engine air filter

p Illuminates if the air filter is dirty.
Change the filter element; ➠ Maintenance manual.
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Operating Instructions GMK 6300 2 084 548 en 10 - 25
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for crane engine oil pressure

L Illuminates if the oil pressure is too low; ➠ Malfunctions in the crane engine,
p. 15-15.

Status display for fuel reserve

Never allow the fuel tank to become completely empty! ➠ p. 11-9.

C0013

Engine electronics warning lamp;

à Illuminates when the ignition is switched on.
Goes out when the engine is running and the engine’s electrical system is
functioning properly.
Flashes if there is a malfunction in the engine electronics; ➠ p. 11-14.

Outrigger ➠ Outrigger, p. 13-13

operation

Toggle switch for preselection of direction of outrigger movement

Extending outrigger beam or cylinder: Rocker switch upwards;
➠ Extend outriggers,
p. 13-23.
Retracting outrigger beam or cylinder: Rocker switsch downwards;
C0120 ➠ Retract outrigger beam,
p. 13-26.

Toggle switch for preselection of outrigger cylinder / outrigger beam

Extend / retract outrigger beam: Rocker switch upwards;
➠ Extend outriggers,
p. 13-23.
Extending / retracting outrigger cylinder: Rocker switsch downwards;
C0121 ➠ Extend/retract outrigger
cylinders, p. 13-30.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Central toggle switch for outriggers with speed control

Moving outriggers with the crane Push upwards to build up

engine idling: outrigger pressure.

Move outriggers at approx. Push downwards to build up

1100 rpm crane engine speed: outrigger pressure;
➠ Extend outriggers, p. 13-23.
C0119

Toggle switch for front right outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this

switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.
C0122

Toggle switch for front left outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this
switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.
C0123

Toggle switch for rear right outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this
switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.

C0124

Toggle switch for rear left outrigger

Movement of the outrigger cylinder or outrigger beam by pressing this
switch and the central toggle switch for Outriggers simultaneously;
➠ Extending the outrigger beams, p. 13-23.
C0125
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Operating Instructions GMK 6300 2 084 548 en 10 - 27
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Counterweight The crane engine must be running to activate the counterweight lifting
lifting gear and cylinder on the 8 t base plate.
lock

Knob for releasing for the switch unit

The counterweight lifting gear switch unit is equipped for 2-hand opera-
tion. The following switches are only active when the Release switch unit
knob is turned to the right and held there.

Switch to lock counterweight with counterweight locked indicator lamp

To turn the hasps into the locked position press this switch in addition to
the Release switch unit knob.
The Counterweight locked indicator lamp lights up in the switch when the
adjusting cylinder for the hasps is locked in position.
The hasps move for as long as you keep the button depressed or until the
end position is reached.
➠ Locking / unlocking the counterweight on the turntable, p. 13-59.

Switch to unlock counterweight with counterweight unlocked

warning lamp
To turn the hasps into the unlocked position press this switch in addition to
the Release switch unit knob.
The Counterweight unlocked warning lamp lights up in the switch when
the adjusting cylinder for the hasps is unlocked in position.
The hasps move for as long as you keep the button depressed or until the
end position is reached.
➠ Locking / unlocking the counterweight on the turntable, p. 13-59.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Extend counterweight lifting cylinder / lift counterweight switch

To extend the counterweight lifting cylinders, press this switch in addition
to the Release switch unit knob.
If the counterweight is on the counterweight platform, it is lifted by this
movement.
If the counterweight is locked on the turntable, the lifting cylinders move
down out of the 8 t base plate.
The counterweight lifting cylinders continue to move as long as you hold
the switch down or until an end position is reached;
➠ Extending / retracting the lifting cylinders of the 8 t counterweight section /. lif-
ting / lowering counterweight, p. 13-56.

Retract counterweight lifting cylinders / lower counterweight switch

To retract the counterweight lifting cylinders, press this switch in addition
to the Release switch unit knob.
If the counterweight is on the counterweight platform, it is lowered by this
movement.
If the counterweight is locked on the turntable, the lifting cylinders move
up into the 8 t base plate.
The counterweight lifting cylinders continue to move as long as you hold
the switch down or until an end position is reached;
➠ Extending / retracting the lifting cylinders of the 8 t counterweight section /. lif-
ting / lowering counterweight, p. 13-56.
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Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Crane control ➠ Menus in the crane control display, p. 12-79.

Crane control display
Is switched on together with the ignition.
The readiness display SYSTEM OK! appears
******************************* after switching on.
The display shows error messages from the
ECOS
crane control system and information on the
SYSTEM OK! current conditions of different areas.
******************************* Each area has its own menu.

The various menus are selected by pressing the following membrane

switches:

> – Membrane switch Display states

@ – Membrane switch Power unit speeds/critical load control

ü – Membrane switch Control lever emergency program

ä – Membrane switch Display telescope status and teleautomatic

Ä – Membrane switch Enter telescope status after emergency operation

Error messages are displayed with priority immediately after a mal-
function occurs; ➠ Menus in the crane control display, p. 12-79.

H The text of the crane control display can be shown in German, English,
French, Dutch, Spanish, Italian, Danish, Finnish, Swedish, Portuguese,
Polish and Russian. In addition, metres or feet can be set as the unit of
measurement. The language and the unit of measurement are set at ship-
ment. If you need to change the setting, please contact GROVE Product
Support.

Membrane switch for view and entry display

The View and entry display membrane switches serve to acknowledge error
messages and to enter values in the selected range and to switch be-
tween the menu points.
The necessary membrane switches are activated if the Crane control display
indicates an error message or if settings can be carried out in the dis-
played menu.

Both left-hand membrane switches have an additional function and are al-
: ways active. They serve to switch between menu points in increasing or
decreasing order within a menu.
<
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Display states membrane switch

> Pushing the switch selects the Display states menu. This menu shows the
current states and the operating hours of the crane engine, the hoists, the
derricking gear, the slewing gear, the telescoping gear, the control units
and the locking devices. If a function is completely or partially blocked by
the crane control system due to a malfunction, the menu displays that a
malfunction is present; ➠ Display states menu, p. 12-79.

Power unit speeds/critical load control membrane switch

@ Pressing the switch selects the Power unit speed/Critical load control menu.
In this menu, you can enter the maximum speed for main boom and latti-
ce extension operation for the slewing gear, hoists, telescoping gear and
derricking gear. The critical load control can be switched on and off in
another submenu; ➠ Power unit speed/critical load control menu, p. 12-83;
➠ Critical load control, p. 12-90.
Control lever emergency program membrane switch
ü Pushing the switch selects the Control lever emergency program menu. If one
control lever fails, the corresponding crane motions can be carried out in
an emergency using this menu; ➠ Control lever emergency program, p. 15-72.

Display telescope status and teleautomatic membrane switch

ä Pressing the switch selects the Display telescope status and teleautomatic
menu. This menu shows the current telescoping status of all telescope
sections as a percentage.
If all telescope sections are locked, the current extended length of the tele-
scoping cylinder is shown in feet; ➠ Telescoping gear, p. 12-47.
By pressing the switch again, the submenu Fully automatic telescope is
selected; ➠ Telescoping with fully automatic control, p. 12-73.

Entering telescope status after emergency operation membrane switch

Ä The menu Enter telescope status after emergency operation is selected with the
switch. In order to select the menu, the switch must be pressed three
times in a row within 2 seconds. This menu is required to enter the
current telescope status if the crane control system is to be suddenly cut
off from the power supply during storage of the values or if telescoping
was done in emergency mode; ➠ Enter telescope status after emergency
operation, p. 15-80.
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Operating Instructions GMK 6300 2 084 548 en 10 - 31
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Crane control emergency stop switch

To switch off the crane control system in an emergency. Switches off all
crane engine immediately. Crane functions are stopped suddenly.

Stop crane functions: Push in the emergency stop switch

The switch clicks in

Release crane functions again: Turn the emergency stop switch

The switch pops back out
➠ Crane control emergency stop, p. 15-2

Main hoist ➠ Main hoist, p. 12-36

Rocker switch for main hoist shutdown
ü Shuts off the main hoist to prevent inadvertent operation.
Switching off the main hoist: Press rocker switch down
Switching on the main hoist: Press rocker switch up
Righthand control lever
Lifting the main hoist: Control lever to the rear
Lowering the main hoist: Control lever forward

Foot-operated switch fast speed hoisting gear

Switches on the fast speed for the main hoisting gear and auxiliary hoist
gear (additional equipment).

Switching on fast speed: Press foot-operated switch down and hold

Switching off fast speed: Release foot-operated switch

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-27.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permissible load has
been reached (overload) or an error has occured. A continuous buzzer
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tone sounds at the same time; ➠ SLI shutdown, p. 12-27.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for lifting limit switch shutdown

K Illuminates when shutdown of the hoisting gear is triggered by the lifting
limit switch. The SLI displays no error messages; ➠ Lifting limit switch,
p. 10-61.

Auxiliary hoist
(additional
equipment) ➠ Auxiliary hoist, p. 12-39

Rocker switch for auxiliary hoist shutdown (additional equipment)

C Shuts down the auxiliary hoist to prevent inadvertent operation.
Switching off the auxiliary hoist: Press rocker switch down
Switching on the auxiliary hoist: Press rocker switch up
Lefthand control lever
Lifting the auxiliary hoist: Control lever to the rear
Lowering the auxiliary hoist: Control lever forward

Foot-operated switch fast speed hoisting gear

Switches on the fast speed for the main hoisting gear and auxiliary hoist
gear (additional equipment).

Switching on fast speed: Press foot-operated switch down and hold

Switching off fast speed: Release foot-operated switch

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-27.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
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tone sounds at the same time; ➠ SLI shutdown, p. 12-27.

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Operating Instructions GMK 6300 2 084 548 en 10 - 33
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for lifting limit switch shutdown

K Illuminates when shutdown of the hoisting gear is triggered by the lifting
limit switch. The SLI displays no error messages; ➠ Lifting limit switch,
p. 10-61.

Slewing gear ➠ Slewing gear, p. 12-43

➠ Mechanical superstructure lock, p. 12-6
Rocker switch for superstructure lock
§ Locks the superstructure in 0 or 180° position to the carrier.

Lock the superstructure: Press rocker switch down

Unlock superstructure: Press rocker switch up
The appropriate indicator lamp illuminates in end position.

Indicator lamp for locked superstructure

! Illuminates when the locking pin has reached the lower end position and
the superstructure is locked.

Indicator lamp for unlocked superstructure

¥ Illuminates when the locking pin has reached the upper end position and
the superstructure is unlocked.

Rocker switch for slewing gear permanent brake

Y Closes the slewing gear permanent brake when the crane engine is
running and secures the left control lever for slewing crane movement
against unintentional activation.
Engage the slewing gear permanent
brake: Press rocker switch down
Release the slewing gear permanent
brake: Press rocker switch up

Indicator lamp for slewing gear permanent brake

Y Illuminates when the slewing gear permanent brake is closed.

Lefthand control lever

Turn superstructure to left: Control lever to the left
Turn superstructure to right: Control lever to the right
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Foot-operated switch free movement of the slewing gear

If the free movement of the slewing gear is switched on, the superstructure
can adjust to external forces.

Switch on the free movement of the Push the foot-operated switch

slewing gear: downwards and hold it down
Switch off free movement of the
slewing gear: Release the foot-operated switch

Derricking gear ➠ Derricking gear, p. 12-41

Rocker switch for derricking/telescoping control level function
_ preselection
Switches the control lever function between derricking gear and telesco-
ping gear.
Derricking control lever function: Press rocker switch down.
Telescoping control lever function: Press rocker switch up.

Indicator lamp for right-hand control lever in derricking function

U Illuminates when the control lever function derricking has been selected.

Rocker switch for switching off derricking gear

Ü For deactivating the Derricking function to prevent inadvertent activation.

Righthand control lever

Raise (= raise boom): Control lever to the left
Lower (= lower boom): Control lever to the right

Foot-operated switch for fast speed derricking gear/telescoping gear

Switching on fast
speed mode: Push down foot-operated switch and hold it down
Switching off fast
speed mode: Release foot-operated switch

H
01.02.2000

During lowering of the boom, fast speed mode only supports the start-up
of the derricking procedure at extreme boom positions. It does not increa-
se the derricking speed; ➠ Derricking gear fast speed, p. 12-42.
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Operating Instructions GMK 6300 2 084 548 en 10 - 35
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-27.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
tone sounds at the same time; ➠ SLI shutdown, p. 12-27.

Telescoping gear ➠ Telescoping gear, p. 12-47.

Rocker switch for telescoping gear shutdown

Ö Shuts off the telescoping gear to prevent inadvertent operation.

Switch off telescoping gear: Press rocker switch down.

Switching on telescoping gear: Press rocker switch up.

Rocker switch for preselection of control lever function

_ derricking / telescoping
Switches the control lever function between derricking gear and
telescoping gear.
Derricking control lever function: Press rocker switch down.
Telescoping control lever function: Press rocker switch up.
Indicator lamp for telescoping gear control lever function switched on
T Illuminates if the control lever function Telescoping gear is switched on.

Righthand control lever

Telescoping in: Control lever to the left

Telescoping out: Control lever to the right

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Indicating lamp for telescoping cylinder in foot section I

V Flashes if the head of the telescoping cylinder moves into the locking ran-
ge in the foot section of telescope section I.
Lights up when the telescoping cylinder in the telescope section I foot sec-
tion is locked.
Goes out if the head of the telescoping cylinder leaves the locking range
in the foot section of telescope section I.

Indicator lamp for telescoping cylinder in foot section II

e Flashes if the head of the telescoping cylinder moves into the locking
range in the foot section of telescope section II.
Lights up when the telescoping cylinder in the telescope section II foot
section is locked.
Goes out if the head of the telescoping cylinder leaves the locking
range in the foot section of telescope section II.

Indicator lamp for telescoping cylinder in foot section III

f Flashes if the head of the telescoping cylinder moves into the locking
range in the foot section of telescope section III.
Lights up when the telescoping cylinder in the telescope section III foot
section is locked.
Goes out if the head of the telescoping cylinder leaves the locking range
in the foot section of telescope section III.

Indicator lamp for telescoping cylinder in foot section IV

g Flashes if the head of the telescoping cylinder moves into the locking
range in the foot section of telescope section IV.
Lights up when the telescoping cylinder in the telescope section IV foot
section is locked.
Goes out if the head of the telescoping cylinder leaves the locking
range in the foot section of telescope section IV.
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Operating Instructions GMK 6300 2 084 548 en 10 - 37
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Telescoping cylinder at locking point indicator lamps

9 These indicator lamps serve mainly as support during Retract emergency
8 operation and during the Emergency program submenu;
➠ Emergency program, p. 15-44.
➠ Retract emergency operation, p. 15-74.
The indicator lamps show the direction in which the telescoping cylinder
must be moved in order to be at the locking point:
If only the upper indicator lamp lights up, you can reach the proper positi-
9 on for mechanically locking by retracting the telescoping cylinder.
The upper indicator lamp flashes when the telescoping cylinder is
extended or retracted at the end of the permitted range. Movement of the
telescoping cylinder is switched off.

If only the lower indicator lamp lights up, you can reach the proper positi-
8 on for mechanically locking by extending the telescoping cylinder.

If both indicator lamps light up, the telescoping cylinder is directly at the
9 locking point.

8
Rocker switch to select lock/release
. To lock or release 2 telescope sections to/from each other or a telescoping
cylinder to/from a telescope section.

Select release telescoping cylinder: Press rocker switch down

Select unlock telescope section: Press rocker switch up

Select lock telescope section/

Rocker switch in central position
telescoping cylinder:

In the central position, the crane control system automatically selects the
necessary locking procedure depending on whether one is telescoping or
moving the telescoping cylinder without a telescope section.
The selection to release is only accepted by the crane control system if
both the telescope section and the telescoping cylinder are locked.
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Warning lamp for telescoping cylinder is unlocked

i Shows the position of the locking pins of the telescoping cylinder.
Flashes as soon as release is selected if the locking pins are retracted and
the end position has not been reached.
Illuminates when the locking pins are have been retracted to the end
position during release.
Goes out when the locking pins are extended to the end position during
locking.

Indicator lamp for locked telescoping cylinder

h Shows the position of the locking pins of the telescoping cylinder.
Flashes when locking is selected and keeps flashing until the locking pins
are pushed out and the locking process is finished.
Illuminates when the locking pins are pushed out to the end position
during locking and the locking process is finished.
Goes out when the locking pins are retracted to the end position during
release.

Indicator lamp for telescope section locked (green)

j Shows the position of the locking pins of the telescope section in which
the head of the telescoping cylinder is located.
Flashes when locking is selected and keeps flashing until the telescope
section is on the pushed out locking pins.
Illuminates when the locking pins are pushed out of the telescope section
into the telescope section above and the telescope section is on the pins.
Goes out if the locking pins in the telescopic section are retracted.

Warning lamp for telescope section released (red)

j Shows the position of the locking pins of the telescope section in which
the head of the telescoping cylinder is located.
Flashes as soon as relaese ist selected if the locking pins are retracted and
the end position has not been reached.
Illuminates if the locking pins in the telescopic part are retracted.
Goes out when the locking pins are extended from the telescope section
into the telescope section above it.
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Operating Instructions GMK 6300 2 084 548 en 10 - 39
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Foot-operated switch for fast speed derricking gear / telescoping gear

Switching on fast speed mode: Push down foot-operated switch and
hold it down
Switching off fast speed mode: Release foot-operated switch

SLI early warning lamp

x The SLI early warning lamp will illuminate when the actual load reaches
90 % or more of the maximum permissible load. An intermittent buzzer
tone sounds at the same time; ➠ SLI early warning, p. 12-27.

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
tone sounds at the same time; ➠ SLI shutdown, p. 12-27.

Safe load
indicator Operation of safe load indicator ➠ p. 12-13

The elements in a display

1–4 Values
5 Signalling point
6 Decimal point;
in the Working position display:
Separator point between the SLI code
and supplement
7–8 Decimal points

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Status display, telescope status (telescope sections I – V)

85 Displays the current telescoping status of telescope sections I to V.
Fixed lengths are indicated as decimal values (0.0, 0.5 and 1.0).
Intermediate and telescoping lengths up to 99 % are indicated as percent-
ages (00 to 99).
The intermediate length of 100 % is indicated as a decimal value with a
signalling point (1.0.) and the display flashes.
Structure of a status display; ➠ The elements in a display, p. 10-40.

Status display for length of lattice extension with membrane switch

2!0 m Displays the length of lattice extension in meters. The status display is ac-
tivated when an SLI code for working with the lattice extension is entered
in the Rigging mode status display. In both cases the displayed length is ob-
tained from the entered SLI code.
If the Rigging mode display of the entry mode is switched on, pressing the
membrane switch repeatedly displays other values which are permitted
according to the Lifting capacity table.
When the greatest length is reached and the membrane switch is pressed
again, the display starts again at the beginning with the lowest value.

Status display for angle of lattice extension with membrane switch

1%0 n° Displays the inclination of lattice extension to the main boom in degrees.
The status display is activated when an SLI code for working with the lat-
tice extension is entered in the Rigging mode status display.
For the luffing jib (additional equipment), the currently measured angle is
displayed and no values can be selected from the display.
For the boom extension (additional equipment), the displayed angle is de-
rived from the entered SLI code. If the entry mode is activated in the
Rigging mode display, pressing the membrane switch repeatedly displays
other values which are permitted according to the Lifting capacity table in
ascending order.
When the greatest inclination is reached and the membrane switch is pres-
sed again, the display starts again at the beginning with the lowest value.

Status display – Current main boom angle

5&0 n°
Displays the current main boom angle to the horizontal in degrees.
For negative angles, a minus sign (–) appears to the left of the number.

Status display – Current radius

1"8 m Displays the current radius in meters.

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Operating Instructions GMK 6300 2 084 548 en 10 - 41
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Status display – Maximum load

3"( tmax
Displays the shutdown value, i.e. the maximum possible load in tonnes.
The SLI calculates this value from:
– The rigging mode set in accordance with the Lifting capacity table
– The set reeving mode
– The actual main boom length
– The current main boom inclination
– The current lattice extension inclination.
The signalling point shows a reduction due to the reeving entered.
The maximum possible load (according to the Lifting capacity table without
reduction) can be displayed in this case by pressing the Reeving membra-
ne switch (length of display, about 3 seconds).

Status display – Actual load

2"% t
Displays the actual load in tonnes.
The actual load comprises
the load to be lifted by the crane + the hook block + the lifting gear.
The signalling point displays a shutdown when overloaded.

Status display – Degree of utilization

Displays the instantaneous degree of utilization as a percentage, which
relates to the maximum and the actual loads:
– green LED display: 0 – 80 %
– yellow LED display: approx. 80 – 100 %
– red LED display: greater than 100 %

Membrane switch with warning lamp for error information

t The red warning lamp in the switch flashes if an error message occurs.
If this error leads to a shutdown, the SLI shutdown indicator lamp illumina-
tes at the same time, and a continuous buzzing tone sounds. An error
code appears in the Information display. When the Error information mem-
brane switch is pushed, other pending error messages (➠ Error messages,
p. 12-28).
The green indicator lamp in the switch has no function.

Without function.
y After pressing the switch, the value shown in the Information status
display does not change.
No lamps light up in the switch.

Membrane switch with indicator lamp for permitted slewing range

A After pressing the switch, the green indicator lamp in the switch lights up
and the permissible slewing range of the superstructure is shown in the
status display Information. The current value is derived from the set SLI
01.02.2000

code.
The red warning lamp in the switch has no function.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Membrane switch with indicator lamp for angle of main boom

B After pressing the switch, the green indicator lamp in the switch lights up
and the current main boom angle, in relation to the horizontal is shown in
the status display Information.
The red warning lamp in the switch has no function.

Membrane switch with indicator lamp for length of main boom

C After pressing the switch, the green indicator lamp in the switch lights up
and the current main boom length is shown in feet in the Information
status display.
No differentiation is made in the status display between fixed and interme-
diate or telescoping lengths.

Membrane switch with indicator lamp for height of single-sheave boom

G top
After pressing the switch, the green indicator lamp in the switch lights up
and the current height of the single-sheave boom top of the main boom
or the lattice extension is shown in feet in the Information status display.
The height displayed relates to the bottom axle of the boom and the
lower head sheave axle.

Membrane switch with indicator lamp for angle of lattice extension

K After pressing the switch, the green indicator lamp in the switch lights up
and the current angle of the lattice extension, in relation to the horizontal
is shown in the status display Information.

Membrane switch with indicator lamp for degree of utilization

M After pressing the switch, the green indicator lamp in the switch lights up
and the current degree of utilization is shown in percent in the Information
status display.

Without function.
u After pressing the switch, the value shown in the Information status
display does not change.
No lamps light up in the switch.

Membrane switch with indicator lamp for hydraulic oil pressure in lower
k chamber of derricking cylinder from sensor A
After pressing the switch, the green indicator lamp in the switch lights up
and the current hydraulic oil pressure which is measured by the first
sensor on the piston surface of the derricking cylinder is shown in psi in
the status display Information.
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Operating Instructions GMK 6300 2 084 548 en 10 - 43
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Membrane switch with indicator lamp for hydraulic oil pressure in lower
l chamber of derricking cylinder at sensor B
After pressing the switch, the green indicator lamp in the switch lights up
and the current hydraulic oil pressure which is measured by the second
sensor on the piston surface of the derricking cylinder is shown in bar in
the status display Information.
Membrane switch with indicator lamp for hydraulic oil pressure in
m derricking cylinder upper chamber
After pressing the switch, the green indicator lamp in the switch lights up
and the current hydraulic oil pressure on the derricking cylinder surface of
the piston ring is shown in bar in the Information display.
Status display – Information

348 Displays the corresponding value when one of the following keys is pressed:
– Membrane switch Error information,
– Membrane switch Permitted slewing range,
– Membrane switch Main boom angle,
– Membrane switch Main boom length,
– Membrane switch Height of the single-sheave boom top,
– Membrane switch Angle of the lattice extension,
– Membrane switch Degree of utilization,
– Membrane switch Hydraulic oil pressure in lower chamber of derricking
cylinder at sensor A,
– Membrane switch Hydraulic oil pressure in lower chamber of derricking
cylinder at sensor B,
– Membrane switch Hydraulic oil pressure in upper chamber of derricking cylinder.

If one of the switches without functions is pushed, the value in the display
does not change.

SLI early warning lamp

x The SLI early warning lamp illuminates when the actual load reaches 90 %
or more of the permissible load. An intermittent buzzing tone sounds at
the same time (➠ SLI early warning, p. 12-27).

Warning lamp for SLI shutdown

w Illuminates when the SLI switches off the load moment increasing crane
movements because approx. 100 % of the maximum permitted load has
been reached (overload) or an error has occured. A continuous buzzer
tone sounds at the same time (➠ SLI shutdown, p. 12-27).

Status display – counterweight with membrane switch

5=0 t Displays the counterweight which is to be used in kilopounds (klbs).

The value is derived from the set SLI code.
01.02.2000

If the Rigging mode display of the entry mode is switched on, pressing the
membrane switch repeatedly displays other values which are permitted
according to the Lifting capacity table.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Status display, working position with membrane switch

11=0 Displays the set SLI code.

When entry mode is switched on in this display, the required SLI code can
P be entered by pressing the membrane switch Rigging mode repeatedly or
by entering on the numerical pad.
The SLI code entered appears in the first three spaces of the Rigging mode
status display, and the supplement to the SLI code in the fourth.
The SLI code and its supplement are separated by a decimal point;
➠ The elements of the display, p. 10-40.
Reeving display with membrane switch
/ n= Displays the number of ropes reeved on the hoist indicated by the Hoist
position lights.
Main hoist: lamp I illuminates
Auxiliary hoist: lamp II illuminates

When entry mode is switched on in the display, the desired reeving can
O be entered by pressing the membrane switch Reeving repeatedly or by en-
tering on the numerical pad.

If the maximum load is reduced because of the reeving, pressing the

O membrane switch displays the maximum load (according to the Lifting
capacity table) for about three seconds in the Maximum load display.

Hoist position lights

Indicates which hoist is monitored by the SLI:

Lamp I illuminates: Main hoist is switched on and the display Reeving

applies to this hoist.
Lamp II illuminates: Auxiliary hoist (additional equipment) is switched
on and the display Reeving applies to this hoist.
If a lamp flashes, the corresponding hoist is switched on and but the
display Reeving applies to the other hoist; ➠ Display lamps, p. 12-22.

Service key switch

May only be operated by GROVE Product Support. No key is delivered for
this key switch.

C0018
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 10 - 45
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Outrigger span display panel with membrane switch

Displays the required supporting span corresponding to the SLI code
entered:

If the Rigging mode display of the entry mode is switched on, pressing the
membrane switch (1) repeatedly displays other values which are permit-
ted according to the Lifting capacity table.

The light-emitting diodes in the display show the different outrigger

spans in the following way:

Outrigger span Outrigger span

8.70 x 8.50 m 8.70 x 6.00 m

Outrigger span Outrigger span

8.70 x 2.68 m 8.70 x 8.50 / 2.84 m

Membrane switch acknowledge

p Used to
– confirm after changing a setting,
– switch off an acoustic warning signal.

Membrane switch confirm

v Used to confirm the entered value.

Numerical pad
abc The switches 1 to 0 are used to enter new values into the SLI. Some
01.02.2000

switches have two assignments. The second level of the switch is acti-
vated if the membrane switch membrane Switch on 2nd level is pressed.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Entry mode membrane switch

n Q +
Is always used in combination with one of the two membrane switches
Reeving or Rigging mode. First the membrane switch Reeving is pushed,
then also one of the two membrane switches Reeving or Rigging mode.
Switches on the entry mode in the following way:
– The entry mode in the display Rigging mode is switched on by pressing
n P +
the Rigging mode membrane switch at the same time.
– The entry mode in the display Reeving is switched on by pressing the
n O +
Reeving membrane switch at the same time.

Membrane switch to switch on 2nd level

o Q +
Is always pressed in combination with one of the other membrane
switches. First the membrane switch Switch on 2nd level is pressed, then
also the other membrane switch. Switches to the assignment on the
2nd level if a switch is assigned two functions or if a switch is only
assigned at the second level for reasons of safety.

Membrane switch for lamp test

o a +
This function of the switch is only active if the membrane switch Switch on
2nd level is pressed. To carry out a lamp test.
All displays, warning and indicator lamps illuminate for approx. 2 seconds
with maximum brightness, then with automatically adjusted brightness.

H
Lamp test and dimmer for SLI status displays

After switching on the ignition, the basic brightness of the SLI displays,
warning and indicator lamps automatically adapt to the ambient light.
The brightness of the SLI dispaly can be adjusted with the following mem-
brane switches.

Membrane switch for brighter dimmer

o b +
This function of the switch is only active if the membrane switch Switch on
2nd level is pressed. To adjust the brightness of the LMB displays.
Every time the switch is pushed, the display becomes a step brighter until
the maximum brightness is reached.

Membrane switch for darker dimmer

o c +
This function of the switch is only active if the membrane switch Switch on
2nd level is pressed. To adjust the brightness of the LMB displays.
Every time the switch is pushed, the display becomes a step darker until
the minimum brightness is reached.
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Operating Instructions GMK 6300 2 084 548 en 10 - 47
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Hydraulics
Hydraulic system oil temperature display
°C
The hydraulic oil temperature should not exceed 80 °C while working with
crane; ➠ p. 12-92.

C0006

Warning lamp control circuit hydraulic oil filter

g Illuminates if the hydraulic oil filter in the control circuit is dirty.
Change the filter cartridge; ➠ Maintenance manual.

Warning lamp for feed circuit hydraulic oil filter

g Illuminates if the hydraulic oil filter in the feed circuit is dirty.
Change the filter cartridge; ➠ Maintenance manual.

Warning lamp for hydraulic oil return flow filter

g Lights up if the return flow filter in the hydraulic oil return is dirty.
Change the filter element; ➠ Maintenance manual

Hydraulic oil return fine filter warning lamp

g Lights up if the fine filter in the hydraulic oil return is dirty.
Change the filter element; ➠ Maintenance manual

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Electronics
Ignition lock
0 Ignition off, crane engine and crane functions off, key may be
removed.
R, 1 Ignition on, instrument lighting on.
Additional power supply on for:
Control units of the crane control, engine control, SLI 2
2 Starting position; ➠ Starting the crane engine, p. 11-10.

Warning lamp for charge indicator

q Illuminates if the ignition is switched on and the crane engine is switched
off. Goes out after the crane engine is started;
➠ Starting the crane engine, p. 11-12.
Rocker switch for socket for spotlight
G (left and center rocker switches)
The two sockets in front of the crane cab for the Crane cab working spotlights
are standard components. The working spotlights are used to illuminate
the working area in front of the crane cab.
Switching on the spotlight for
working area: Press rocker switch down.
Switching off the spotlight for
working area: Press rocker switch up.

Rocker switch for hoist rope control spotlight (additional equipment)

G (Right-hand rocker switch)
A spotlight can be connected as additional equipment for illuminating the
rope drum. This enables the orderly reeling in of the hoist rope even
when it is dark.
Switching on the spotlight: Press rocker switch down.
Switching off the spotlight: Press rocker switch up.

Other operating
instruments

Rocker switch for windscreen wiper

D Used to activate the windscreen wiper on the crane cab.
Switching on: Press rocker switch down.
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Switching off: Press rocker switch up.

The windscreen wiper returns to end position after switching off.
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Operating Instructions GMK 6300 2 084 548 en 10 - 49
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Rocker switch for roof window wiper

F Used to activate the roof window wiper on the crane cab.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.
The windscreen wiper returns to end position after switching off.

Rocker switch for intermittent wiper operation – windscreen and roof

E window
Used to activate the intermittent wiper function for the windscreen and
the roof window.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.
The windscreen wiper returns to end position after switching off.

Rocker switch for windscreen wiper/washing system

H Used to activate the wiper/washing function on the windscreen and
skylight of the crane cab. Activates the water pump and the windscreen
wiper several times.
Switching on: Press rocker switch down.
Switching off: Press rocker switch up.

Rocker switch for constant motor speed

å To activate and adjust and deactivate a constant engine speed. To take over
the engine speed preselected with the accelerator. When the rocker switch is
pressed down once, the speed of the crane engine preselected with the accele-
rator is set as a constant engine speed.

Take over preselected Press rocker switch down

engine speed:
Increase constant Press rocker switch up
engine speed:
Switch off constant Press rocker switch down with the accelerator
engine speed released
01.02.2000

➠ Setting constant motor speed, p. 12-89.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Rocker switch to incline crane cab

: To incline the crane cab from the horizontal to the rear and back to
horizontal.

Incline crane cab to the rear: Press rocker switch down.

Incline the crane cab back to the
horizontal: Press rocker switch up.

➠ Incline crane cab, p. 12-91.

Key-operated switch for override
With the key-operated switch the shutdown of the SLI and the lifting limit
switch can be bypassed (switched off).
Override SLI shutdown: Insert the key, turn to the left
and hold
Overriding the lifting limit switch Insert the key, turn to the right
shutoff system and the SLI shutoff: and hold
Switch off override: Release the key, lock returns to its
start position, remove the key.
Observe the warnings in the appropriate sections:
➠ SLI override, p. 12-30.
➠ Override lifting limit switch shutdown, p. 10-61.

Electronic level in Display of the electronic level in the control box on the carrier;
crane cab ➠ Reading the electronic level display, p. 13-33.

Displays the current inclination of the truck

crane in the LED display (1); ➠ Crane work
with the main boom – horizontal inclination,
p. 12-31.

The electronic level in the crane cab only dis-

plays correct values when the ignition has
been turned off in the carrier.

Two different measurement ranges can be

set.
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Operating Instructions GMK 6300 2 084 548 en 10 - 51
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Switching the rocker switch with indicator lamp for measurement range
.1°
level indicator (crane cab)
Changes the measurement range of the electronic level in the crane cab
between 1° and 5° angle.

Measuring range angle 0° to 1°: Press in the rocker switch at the top,
indicator lamp lights up.
1 graduated collar corrsponds to 0.2°.
Measuring range angle 0° to 5°: Push rocker switch upwards,
1 graduated collar corrsponds to 1°.

Toggle switch (Toggle switches in the outrigger switch boxes)

to change mea- ➠ Align truck crane horizontally – change measuring range, p. 13-34.
suring range
Changes the measurement range of the electronic level on the carrier
between 1° and 5° angle.

Measuring range angle 0° to 1°: Push the toggle switch upwards.

Measuring range angle 0° to 5°: Push the toggle switch downward.

Crane cab ➠ Crane cab heating and ventilation, p. 12-101.

heating system
1 Heater fan rotary knob (3-level)
2 Regulator for recirculated air / fresh air
mode
up: fresh air mode
down: recirculated air mode
3 Air distribution regulator
up: bottom of windscreen
down: cab floor
4 Regulator to increase
temperature: cold
downwards: warm
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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Rocker switch with indicator lamp for additional heating system

0 (additional equipment)
Switching on: press downward
Switching off: press upward

➠ Additional water heating system (additional equipment), p. 12-102.

Lattice extension ➠ Operating Instructions Lattice extension, p. 14-1

(additional
equipment)

Anemometer An anemometer can be attached to the main boom point of your crane for
wind monitoring; ➠ p. 13-79.

The Anemometer status display in the instru-

ment panel of the superstructure displays
the wind speed in m/sec and in the Beaufort
scale.
25
20
m/sec 15 9
7
10
5 BEAUFORT

5
3

C0102
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 10 - 53
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Outrigger pressu- Display of the outrigger pressure in the control boxes on the carrier;
re display (addi- ➠ Outrigger pressure display for extending/retracting outrigger cylinder, p.13-35.
tional eqipment)

Front right outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the front
right outrigger cylinder.

Front left outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the front
left outrigger cylinder.

Rear right outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the rear
right outrigger cylinder.

Rear left outrigger pressure display

02"8 Shows the outrigger pressure in tonnes (t) which is measured in the rear
left outrigger cylinder.

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Air-conditioning ➠ Air-conditioning system, p. 12-105.

system (additio-
nal equipment)
The air-conditioning system is installed at
the rear of the crane cab.

1 Air outlets, volume of air and direction of

air can be adjusted
2 Knob switch for thermostat
3 Knob switch for blower

Rotary knob for thermostat

Turning the rotary switch to the right increases the cooling output.

Blower knob

0 Fan and air-conditioning system off

1 Low output level
2 Medium output level
3 High output level
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Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

10.2.2 Other operating instruments on the crane cab

Doors, keys, The following keys belong to the crane cab of your truck crane:
windows

1 Crane cab door lock

2 Crane cab ignition lock
3 Key switch for override
4 Crane engine service flap

The lock on the door of the crane cab may be

locked from the outside using the door key.

Open lock: Turn key (1) to the

right
Close lock: Turn key (1) to the left
Open door: Raise grip (2)

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 Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

A release lever is mounted on the handle bar

to open the door from the inside.

Open door: Press lever (2).

The door of the crane cab cannot be locked
from the inside.

Open sliding window

The sliding window in the door (if there is
additional equipment, also the window on
the rear wall of the cab) may be opened from
the inside using release lever (1).

The windscreen of the crane cab may be

opened.

Opening the Pull both handles (1)

windscreen: outwards and press down the
brake lever (2). Push the
windscreen forwards, until
the desired position of the
2
windscreen is reached, then
release the brake lever.
Closing the Pull both handles (1)
1 windscreen: outwards and press down the
brake lever (2). Pull wind-
screen back, until it latches in.

Fire extinguisher The fire extinguisher (additional equipment) is located in a holder behind
(additional the crane cab’s crane operator’s seat.
equipment)
• Follow the instructions for use on the fire extinguisher.
• Have the fire extinguisher serviced in good time by trained personnel
before the service interval given on the label expires.
01.02.2000

Proper functioning of the fire extinguisher is no longer guaranteed once

the service interval on the sign has expired.

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Operating Instructions GMK 6300 2 084 548 en 10 - 57
Description of the truck crane – crane section
10.2 Functional description of the display and operating instruments

Seat adjustment You may adjust the hydraulically spring-mounted seat in the crane cab to
your respective height and weight.
1 Unlocking and adjusting height of the left
armrest
2 Backward/forward adjustment of the
entire seat including the control consoles
3 Adjusting the suspension stiffness to
your weight in kg
4 Backward/forward adjustment of the seat
and the back rest without the control
consoles
5 Angle of the front seat
6 Angle of the rear part of the seat
7 Unlocking and adjusting height of the
right armrest
8 Angle of the back rest

VDO electronics
crane engine

The VDO electronics provide the service

personnel with the opportunity of connect-
ing measuring devices and may only be
operated by the service personnel.

There is a cover in the side panelling at the

rear right of the crane cab.

The VDO electronics (1) can be accessed

once the cover has been removed.
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 Description of the truck crane – crane section
10.3 Functional description of the safety devices

10.3 Functional description of the safety devices

10.3.1 Safe load indicator (SLI)

To increase operational safety, the GMK 6300 truck crane is equipped with
a safe load indicator (SLI) as overload protection.

G
Danger of overturning with two-hook operation!
Two-hook operation with the boom extension is not stored by the SLI and
is not permissible!
Loads can only be turned with the main boom and the auxiliary single-
sheave boom top or the telescopic swing-away lattice extension, as
described in the respective chapters of the GMK 6300 Lattice extension ope-
rating manual.

The safe load indicator serves to prevent the permissible load bearing
capacity of the truck crane from being exceeded at a particular radius.
The load bearing limit can be exceeded, for example, during crane operation
when the main boom is telescoped out or lowered further than is allowed.

The safe load indicator is an electronic unit.

It is used to set the truck cranes rigging mode.

The SLI automatically registers These factors must be set according

the following factors: to the current rigging mode:
– Length of the main boom – Supporting span
– Counterweight mass
– Angle of main boom
– Length of the lattice extension
– Actual load – Boom extension-inclination or the
(from the pressure load telescopic-swing-away lattice
on the derricking cylinder) extension (both additional
equipment)
– Number of falls of the hoist cable
– Angle of the luffing Setting either by entry of the
jib (additional equipment) individual components or by SLI
code.

G
Danger of overturning if wrong settings are entered into the SLI!
The SLI does not automatically assimilate all information in crane
operation required to calculate the load limit.
You must therefore enter the rigging mode (SLI code) and the reeving
mode at the SLI control unit manually.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 10 - 59
Description of the truck crane – crane section
10.3 Functional description of the safety devices

Sensors are attached to the truck crane which supply the central electro-
nics with current load values. The current and maximum load values are
continuously displayed on the SLI control unit in the crane cab. Before
reaching the load limit, the SLI signals that the warning limit has been
reached by giving a visual and an acoustic (intermittent buzzing tone)
signal. The acoustic signal can be switched off.

If the load moment continues to increase, the SLI shuts down all move-
ments which increase the load moment when the load limit is exceeded
and signals that the shut-down limit has been reached with a visual and
acoustic (continuous buzzing tone) signal. The acoustic signal can be
switched off.

The values necessary for the operation are constantly displayed on the
SLI (e. g. reach, actual load, main boom length, maximum load).

G
Risk of accidents if SLI is incorrectly set!
If the actual rigging mode is not set, the maximum load calculated by the
SLI will not correspond with the actual permissible load capacity!
An incorrectly set safe load indicator only gives you a false sense of
security. Overloading of the truck crane will most certainly result in an
accident!

10.3.2 Lowering limit switch

The lowering limit switch prevents the hoist rope from being reeled off
the drum completely. It deactivates the Lower hoist movement when five
turns of rope are left on the hoist drum.

The switching point must be reset when the hoist rope is replaced;
➠ Maintenance manual.

G
Risk of accidents if the lowering limit switch is incorrectly set or defective!
Reset the lowering limit switch after every hoist rope change and do not
do any crane work if the lowering limit switch is damaged, incorrectly set
or disabled. This avoids damage to the hoist rope after it is completely
unreeled which can lead to the load falling.

If the unreeved hoist rope is completely reeled up (e. g. when rigging the
auxiliary hoist) and the hoist rope is unrolled from the stationary rope
drum, the lowering limit switch must be reset.
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 Description of the truck crane – crane section
10.3 Functional description of the safety devices

G
Risk of accidents from incorrect setting of the lowering limit switch!
Only unreel the hoist rope with Lower hoist. If you unreel the hoist rope
from the stationary rope drum, the lowering limit switch does not detect
the number of winds and you must reset the lowering limit switch before
starting crane work. This keeps the lowering limit switch from switching
off too late or not at all, which causes the load to crash to the ground.

10.3.3 Lifting limit switch

The lifting limit switch reacts as soon as it is no longer under the load of
the lifting limit switch weight. This is the case if:

– during crane work, the hook block lifts the lifting limit switch weight or
if one derricks so far that the lifting limit switch weight is lying on the
ground,
– or if during rigging the lifting limit switch weight is still not attached or
is lying on the ground.
In these cases, the lifting limit switch activates and switches off all load
moment increasing motions. Load moment increasing motions are lifting,
lowering the boom and telescoping out.

The Lifting limit switch shutdown warning lamp illuminates when the lifting
K limit switch is deactivated.

If there is a shutdown, one must leave the shutdown area with a different
motion or by setting down the load.

The lifting limit switch must not be activated during normal operation.

Overriding the The shutoff system of the lifting limit switch can be overridden from the
lifting limit crane cab together with the SLI, and the lifting limit switch can be blocked
switch shutdown mechanically on the main boom.

G
Risk of accidents from overridden safety devices!
When overriding the lifting limit switch with the key switch Override,
crane operation is no longer monitored by the SLI! The lifting limit switch
therefore may not be overridden while the cane is being operated. It is
not permitted to work with an overridden or defective lifting limit switch!
Before beginning crane work, check whether the locking system of the
lifting limit switch on the main boom is deactivated and deactivate it if
necessary; ➠ Check and if necessary deactivate the lifting limit switch on the
01.02.2000

main boom, p. 13-73.

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Operating Instructions GMK 6300 2 084 548 en 10 - 61
Description of the truck crane – crane section
10.3 Functional description of the safety devices

S
You may only override the lifting limit switch when carrying out main-
tenance or rigging work in accordance with the Operating Instructions.
In these cases, the lifting limit switch may only be overridden when there
is no load on the hook. On operate at minimum hoist speed with an over-
ridden lifting limit switch.

The shutoff system of the lifting limit switch can be overridden (switched
off) together with the SLI with the key switch Override.

• Insert the key into the key-operated switch.

• Turn the key to the right.
• Hold the key in this position.
The lifting limit switch is overridden as long as you hold the key in this
position.

S
Always pull the key out of the Override key switch after overriding!
The key must not be left in the key-operated switch while the crane is in
operation!

H The key switch has another position which only overides the SLI;
➠ SLI override, p. 12-30.

10.3.4 Dead man’s and seat contact switches

All crane functions are protected by a dead

man’s switch system. This system includes
one Dead man’s switch (1) on each of the two
control levers and a seat contact switch in
the crane cab seat.

Crane movements may only be controlled

when you are sitting on the seat inside the
crane cab or are pressing at least one of the
two dead man’s switches. If you leave the
seat and neither of the dead man’s switches
are being pressed, all crane movement will
stop within approx. 1 second.
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 ____________________________________________________________________________________ 11
11 Crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 1
11.1 Starting/turning off the crane engine . . . . . . . . . . . . . . . . . 11 - 1
11.1.1 CHECK LIST: Starting the crane engine . . . . . . . . . . . . . . . . . . . 11 - 1
11.1.2 CHECKLIST: In winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 3
11.1.3 Inspections before starting the crane engine . . . . . . . . . . . . . . . . 11 - 4
11.1.4 Starting the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 10
11.1.5 Inspections after starting crane engine . . . . . . . . . . . . . . . . . . . 11 - 14
11.1.6 Switch off the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 15
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2 084 548 en Operating Instructions GMK 6300

 Crane engine
11.1 Starting/turning off the crane engine

11 Crane engine

11.1 Starting/turning off the crane engine

11.1.1 CHECK LIST: Starting the crane engine

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Checking the oil level in the crane engine; ➠ Checking the oil level in the
crane engine, p. 11-4.

2. Check the coolant level of the crane engine; ➠ Checking coolant level,
p. 11-8.

3. Check oil level in the hydraulic system; ➠ Checking hydraulic oil level,
p. 11-6.

4. Checking the setting of the stop cock of the hydraulic system;

➠ Checking the stop cock in the hydraulics system, p. 11-7.
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Operating Instructions GMK 6300 2 084 548 en 11 - 1
Crane engine
11.1 Starting/turning off the crane engine

5. Switching on the battery master switch; ➠ Switching on battery master

switch, p. 11-7.

6. Check the level of the fuel tank; ➠ Refueling, p. 11-9.

C0013

7. Turn on ignition and check instruments; ➠ Turning on ignition,

p. 11-10.

8. Start the crane engine; ➠ Starting crane engine, p. 11-12.

9. Check the instruments with the engine running; ➠ Checking the

instruments, p. 11-14.

10. Also observe the In the winter checklist when the temperatures are
low; ➠ p. 11-3.
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 Crane engine
11.1 Starting/turning off the crane engine

11.1.2 CHECKLIST: In winter

The following additional points must be observed when using the truck
crane in winter:

1. Fuel and engine oil must comply with the specifications given in the
supplied crane operating manual for the respective external tempera-
tures.

2. The engine coolant must contain sufficient antifreeze (see supplied

crane engine operating manual).

3. The crane engine can be preheated by the engine-independent additio-

nal water heating system (additional equipment); ➠ Auxiliary water
heating system, p. 12-102.

4. The hydraulic oil must be preheated; ➠ Prewarming hydraulic oil,

p. 12-5.
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Operating Instructions GMK 6300 2 084 548 en 11 - 3

Crane engine
11.1 Starting/turning off the crane engine

11.1.3 Inspections before starting the crane engine

Checking the oil Check the oil level in the crane engine daily before commencing work.
level in the crane The truck crane must be on a horizontal surface when the oil is checked.
engine
The dipstick (1) is located at the front of the
crane engine and can be reached through an
opening in the panelling.

Prior to main check

• Check the oil level. The oil level has to be

at the max.-mark (arrow marks).
• If necessary, fill the oil up to the
max.-mark.

Inspection
01.02.2000

• Start the crane engine and let it run in idling speed. Observe the oil pres-
sure display.

11 - 4 2 084 548 en Operating Instructions GMK 6300

 Crane engine
11.1 Starting/turning off the crane engine

S
Danger of damage to the motor caused by the oil pressure being too low!
If no oil pressure is shown after 10 seconds, turn off the motor and deter-
mine the cause; ➠ Malfunctions of the crane motor, p. 15-15.

• Switch off the engine after approx.

1 minute.
• After about five minutes, check whether
the oil level on the dipstick is at the
max.-mark.
• Top up with motor oil to the max.-mark if
necessary.

Adding engine oil Data concerning the prescribed oil specification may be found in the
Mercedes-Benz operating manual.

G
Risk of burning when the crane engine is hot!
During operation, the crane engine and add-on parts can reach temperatu-
res of up to 400 °C. Wear appropriate protective gloves and be careful not
to touch hot parts when filling a hot crane engine.

The oil filler neck is located at the top of the

crane engine and can be reached through
the front crane engine flap.

• Fill the engine oil through the filler neck (1).

01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 11 - 5
Crane engine
11.1 Starting/turning off the crane engine

S
Damage may occur to the engine if the oil level is too high!
Do not overfill motor oil. The oil level may not exceed the upper arrow
mark (max).

Check hydraulic Check the level of the hydraulic oil tank daily before commencing work.
oil level
The truck crane must be on a horizontal surface when the oil level is
checked.

Requirements:
– The telescope section of the main boom
– must be fully retracted and
– the main boom must be resting on the
– boom support.

• Check the level of the hydraulic oil tank

through the inspection glass (1).
The hydraulic oil should be visible in the
centre of the inspection glass when cold.

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 Crane engine
11.1 Starting/turning off the crane engine

Check the stop To start the crane engine, the stop cock in the suction line of the hydraulic
cock of the system must be open.
hydraulics system

S
Damage may occur to the hydraulic pumps!
The vehicle engine may only be started if the stop cock in the suction line
of the hydraulic pumps is open!
The stop cock is open when the handle is parallel to the suction line.

The stop cock (2) is located on the inner side

wall of the hydraulic oil tank (1) for the super-
structure behind the cover plate in the suction
line of the hydraulic pump.

• Check that the stop cock (2) is open.

Switching on the
battery master
switch

The battery master switch (1) is located on

the right-hand side of the superstructure,
under the battery box behind the side plate,
and is accessible from below.

• Switch on the battery master switch.

The battery master switch is switched on if
the selector handle cannot be pulled off.
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Operating Instructions GMK 6300 2 084 548 en 11 - 7
Crane engine
11.1 Starting/turning off the crane engine

Checking the Information concerning the prescribed coolant agents may be found in
coolant level the supplied Maintenance Manual.

G
Risk of burning when the crane engine is hot!
The hot cooler is pressurized. Be careful to avoid burning on the hot
cooler, with escaping steam or any escaping coolant if you remove the lid
of the cooler when the crane engine is hot.
Wear suitable protective gloves and cover the lid of the cooler with a
cloth before opening it.
Turn the cooler lid slowly to the first notch in order to allow the excess
pressure to be released.

Do not open the pressure relief valve (2) on

the side of the compensation container.

• Loosen (do not open!) the cap on the fil-

ling hole (1) with the coolant at operating
temperature to release the pressure.
• Remove the cap.
The coolant must reach the lower edge of
the pipe in the filler neck.
If the coolant level is too low:
Top up coolant.
See the Mercedes-Benz operating manual for
the composition of the coolant.

• Screw the filling hole cap on until it

reaches end position.

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 Crane engine
11.1 Starting/turning off the crane engine

Refuelling

Monitor the Fuel supply status display, even when working with the crane.
Refuel with diesel whenever necessary.

C0013

S
Fires may occur due to flammable gases!
Switch off the crane engine, crane cab heater and all additional heating
devices before refuelling.

The diesel tank is located at the rear on the

right side of the superstructure. The filler
neck (2) is run upwards through the sheet
metal.

• Attach the ladder (3) to the attachment

points (1).
Always use a funnel and filter when
refuelling.

The fuel tank holds approx. 330 l.

You can find information about the prescri-

bed fuel specifications in the supplied crane
engine operating manual.

G
Danger of accident if the fuel tank is not closed!
Screw the sealing cover back on after each refueling. In this way you
prevent vehicles behind you from being endangered by the sealing cover
falling off or fuel escaping.
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Operating Instructions GMK 6300 2 084 548 en 11 - 9
Crane engine
11.1 Starting/turning off the crane engine

11.1.4 Starting the crane engine

Activating the
ignition

• Switch on the ignition. Insert the ignition key into the ignition lock as far
as it will go and turn the key to position 1.

Lamp test by crane control system

S
After switching on the ignition the crane control system carries out a
lamp test with the most important warning, indicator and display lamps.
Change faulty lamps immediately!

• Check that, after switching on the ignition, the following warning,

indicator and display lamps illuminate for approx. 2 seconds.
If necessary switch on the ignition several times until you have checked
all lamps.
Under the display Crane control system:
– the four display lamps (1),
– the two warning lamps (2) and
– the four indicator lamps (3),
must illuminate for approx. 2 seconds.

• Replace any defective lamps immediately.

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 Crane engine
11.1 Starting/turning off the crane engine

If the truck crane is equipped with a luffing

jib (additional equipment), the respective six
warning and indicator lamps in the right-
hand plug-in module next to the Crane control
also have to light up for about 2 seconds.

The lamps are all arranged together (arrow).

S
When starting the ignition or the crane engine, indicator lamps which
serve as warning lamps for functions that fail during operation are tested.
Replace any defective lamps immediately!

The following indicator and warning lamps must illuminate:

Crane engine oil pressure

L

H
Charge indicator lamp
q
If the Charge indicator warning lamp does not illuminate, the alternator will
not generate any charging current when the crane engine is running.

The indicator lamp Flame start system (additional equipment) lights up.
z The time it takes to go out depends on the temperature of the crane en-
gine; ➠ Start cold crane engine, p. 11-12.

Motor electronics
à
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Operating Instructions GMK 6300 2 084 548 en 11 - 11
Crane engine
11.1 Starting/turning off the crane engine

Starting the To operate the crane engine refer to the enclosed crane engine operating
crane engine instructions.

Starting the crane engine in low temperatures can be made easier by pre-
heating the coolant using the additional water heating system (additional
equipment); ➠ Additional water heating system, p. 12-102.

Starting a cold crane engine with additional equipment with

flame start system
With additional equipment, the crane engine is equipped with a thermo-
stat-controlled flame start system. If the temperature of the coolant is low,
the flame start system heats the suction air of the crane engine by bur-
ning fuel in the suction line.

S
Risk of explosion!
Do not use volatile cold start assisting agents underground or in a tunnel.
The cold start assisting agent can ignite from contact with other ignition
sources. Ask for details in your local mining authority office.

The flame start system is activated every time the ignition is started.
z Depending on the temperature of the coolant, it can take up to 20 seconds
until the crane engine is ready to start. The engine is ready when the
Flame start system indicator lamp goes off. The crane engine should be

H
started up within the next 30 seconds.

If the flame-start device indicator lamp does not go out after approx.
20 seconds, there is a malfunction of the flame-start device; ➠ Problems

H
with the cranemotor, p. 15-15.

If you already had the ignition switched on for some time with a cold, sta-
tionary crane engine, you must switch the ignition off and back on again
to activate the flame start system before starting.

• Check whether the flame start system indicator lamp illuminates.

z • Wait until the flame start system indicator lamp goes out.

H
• Leave the crane engine on, as with engines without a flame start system

You should not start the crane engine until the indicator lamp for the flame
start system has gone out. If you start the crane engine before the lamp
goes out and the temperature of the coolant is low, the crane engine will
emit smoke for several minutes after start-up.
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 Crane engine
11.1 Starting/turning off the crane engine

Starting a cold or warm crane engine without flame start system

• Do not depress the accelerator.

• Turn the ignition key to position 2 and hold it there until the crane engi-
ne starts up.
• Release the ignition key after the crane engine starts up.
If the engine does not start, abort the starting procedure after approx.
15 seconds and wait one minute before reattempting to start the engine.

Starting a warm crane engine

• Do not depress the accelerator.

S
Danger of explosions when using starter fuel!
The warm crane engine may never be started with the aid of starter fuel
(e. g. starter spray). Starter fuel sprayed into the suction unit can ignite.

zH For additional equipment with flame start system, the indicator lamp for
the flame start system lights up shortly (2 to 3 seconds) even with a warm
crane engine after the ignition has been started. You do not need to wait
until the indicator lamp goes out.
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Operating Instructions GMK 6300 2 084 548 en 11 - 13

Crane engine
11.1 Starting/turning off the crane engine

11.1.5 Inspections after starting crane engine

Checking The following indicator lamps and warning lights must go out when the
instruments crane engine is running:

• Monitor the Crane engine oil pressure status display as soon as you have
L started the crane engine.
If the oil pressure does not increase after approx. 10 seconds and the
warning lamp in the crane engine oil pressure display does not go out,
switch off the crane engine by turning the ignition key to the 0 position.

H
Charge indicator lamp
q
If the Charge indicator warning lamp illuminates when the charge engine is
running, switch off the vehicle engine and attempt to find the cause of the
problem; ➠ Malfunctions in the crane engine, p. 15-15.

Motor electronics
à If the Motor electronics warning light does not go out when the crane engine
is running, there is a malfunction of the motor electronics. Switch off the
crane engine and inform GROVE Product Support.
• The following indicator lamps should also be monitored – during crane
work:
Crane engine air filter
p Hydraulic oil filter for control circuit
g Hydraulic oil filter for feed circuit
g Return flow fine filter for hydraulic oil
g Hydraulic oil return flow filter
g Flame start system (additioaal equipment)
z Status display with warning lamp Temperature of crane engine coolant
01.02.2000

If one of the indicator lamps illuminates: Refer to ➠ Malfunctions in the

superstructure, p. 15-1.

11 - 14 2 084 548 en Operating Instructions GMK 6300

 Crane engine
11.1 Starting/turning off the crane engine

If the warning lamp Crane engine coolant level illuminates, the coolant level
t has decreased too much.
Switch the crane engine off and add coolant;
➠ Checking coolant level, p. 11-8.
You can display the current speed of the crane engine in the Crane control
@ display; ➠ Display to display conditions, p. 12-82.

11.1.6 Switch off the crane engine

G
Risk of accidents when the load is suspended!
Never turn the crane engine off while a load is suspended on the hook.
Never leave the crane cab while a load is suspended on the hook block.
Always keep your hand close to the control levers while a load is suspended
on the hook so that you are able to react correspondingly at all times.
Always put down the load before you stop work!

• To turn off the crane engine, turn the ignition key to the 0 position and
pull the ignition key out.

In an emergency or if the crane engine does

not stop after you have turned the ignition
key to the 0 position, you can also turn the
crane engine off from outside of the crane
cab.

The battery master (1) switch is located at

the right-hand side of the superstructure un-
der the battery box behind the panel and is
acessible from below.

• To do so, switch the battery master switch

off. The battery master switch is off when
the selector handle cannot be removed.
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Operating Instructions GMK 6300 2 084 548 en 11 - 15

Crane engine
11.1 Starting/turning off the crane engine

Blank page

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11 - 16 2 084 548 en Operating Instructions GMK 6300

 ____________________________________________________________________________________ 12
12 Crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 1
12.1 Checking the truck crane before working with the crane . . . . . 12 - 1
12.1.1 CHECK LIST: When truck crane is rigged . . . . . . . . . . . . . . . . . . 12 - 1
12.1.2 Preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 5
12.1.3 Mechanical superstructure lock . . . . . . . . . . . . . . . . . . . . . . . 12 - 6
12.1.4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 7
12.1.5 Check the position of the hoist ropes . . . . . . . . . . . . . . . . . . . . 12 - 8
12.1.6 Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 8
12.1.7 Visual inspection of the entire crane . . . . . . . . . . . . . . . . . . . . . 12 - 9
12.1.8 Checking the reservoir of the windscreen washing system . . . . . . . . 12 - 9
12.1.9 Checking the safety devices . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 10
12.2 Operating the safe load indicator . . . . . . . . . . . . . . . . . . . . 12 - 13
12.2.1 Switching on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13
12.2.2 Setting rigging mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 16
12.2.3 Checks before working with the crane . . . . . . . . . . . . . . . . . . . . 12 - 23
12.2.4 During crane work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 25
12.3 Crane work with the main boom . . . . . . . . . . . . . . . . . . . . 12 - 31
12.3.1 External influences during crane operation . . . . . . . . . . . . . . . . . 12 - 31
12.3.2 Slewing ranges permitted for working with the crane . . . . . . . . . . . 12 - 35
12.3.3 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 36
12.3.4 Derricking gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 41
12.3.5 Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 43
12.3.6 Telescoping gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 47
12.3.7 Fast speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 78
12.3.8 Menus on the crane control display . . . . . . . . . . . . . . . . . . . . . 12 - 79
12.3.9 Setting a constant engine speed . . . . . . . . . . . . . . . . . . . . . . . 12 - 89
12.3.10 Critical load control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 90
12.3.11 Incline crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 91
12.3.12 Cooling the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 92
12.3.13 Possible movement combinations . . . . . . . . . . . . . . . . . . . . . . 12 - 92
12.4 Driving with a rigged crane . . . . . . . . . . . . . . . . . . . . . . . . 12 - 93
12.4.1 Driving route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 93
12.4.2 Position of the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 94
12.4.3 Driving the rigged truck crane . . . . . . . . . . . . . . . . . . . . . . . . 12 - 96
12.5 Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 99
12.5.1 Short work break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 99
12.5.2 Work breaks lasting more than 8 hours . . . . . . . . . . . . . . . . . . . 12 1 - 00
12.6 Crane cab heating and ventilation . . . . . . . . . . . . . . . . . . . . 12 1- 01
12.6.1 Heating the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 01
12.6.2 Additional water heating system (additional equipment) . . . . . . . . . 12 1
- 02
12.6.3 Additional heating system with timer (additional equipment) . . . . . . . 12 1
- 03
12.6.4 Ventilating the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 04
12.7 Air-conditioning system (additional equipment) . . . . . . . . . . 12 1- 05
12.7.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 05
12.7.2 Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1- 05
12.7.3 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1
- 06
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2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.1 Checking the truck crane before working with the crane

12 Crane operation

12.1 Checking the truck crane before working with the

crane

12.1.1 CHECK LIST: When truck crane is rigged

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-

H
references. Observe the warning and safety information given there!

This check list only applies if the truck crane has been rigged and is on
the site.
If the truck crane is not yet rigged, you must proceed according to the
CHECK LIST: Rigging; ➠ p. 13-1.

1. Carry out the activities and checks for starting the crane engine;
➠ CHECK LIST: Starting the crane engine, p. 11-1, Points 1–6.
Check also the relevant lamps with the lamp test crane control
system; ➠ Switching on the ignition, p. 11-10.

2. The suspension system is locked; ➠ Locking the suspension, p. 13-20.

u
3. All four outrigger beams on the outrigger are extended to the
necessary span and locked; ➠ Support variants, p. 13-17.

4. The outrigger pads are propped in such a way that the outrigger
pressures that occur during crane work cannot exceed the load
bearing capacity of the ground under any circumstances;
➠ Load bearing capacity of the ground and the outrigger, p. 13-7.
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Operating Instructions GMK 6300 2 084 548 en 12 - 1
Crane operation
12.1 Checking the truck crane before working with the crane

5. No wheels now touch the ground;

➠ Extending / retracting the outrigger cylinders, p. 13-30.

6. The truck crane is horizontally aligned with the electronic level;

➠ Extending / retracting the outrigger cylinders, p. 13-30.

7. While inspecting the truck crane look out in particular for any
escaping fluids (oil, fuel or water).

8. The safety devices have been checked for perfect working order:
– SLI
– Lifting limit switch
– Dead man’s switch system
– Crane control emergency stop switch
➠ Monitoring the safety equipment, p. 12-10.

9. The required counterweight combination is rigged;

➠ Counterweight, p. 13-37.

10. The position of the hoist ropes on the hoist drum have been checked;
➠ Checking the position of the hoist ropes, p. 12-8.
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 Crane operation
12.1 Checking the truck crane before working with the crane

11. The truck crane is earthed accordingly;

➠ Earthing the truck crane, p. 13-11.

12. The key from the key-operated switch Override for SLI and lifting limit
switch has been removed; ➠ SLI override, p. 12-30.

13. Operating mode selector switch (additional equipment only for truck
crane with luffing jib) is in position 0 for working with the main boom;
2
1 ➠ GMK 6300 Lattice extension operating manual.
0

14. The current rigging mode is set on the SLI and the accompanying SLI
11== code is displayed according to the Lifting capacity table; ➠ Entering
values, p. 12-19.

15. The number of the reeved rope lines for the corresponding hoist has
2 n= been entered with the membrane switch or via the numerical pad and
appears in the display Reeving; ➠ Setting rigging mode, p. 12-16.

16. The telescope status has been checked; ➠ Check before telescoping for the
first time, p. 12-53.

17. The maximum permitted slewing speed for the current rigging mode
is set; ➠ Maximum permitted slewing speeds, p. 12-45.
SPEEDS
SLEW
NORMAL : ❙
POINT :

18. The lamp test has been performed on the SLI and the brightness of
oa +
the SLI status display has been set in such a way that all of the
displays are easily read; ➠ p. 12-15.
o bc +
,
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Operating Instructions GMK 6300 2 084 548 en 12 - 3
Crane operation
12.1 Checking the truck crane before working with the crane

19. The level of the windscreen washing system is regulated;

➠ Checking the windscreen washing system reservoir, p. 12-9.

20. The superstructure lock is released;

¥ ➠ Mechanical superstructure lock, p. 12-6.

21. The crane operator’s seat has been suitably adjusted;

➠ Adjusting the seat, p. 10-58.

22. The mirrors for monitoring the hoisting gear have been correctly
adjusted; ➠ Adjusting the mirrors, p. 12-8.

23. The electrical system (spotlight for working area, windscreen wiper/
washing system, horn) has been checked to ensure perfect working
order; ➠ Electrical system, p. 12-7.

24. Check the temperature of the hydraulic oil; preheat the hydraulic oil if
°C
necessary; ➠ Preheating the hydraulic oil, p. 12-5.
20 100

C0388
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 Crane operation
12.1 Checking the truck crane before working with the crane

12.1.2 Preheating the hydraulic oil

The hydraulic oil must be preheated before beginning crane work if

the truck crane is operated at a temperature of under 0 °C.
The Hydraulic system oil temperature status display in the crane cab is
°C definitive.
20 100

C0388

For oil tempe- You may carry out crane movements without loads at an average engine
ratures between speed and average operating speed in normal gear.
–15 °C and 0 °C:
• Do not increase the engine speed and operating speed until the Hydrau-
lic system oil temperature status display shows an oil temperature of at
least 10 °C.

For oil tempera- Let the crane engine run at intermediate speed and raise the main boom
tures below to the steepest position. Move the crane function Raise against the end
–15 °C: position until the status display Hydraulic system oil temperature displays an
oil temperature of at least 10 °C.
The preheating procedure may take up to 20 minutes depending on the
initial temperature of the oil.

• Carry out all crane functions at least twice once the oil is heated in

H
order to displace the cold oil in all sections of the hydraulic system.

The warm-up procedure may cause delayed switching of the solenoid

valves or harsh start-up of the power units.
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Operating Instructions GMK 6300 2 084 548 en 12 - 5

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.3 Mechanical superstructure lock

The superstructure may be locked in 0° position facing backward or 180°

position facing forward with a locking pin to prevent it from turning. The
locking pin is hydraulically retracted and extended and can be controlled
from the crane cab.

Always lock the superstructure when:

– You work with the truck crane in position 0° toward the rear,
– You have put the boom in the 180° forwards position for on-road
driving.
– slewing is not allowed with the current rigged counterweight because –
the outrigger span is too small.
A table in section Slewing with rigged counterweight, p. 13-61 shows you with
which combinations of counterweight and outrigger span the super-
structure must be locked.

Also refer to the section Permissible slewing ranges for working with the crane,
➠ p. 12-35.

G
The crane can overturn if the superstructure lock is released!
Always lock the superstructure when one of the prerequisites indicated
above applies. This prevents the superstructure from overturning due to
unfavourable conditions (e. g., inadvertent actuation of the slewing gear
or swinging loads) comes out of the 0° position, which could cause the
truck crane to overturn or, because of too great a counterweight mass, to
tip to the rear.

Disengaging
the lock
If the Superstructure locked indicator lamp illuminates, the lock is in place.
! • Press the Superstructure lock rocker switch upward.
§ When the locking pin moves, the Superstructure locked indicator lamp is
extinguished.

The Superstructure unlocked illuminates when the locking pin has reached
¥

H
the upper end position.

The superstructure is not properly unlocked if the Superstructure unlocked

01.02.2000

indicator lamp does not illuminate. In this case turn it slightly from side to
side until the indicator lamp illuminates.

12 - 6 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.1 Checking the truck crane before working with the crane

Engaging the lock You can only engage the lock when the superstructure is in the 0° or 180°
position.

• Slew the superstructure to the 0° or the

180° position.
If the superstructure is in the 0° or 180°
position, the arrow (1) on the turntable
points to the respective marked screw
of the roller slewing ring.

• Press the Superstructure lock rocker switch downward.

§ When the locking pin moves, the Superstructure unlocked indicator lamp is
¥ extinguished.

The Superstructure locked indicator lamp illuminates when the locking pin
!

H
has reached the lower end position.

If the locking pin does not exactly engage with the bore in the carrier, the
Superstructure locked indicator lamp does not illuminate. In this case turn it
slightly from side to side until the indicator lamp Superstructure locked
illuminates.

12.1.4 Electrical system

• Check that the following parts of the components of the electrical

system are functioning perfectly:
– horn,
– spotlight for working area,
– instrument lighting,
– control and warming indicators,
– windscreen wipers and
– windscreen washing system.
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Operating Instructions GMK 6300 2 084 548 en 12 - 7

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.5 Check the position of the hoist ropes

G
Risk of accidents with turning rope drum!
Keep yourself and other people away from the turning rope drum. If you
take hold of the turning rope drum, your fingers and hands could be
crushed between the rope drum and hoisting gear frame or get caught
and drawn in by the turning drum.

Check the position of the hoist ropes (1) on

the rope drums of the hoists.

• Slowly turn the rope drum at least one

turn in the lowering direction. At the same
time, watch the unreeled rope.
– The rope must be wound evenly on the
drum.
– The turns on the drum must all be at an
equal distance of 0 to 2 mm.
– The cross-over points must be at an angle
of approx. 180° to each other.
(The upper layer of rope lies over the
lower layer at the cross-over points.)

12.1.6 Adjusting the mirrors

• Adjust the mirrors (1) on the crane cab and

the hoist so that you have a clear view of
the rope running on the hoist.
If your truck crane is equipped with an
auxiliary hoist (additional equipment), also
adjust the mirror on the auxiliary hoist.
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 Crane operation
12.1 Checking the truck crane before working with the crane

12.1.7 Visual inspection of the entire crane

• Walk around the truck crane before beginning crane work.

Check in particular for any escaping fluids such as oil, fuel or water.

G
Remember that loss of oil can mean that crane movements can not be car-
ried out (even in emergency situations, e. g. when raising in emergency
operation).

O
Attend to leakages out of which oil or fuel discharges or have them taken
care of so that no oil or fuel discharges, seeps into the ground, or ends up
in bodies of water while working with the crane.

12.1.8 Checking the reservoir of the windscreen washing system

The windscreen washing system reservoir is located beside the crane

operator’s seat.

Remove the cap of the reservoir to check its

contents.

Keep the reservoir (1) full at all times and

add a cleaning agent and, if necessary,
antifreeze to the water.
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Operating Instructions GMK 6300 2 084 548 en 12 - 9

Crane operation
12.1 Checking the truck crane before working with the crane

12.1.9 Checking the safety devices

G
Accidents may occur when working with defective safety devices!
It is strictly prohibited to operate the crane with non-operational or
overridden safety devices!
Defective safety devices are to be repaired immediately by GROVE
Product Support only.

Safe Load • Switch on the safe load indicator;

Indicator ➠ Switching on the SLI, p. 12-13.
• After the test program has run check if:
– an error message is displayed,
– the SLI early warning and SLI shutdown warning lamps light up,
xw – a continuous buzzer tone sounds.
• Carry out a test of the lamps; ➠ Switching on the SLI, p. 12-13.
All display, warning and indicator lamps on the SLI must light up at
maximum brightness.

The SLI will now function properly if:

– no error messages are displayed,
– both warning lamps illuminate,
– the continuous buzzer tone sounds and
– the lamp test resulted in no failures of lamps and lights.
If the SLI is not functioning correctly, do not start crane work. Notify the
responsible GROVE Product Support and have them repair the SLI.

Lifting limit • Raise the main boom.

switch
• Slowly raise the hook block until the hook block has been lifted away
from the lifting limit switch weight.
• Check whether the warning lamp Lifting limit switch shutdown illuminates.
K • Check whether the crane movements that increase the load moment are
deactivated. Check the crane movements of all crane movements which
increase the load moment!
Movements which increase the load moment are: lifting loads, lowering
the main boom and extending the main boom.
The lifting limit switch now functions properly if the warning lamp Lifting
limit switch shutdown illuminates and the movements which increase the
01.02.2000

load moment have been shut down.

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 Crane operation
12.1 Checking the truck crane before working with the crane

If the lifting limit switch is not functioning correctly, do not start crane
work. Notify the appropriate GROVE Product Support and have them
repair the anchor-to-bracket switch.

Dead man’s
switch system

G
Risk of accidents if dead man’s switch system is defective!
Do not stand beside the crane cabin on the carrier during this check. If the
dead man’s switch is defective, the superstructure can turn and knock you
off the crane. Get inside the crane cab!

Monitoring the dead man’s switch system in the crane operator’s seat
• Do not sit on the crane driver’s seat.
• Do not press either of the dead man’s switches on the control levers.
• Check that no crane movement can be carried out.

Monitoring the dead man’s switch system on the control levers

• Slowly raise the hook block. At the same time press the dead man’s
switch on a control lever.
• Release the dead man’s switch. After approx. 1 second the crane move-
ment must be shut down.
• Repeat the check. Press the dead man’s switch on the other control
lever.
The seat contact switch and dead man’s switch are functioning properly if
crane movement is not allowed when the crane operator’s seat is unoccu-
pied and the dead man’s switch has not been pushed; and if crane motion
stops upon release of the dead man’s switch.

If the dead man’s switch is not functioning correctly, do not start crane
work. Inform the appropriate GROVE Product Support and have them
repair the dead man’s switch.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 12 - 11
Crane operation
12.1 Checking the truck crane before working with the crane

Crane control • Set down the main boom in the boom support and let go of both
emergency stop control levers.
switch
• Press the Crane control emergency stop switch so that it snaps in.
The Crane control emergency stop switch is working correctly up to this
point if the crane engine stalls.

If the crane control emergency stop switch does not function correctly, do
not start crane work. Notify the responsible GROVE Product Support and
have them repair the Crane control emergency stop switch.

01.02.2000

12 - 12 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

12.2 Operating the safe load indicator

12.2.1 Switching on the SLI

Switching on
The SLI is switched on with the ignition.

You can turn the ignition key both into position R and position 1.

A test programme is run in the SLI in the first 5 seconds. During this time
– the SLI early warning and SLI shutdown warning lamps illuminate,
xw – the numbers in the displays constantly change or flash and
– an acoustic signal sounds (continuous buzzer tone).

H
The test programme also runs after every voltage drop.

If, when restarting the motor, you do not turn the ignition key to position
0, but to position R instead, the SLI will not be turned off and you will not

H
have to acknowledge the settings again.

After completion of the test program

– the SLI shutdown warning lamp lights up,
– the SLI early warning warning lamp lights up,
– the continuous buzzer tone continues to sound.
Depending on how long the SLI was switched off, the displays Rigging
mode and Reeving are activated differently.

Status displays after a short period of standstill:

If the SLI was switched off only briefly (less than 24 hours), the last setting
is shown on the displays.
If then displayed values do not correspond to the current rigging mode of
the truck crane, you must set the current rigging mode;
➠ Setting rigging mode, p. 12-16.
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Operating Instructions GMK 6300 2 084 548 en 12 - 13
Crane operation
12.2 Operating the safe load indicator

The signalling point Reeving appears on the status display in order to

" n= remind you that the value for the reeving must be transferred to the SLI
before operating the crane.
If the value displayed coincides with the current reeving, you can transfer
the value; ➠ Transferring values, p. 12-21.

The signalling point now changes to the display Rigging mode. If the value
10== appearing on this display also corresponds to the current rigging mode,
you can transfer the value; ➠ p. 12-21.

Status displays after a long period of standstill:

If the SLI was switched off for longer than 24 hours, the digit zero and
0= n= the signalling point appear in both the Reeving and Rigging mode status
displays.
All other status displays with membrane switches are not activated.
00==
The SLI switches on the entry mode on the display Reeving.
The display flashes and thus requests that you enter the value for the
current reeving.

• Enter the current reeving; ➠ Entering values, confirming entry, transferring

values, p. 12-19 to p. 12-21.
After you have transferred the value on the display Reeving, the entry
mode changes to the display Rigging mode. The display flashes and thus
requests that you enter the current rigging mode of the truck crane;
➠ Setting rigging mode, p. 12-16.
When the current values have been entered and transferred on the
displays Reeving and Rigging mode, you can confirm the SLI shutdown.

• Press the Acknowledge membrane switch.

p The continuous buzzer tone is switched off.
The SLI-early warning and SLI-shutdown warning lamps go out.
w If the SLI is defective, the red warning lamp in the Error information mem-
t brane switch illuminates (Error display ➠ Error message in section “While
working with the crane”, p. 12-28).

G
Accidents may occur when working with defective SLI!
It is prohibited to work with the SLI when it is overridden, out of
operation or defective!
01.02.2000

If no error message is displayed, the SLI is now set for the crane
operation.

12 - 14 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

Lamp test on You should carry out a lamp test before you set the rigging mode.
the SLI
• Keep the membrane switch Switch on second level pressed and, in
o a +
addition, briefly press the membrane switch Lamp test.
All display, warning and indicator lamps in the SLI must illuminate with
maximum brightness.
After approx. two seconds, the normal display reappears with the
brightness automatically set.
If the lamp test shows a display, warning or indicator lamp to be defective
➠ Malfunctions of the SLI, p. 15-29.

G
Risk of accidents when the SLI is defective!
The SLI is faulty if display, warning or indicator lamps fail to light up.
You must never work with a defective SLI!

If you cannot see the SLI status displays due to unfavourable lighting con-
ditions, you can adjust the brightness of the displays using the dimmer.

Dimmers for After switching on the ignition, the basic brightness of the all status
the SLI status displays and warning and indicator lamps in the SLI automatically adapt
displays to the ambient light. If necessary, you can readjust the brightness of the
status display.

• Keep the membrane switch Switch on second level pressed and, in

o b +
addition, press the membrane switch Dimmer brighter.
The status display gets brighter by one level every time the mem-
brane switch is pressed until the maximum brightness has been
reached.
• Keep the membrane switch Switch on second level pressed and, in
o c +
addition, press the membrane switch Dimmer darker.
The status display gets darker by one level every time the membrane
switch is pressed until the minimum brightness has been reached.
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Operating Instructions GMK 6300 2 084 548 en 12 - 15

Crane operation
12.2 Operating the safe load indicator

12.2.2 Setting rigging mode

There are two ways of setting the rigging mode on the SLI:
– via the SLI code,
– via individual components.

Setting using the When setting the rigging mode using the SLI code, the SLI code for the
SLI code rigging mode is entered according to the Lifting capacity table. The SLI code
is entered in the Rigging mode status display. After entry the SLI indicates
the required rigging mode on the various status displays.
You must additionally enter the reeving on the status display Reeving.

G
Risk of accidents when the rigging mode is set incorrectly!
The actual rigging mode must coincide with the rigging mode displayed
on the SLI. Compare the displayed rigging mode with the actual rigging
mode; ➠ Checks before working with the crane, p. 12-23.
In addition to the SLI code, enter the current reeving on the Reeving display.
In this way you prevent the SLI from incorrectly calculating the permissible
load and that the truck crane becomes overloaded when in use, thus
causing it to overturn.

Setting using The individual components for the current rigging mode are:
individual – Outrigger span,
components – Counterweight,
– Length of lattice extension,
– Lattice inclination,
– Reeving, and,
– if necessary, the hoist indicator lamp (only with additional equipment
with auxiliary hoist).

You can set the values for the individual components directly using the
membrane switches on the corresponding status display. Here you can
select the respective values which are permitted according to the Lifting
capacity table.
After setting, the SLI code for the recently set rigging mode is displayed in
the Rigging mode display (not with changes on the display Reeving).
Setting the hoist display lights; ➠ Switching over hoist display lights, p. 12-22.
01.02.2000

12 - 16 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

G
Danger of overturning due to incorrectly set rigging mode!
When the individual components are selected, values which have already
been set can change again. After selecting always compare the SLI code
which appears in the Rigging mode status display with the SLI code which
is provided in the Lifting capacity table for the actual rigging mode. If the
SLI changes the components which have already been set, the SLI codes
do not coincide and the settings must be corrected.
In this way you prevent the SLI from calculating with the incorrectly set
components and the truck crane becoming overloaded and overturning
when in operation, ➠ Checks before working with the crane, p. 12-23.

H You cannot enter any value on the status display Lattice extension inclina-
tion when the luffing jib is in operation, since the current angle of the luf-
fing jib is displayed there.

General An error code appears in the status display Information when there is an
instructions error message. This status display automatically switches over if you
enter values on the status display Rigging mode.

In this case the Information status display automatically switches to the dis-
] play of the permitted slewing range and the green indicator lamp in the
Permitted slewing range membrane switch illuminates.

If error messages now occur, you will be able to recognize this by the
t acoustic signal and the red warning lamp in the Error information mem-
brane switch. You can see these error messages in the Information status
display by pressing this membrane switch; ➠ Error messages, p. 12-28.

After you have read the error message, you can cancel the acoustic signal
p by pressing the Acknowledge membrane switch. You can cancel the error
message and warning lamp only after the cause of the error has been
eliminated; ➠ Error messages, p. 12-28.

Sequence during The setting sequence is the same for all status displays. There are only

H
setting differences when the values are entered directly.

If the flashing status display requests that you enter values after having
switched on the SLI, the SLI is already in entry mode and you can directly
enter values; ➠ Entering values, p. 12-19.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 12 - 17
Crane operation
12.2 Operating the safe load indicator

1. Switch the SLI to entry mode; ➠ Switching on entry mode, p. 12-18.

2. Enter new value; ➠ Entering values, p. 12-19.
3. Confirm entry; ➠ p. 12-21.
4. Transfer the new value to the LMB processor; ➠ Transferring values,
p. 12-21.

Switching on If you have switched on the SLI with the ignition, you can switch on the
entry mode entry mode. When doing this you must consider whether:
– you want to change the values on the status display Reeving or
– you want to change the values on another status display.

Changing values on the status display Reeving

• Keep the membrane switch Entry mode pressed and in addition to this
n O +
briefly press the membrane switch Reeving and then let go of both
switches.
The status display flashes and the signalling point is displayed.
! n= Thus the entry mode on the status display Reeving is switched on.
You can now change the value for the reeving.

Changing the values on another status display

• Enter an SLI code for the main boom or the lattice extension in the sta-
00=0 tus display Rigging mode, depending on the intended job.

• Press the membrane switch Confirm entry once.

v • Keep the membrane switch Entry mode pressed and in addition to this
n P +
briefly press the membrane switch Rigging mode and then let go of both
switches.
The SLI code in the display flashes and the signalling point is displayed.
00== This switches on the entry mode for the display Rigging mode.
All the displays of the individual components which are associated with
the flashing SLI code are now activated.
You can now enter the values on the status displays of the individual com-
ponents (except for reeving) or you can enter the SLI code directly on this
status display.
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12 - 18 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

Entering values You can only enter values when the SLI is in entry mode. Depending on
the status display you have two possibilities of entering the desired value.
On the status display you can
– select the desired value in single steps, or
– enter the values directly via the numerical pad.
The following table shows which displays are activated depending on the
flashing SLI code and assigns the entry options to the various displays.

Display individual using

activated with SLI steps numerical
code for pad

MB* BE*

Outrigger span X X X X
Counterweight X X X X

Rigging mode X X X X X

Reeving X X X X X

length of lattice
extension
(additional X X X
equipment)

lattice
extension incli-
nation X X X1)
(additional
equipment)

*MB = main boom

*BE = boom extension
*LJ = luffing jib

1)
When operating with the luffing jib, entries are not possible in this
display; ➠ GMK 6300 Lattice extension operating manual.

H In the detailed descriptions of the entry options in this section the Counter-
weight status display is for the most part given as an example.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 12 - 19
Crane operation
12.2 Operating the safe load indicator

Selecting the desired value in single steps

You can only enter values when the SLI is in entry mode. The SLI is in
entry mode if the status display Rigging mode or (if you want to change the
reeving) Reeving flashes; ➠ Switching on entry mode, p. 12-18.

• Press the membrane switch next to the desired status display (e. g. on
Q the display Counterweight).
The next possible value appears in the status display.
3&0 t

If you press the membrane switch again, the status display jumps to the
5=0 t next highest possible value.

• Continue pressing the membrane switch until the desired value appears
in the status display.
Every time a new value is displayed on the status screen, the status

H
display Rigging mode switches to the corresponding SLI code.

If you have inadvertently skipped the desired value, run through all
possible values until the status display begins again with the initial value.

Entering the values directly via the numerical pad

This entry option is only available for the Reeving and Rigging mode status
displays.
You can only enter values when the SLI is in entry mode. The SLI is in
entry mode if the status display Rigging mode or (if you want to change the
reeving) Reeving flashes; ➠ Switching on entry mode, p. 12-18.

• Enter the desired value; to do this press the corresponding membrane

abc switches on the numerical pad one after the other.
The entered value flashes in the selected status display.
" n=

H If you have inadvertently entered the incorrect value, repeat the entry.
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12 - 20 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

After entering the values

When you have selected all necessary values on the displays or have
entered them via the numerical pad, you must confirm the entry and
transfer the values to the SLI.

Confirming
entry
• Press the membrane switch Confirm entry once.
v The numerical value on the status display Rigging mode or Reeving does
11== not flash any more (depending on on which status display the entry mode
was switched on). The signalling point at the right edge of the respective
status display illuminates.
The entry is now confirmed and the SLI is ready to transfer the entered

H
value.

If you have entered a value which is not allowed according to the Lifting
capacity table, the value is not transferred and the status display continues
to flash after pressing the membrane switch Confirm entry; furthermore an
error message is displayed; ➠ Error messages, p. 12-28.

Transferring For the transfer of newly entered values, you must transfer the value on
values the status display at which the signalling point is displayed:

– A newly entered value for reeving is transferred on the status display

Reeving.
– All other newly entered values are transferred on the status display
Rigging mode.

Press the membrane switch next to the corresponding status display

P (here Rigging mode is used as an example).

The signalling point goes out; the value displayed has been accepted by
11=0

H
the SLI.

If you have changed several rigging components (e. g. the outrigger span
and the length of lattice extension as well), then these values are trans-
01.02.2000

ferred at the same time as the new SLI code.

In addition you must confirm and transfer the current reeving on the
display Reeving.

s
Operating Instructions GMK 6300 2 084 548 en 12 - 21
Crane operation
12.2 Operating the safe load indicator

Once there are no more error messages and you have already acknow-
wx ledged all of the error messages which were issued, both warning lamps
SLI shutdown and SLI early warning go out after pressing the membrane
switch for transferring and you can work with the truck crane.

Switching over Only for additional equipment with auxiliary hoist.

hoist position Of the display lamps Hoists, the lamp for the hoist of which the reeving
lights can be entered on the display Reeving always illuminates.

Lamp I: Main hoist

Lamp II: Auxiliary hoist
The corresponding lamp is activated as soon as the hoist is switched on.
If a hoist is switched on and you additionally switch on the second hoist,
the lamp for the second hoist flashes.
The lamp for the hoist with which the load is to be lifted must always
illuminate.
If the lamp for the hoist not to be used for lifting the load illuminates,
switch this hoist off and the other hoist on.

Example: Switching over status display

For this example the load is to be lifted with the main hoist. But of the display
lamps Hoists, lamp II for the auxiliary hoist illuminates and lamp I for the main
hoist flashes.

Switch over the status display in the following manner:

• Switch off both hoists; to do this, press both rocker switches Main hoist shut-
üC down and Auxiliary hoist shutdown downward.
• Switch on the main hoist; to do this, press the rocker switch Main hoist shut-
ü down upward.

Of the display lamps Hoists, now lamp I for the main hoist illuminates and the
" n= reeving for the main hoist appears on the status display Reeving.

G
Risk of accidents if SLI is incorrectly set!
After switching over the hoisting gear, always check whether the displayed ree-
ving agrees with the current reeving of the indicated hoisting gear and, if neces-
sary, enter the current reeving.
In this way you prevent the SLI from making calculations based on an incorrect
reeving, which can lead to the truck crane overloading or overturning.
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12 - 22 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

12.2.3 Checks before working with the crane

G
Risk of accidents if SLI is incorrectly set!
If the actual rigging mode and the rigging mode indicated by the SLI are
not the same, the permissible load calculated by the SLI is not the actual
permissible load. The consequences are sure to be overloading and an
accident!
The valid SLI codes can be found in the Lifting capacity table.

• Check whether the rigging mode displayed by the SLI is the same as the
actual rigging mode.
• Check
– the reeving of the hook block,
– the mounted counterweight mass,
– the span
and if necessary
– the length of the lattice extension and
– which hoist is switched on (only with auxiliary hoist additional
equipment)
• Check the functioning of all SLI displays, warning lamps and indicator
o a +
lamps by keeping membrane switch Switch on second level pressed and, in
addition, by pressing the membrane switch Lamp test once.
The rigging mode displayed by the SLI and the actual rigging mode must
11== always be the same. If not, the SLI is set incorrectly.

Of the display lamps Hoists, the lamp for the hoist with which the load is
to be lifted illuminates:
Lamp I: Main hoist
Lamp II: Auxiliary hoist

Switch over the status display if necessary; ➠ Switching over hoist display
lights, p. 12-22.

The number of reeved rope lines for the hoist indicated by the display
2 n= lamps Hoists is shown in the Reeving status display.

• If necessary, correct the value for the reeving.

5=0 t The mass of the required counterweight is shown in the Counterweight dis-
play. The value is derived from the set SLI code.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 12 - 23
Crane operation
12.2 Operating the safe load indicator

The required outrigger span is shown in the Outrigger span display. The
light-emitting diodes in the display show the different outrigger spans in
the following way:

Outrigger span Outrigger span

8.70 x 8.50 m 8.70 x 6.00 m

Outrigger span Outrigger span

8.70 x 2.68 m 8.70 x 8.50/2.84 m

The length of lattice extension required is shown in the Length of lattice

1&0 m extension status display.

H If no lattice extension can be mounted in accordance with the SLI code

set, the status display remains dark.

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12 - 24 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

12.2.4 During crane work

Continuous Apart from the displays listed in section 12.2.3 the following information
displays is constantly displayed by the SLI:
The radius of the boom in the Radius status display.
When the lattice extension is mounted, the information refers to the
1"7 m
lattice extension.
The main boom angle in the Boom angle status display.
3&4 n° When the boom is lowered to below the horizontal, a minus sign (–)
appears in the display at the left.
The telescope status of the main boom in the Current telescope status
displays.

– Fixed lengths are displayed as decimal values,

!0
– Intermediate lengths and telescoping lengths are displayed as
89 percentages.
The shutdown value, i.e. the maximum possible load in tonnes, is shown
7/0 tmax in the Maximum load status display.
The SLI calculates this value from
– the rigging mode set,
– the reeving setting,
– the current length of the main boom and

H
– the current boom angle.

If the load is reduced because of reeving, the signalling point is indicated.

The maximum possible load can be displayed for about three seconds by
depressing the Reeving membrane switch.

The load, comprising the load on the hook + the lifting gear + the hook
6"0 t block, in the Actual load status display.

The relationship of the actual load and maximum load in the Degree of
utilization status display.

In the Lattice inclination status display, the lattice extension angle in relati-
19 n° on to the main jib in degrees according to the SLI code set or, when using
the luffing jib (additional equipment), the current measured value dis-
played.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 12 - 25
Crane operation
12.2 Operating the safe load indicator

Optional status The information listed in the following section can be shown in the
displays Information status display.
• To do this, press the appropriate membrane switch.
The green indicator lamp in the membrane switch lights up and the
current value appears in the Information status display.
If a different membrane switch was pressed before the selection was
made, the green indicator lamp in the membrane switch goes out and the
displayed value changes.
– Permissible slewing range in degrees with the
A Permissible slewing range membrane switch
– Current main boom angle in degrees
B using the Main boom angle membrane switch
– Current main boom length in meters
C with the Main boom length membrane switch
– Current height of the single-sheave boom top in meters
G with the Height of the single-sheave boom topmembrane switch
– Current lattice extension angle in degrees
K using the membrane switch Lattice extension angle
– Current degree of utilization
M with the Degree of utilization membrane switch
– Current hydraulic oil pressure in the lower chamber of the derricking
k cylinder in bar with the Hydraulic oil pressure in the derricking cylinder--
lower chamber sensor A membrane switch.
– Current hydraulic oil pressure in the lower chamber of the derricking
l cylinder in bar with the Hydraulic oil pressure in the derricking cylinder--
lower chamber sensor B membrane switch.
– Current hydraulic oil pressure in the upper chamber of the derricking
m cylinder in psi with the Hydraulic oil pressure in the derricking cylinder--
upper chamber sensor A membrane switch.
More detailed information on the respective status displays
➠ Chapter 10.2 Description of the functions of the display and operating display

H
and operating elements.

If a selector key which has no function assigned to it is pressed, the value

in the Information status display does not change and the green indicator
lamp in the key does not light up.

If the maximum load is reduced because of the reeving, the maximum

O load can be displayed according to the Lifting capacity table (without reduc-
tion because of the reeving) on the Maximum load display by pressing the
01.02.2000

Reeving membrane switch. The value is shown for about three seconds.
The display then changes back to the reduced value.

12 - 26 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.2 Operating the safe load indicator

SLI early warning

The SLI early warning lamp will illuminate when the actual load reaches
x 90 % (depending upon the regulations of the respective country) or more
of the maximum permissible load. The intermittent buzzer tone sounds
at the same time.

• Press the membrane switch Acknowledge to switch off the buzzer tone.
p The load is shown in the Degree of utilization status display. The green and
yellow LEDs illuminate.

SLI shutdown There are two types of shut down:

– The shutdown due to overload, when approx. 100 % of the maximum

permissible load is exceeded.
– Shutdown resulting from error messages; ➠ Error message in this
section, p. 12-28.

For both types of shutdown

– all crane movements which increase the load moment are shut down,
– the SLI shutdown warning lamp lights up,
w – the continuous buzzer tone sounds.
A shutdown resulting from overloading can be recognised by the fact that
in addition to the messages mentioned above:
– the signalling point lights up in the Actual load status display and
2$$ t

– the red LEDs light up in the Degree of utilization status display.

If the SLI shuts down due to an error, the red warning lamp in the
t membrane switch Error information also lights up (➠ Error messages in this
section, p. 12-28).

If you would like to switch off the continuous buzzer tone:

• Press the Acknowledge membrane switch.
p
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Operating Instructions GMK 6300 2 084 548 en 12 - 27
Crane operation
12.2 Operating the safe load indicator

For shutdowns caused by overloading, you can cancel the shutdown by

leaving the shutdown area. You may then only perform the crane opera-
tions listed in the following table.

Crane movements switched off Crane movements allowed

Lift load Lower load
Lower main boom Raise main boom
Extend main boom Retract main boom*)

H *)
With certain telescoping states the SLI also shuts down the retraction of
the telescoping for safety reasons. In this case leave the shutdown area
by raising the boom or, if this is not possible, set the load down, tele-
scope to the next fixed length and lift the load again.

If you have not already switched off the buzzer tone, you must press the
p Acknowledge membrane switch after leaving the shutdown area in order to
cancel the shutdown.

The SLI shutdown warning lamp goes out after you leave the shutdown
w area.

Error messages Shutdown due to an error is indicated by the red warning lamp in the
Error information membrane switch.
The code for the error is indicated in the status display Information after
you have pressed the membrane switch Error information. Error codes for
which there are no technical malfunctions are listed along with their
possible countermeasures in a table at the end of this section.

G
Risk of accidents!
You must stop crane operation as soon as an error message occurs!
Repairs to the SLI may only be carried out by properly qualified personnel.

• Press the Error information membrane switch.

t An error code appears in the Information display. If there are several
errors, you can have all of the error codes displayed one after the other
by repeatedly pressing the membrane switch Error information.
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 Crane operation
12.2 Operating the safe load indicator

----
H If the Error information membrane switch is pressed without there being an
error message, a minus sign appears in the Information status display in all
positions.

Example of an error display:

An error message comprises three different numbers, which are separated by pe-
!1§8 riods on the status display. The numbers stand for (from left to right):
the error group: e. g. 1
the components in
this error group: e. g. 13
the type of error: e. g. 8

Table of error messages with possible causes and remedies;

➠ Malfunctions of the SLI, p. 15-29.

Error messages Some error messages are indicated by the respective display flashing, in
with additional addition to SLI deactivations. The follow displays blink:
optical displays

Either:
– the indicators Current length of telescope
section II to IV (1)
or
– the display Actual load (2) and
– the display Current radius (3)
or
– the indicators Current length of telescope
section I to IV (1) and
– the display Actual load (2) and
– the display Current radius (3).

H Flashing values mean that the SLI can no longer safely calculate these
values. The error message occurs if the SLI recognises differences between
the measured and calculated values which are too large, or if the values
from the SLI and the crane control do not agree (e. g., after manually enter-
ing a telescope status on the display Crane control). Countermeasure;
01.02.2000

➠ Malfunctions of the SLI, Error message 1.19.1 and 3.06.3, in the error
messages table beginning on page 15-30.

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Operating Instructions GMK 6300 2 084 548 en 12 - 29
Crane operation
12.2 Operating the safe load indicator

SLI override

G
Risk of accidents if SLI is overridden!
The SLI may not be overridden while the crane is being operated.
It is prohibited to operate the crane if the safe load indicator is switched
off, overridden, out of operation or defective!

S
You may only override the SLI when carrying out maintenance or rigging
work in accordance with the Operating Instructions.
In such cases, the SLI may only be overridden when there is no load on
the hook.

G
Risk of accidents when the SLI is defective!
You may override the SLI if it is defective.
Always put down the load immediately if the SLI is defective!
If there is still a suspended load, do not make any more movements
which increase the load moment (extending the telescope, lowering
the boom).

The SLI shutdown system can be bypassed (deactivated) using the key-
operated switch Override.

• Insert the key into the key-operated switch.

• Turn the key to the right.
• Hold the key in this position.
The SLI is overridden as long as you hold the key in this position.

If the SLI is overridden, the Information display shows error message 9.03.6
)0§6 After overriding you must acknowledge the error message.

S
Always remove the key from the Override key switch after override!
The key must not be left in the key-operated switch while the crane is in
operation!

H The SLI can also be overridden together with the lifting limit switch.
See the instructions in the chapter Overriding the lifting limit switch shutoff
system; ➠ p. 10-61.
01.02.2000

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 Crane operation
12.3 Crane work with the main boom

H
12.3 Crane work with the main boom

If a swing-away lattice extension is reeved during operation with the main

boom, the loads given in the Lifting capacity tables decrease. The values
which have to be taken of the loads are given in the Lifting capacity tables in
their own table.

12.3.1 External influences during crane operation

Horizontal The horizontal alignment of the truck crane may change due to the
alignment varying load on the ground during crane work.

G
Risk of accidents if the truck crane is not horizontally aligned!
The SLI calculates the radius using the length and angle of the main
boom. If the truck crane is not horizontal the actual radius will change
and the crane may overturn!

• Check the horizontal alignment of the crane on the status display of the
Electronic spirit level in the crane cab immediately before commencing
crane work. When the alignment is horizontal, only the two squares in
the center of the status display illuminate.
• Check the electronic level regularly while working with the crane. If a diode
lights up on the crossed bars, the truck crane is no longer positioned
horizontally.
Due to deformation of the frame, the horizontal positioning can change
up to 2° when the superstructure is turned from the 0° or 180° position.
If the truck crane does not return to the horizontal position after turning
back to the 0° or 180° position, you must immediately determine the
cause and eliminate it and realign the crane if necessary. Check the
position of the superstructure when doing so; ➠ p. 13-34.

Safe distances When working with the crane, maintain adequate distance between all
parts of the truck crane including the load and objects on the site as well
as all persons on the site.
Keep a particularly close watch on objects that pose a direct risk
(for example, scaffolding or gas containers).
Keep a safe distance away from electrical lines;
➠ Safe distance from electrical lines, p. 13-10.
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Operating Instructions GMK 6300 2 084 548 en 12 - 31
Crane operation
12.3 Crane work with the main boom

Effect of wind on Strong winds can overstrain the truck crane.

crane operations Monitor the wind speed on the Anemometer continuously during crane
operation.
If your truck crane is not equipped with an anemometer, enquire about
the expected wind speed at the local meteorological office. The per-
missible wind speed for a fully loaded truck crane may be found in the
Lifting capacity table.

Anemometer An anemometer is installed on the tip of the main boom to monitor the

H
wind.

When the lattice extension (additional equipment) is being used, the ane-
mometer must be plugged into the lattice extension; ➠ GMK 6300 Lattice
extension operating manual.

Wind strength Wind speed Effect of wind

inland
Beaufort Name
m/s km/h
scale
0 Calm 0 to 0.2 1 Calm, smoke rises vertically.
Direction of wind shown by
Light smoke but not by wind
1 0.3 to 1.5 1 to 5
draught vanes.
Wind felt on face, leaves
Light rustle, weather vane moved
2 1.6 to 3.3 6 to 11
breeze by wind.
Leaves and small twigs in
Gentle constant motion, wind
3 3.4 to 5.4 12 to 19
breeze extends light flag.
Wind raises dust and loose
Moderate paper, twigs and small
4 5.5 to 7.9 20 to 28
breeze branches are moved.
Small deciduous trees begin
Fresh to sway. Crested wavelets
5 8.0 to 10.7 29 to 38
breeze form on inland waters.
Large branches in motion,
Strong telegraph lines whistle,
6 10.8 to 13.8 39 to 49
breeze umbrellas used with difficulty.
Whole trees in motion,
Moderate inconvenience in walking
7 13.9 to 17.1 50 to 61
gale against wind.
01.02.2000

Breaks twigs off trees,

8 Fresh gale 17.2 to 20.7 62 to 74 generally impedes progress.

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 Crane operation
12.3 Crane work with the main boom

Slight structural damage

9 Strong gale 20.8 to 24.4 75 to 88 occurs (chimney pots and
slates removed).
Trees uprooted, considerable
10 Full gale 24.5 to 28.4 89 to 102 structural damage occurs.

G
Risk of accidents with too high wind speeds!
If the wind speed exceeds the maximum permissible values according to
the Lifting capacity table, you must adjust the crane operation and set the
truck crane to the rigging mode prescribed by the following table.
This applies also when the wind surfaces of the load is smaller than the
permissible specific wind surfaces Aper; ➠ Permissible wind load in the
following section.
There is no automatic shutdown.

If the maximum wind speed according to the lifting capacity table

is exceeded, proceed as follows:

Wind speed less than 20 m/s Wind speed greater than 20 m/s

Put down the load. Put down the load.

Turn the superstructure in such a Completely retract the main boom.

way that the main boom provides
the wind with as little working Turn superstructure to the front
surface as possible. (180° position) or rear (0° position)
of the truck crane and lock the
superstructure.

Set the main boom – if possible –

H
on the main boom support.

Proceed as follows if the permissible wind speed is exceeded while carry-

ing out crane work with the luffing jib or the boom extension;
➠ GMK 6300 Lattice extension operating manual.
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Operating Instructions GMK 6300 2 084 548 en 12 - 33
Crane operation
12.3 Crane work with the main boom

Permissible The permissible specific wind surface of the load (Aperm) during crane
wind load operation is Aperm = 1 m2 per t of lifting capacity.
The wind surface depends on the aerodynamic power correction value cf
of the load. The wind surface of the load must be reduced proportionally
in consultation with the supervisor for cf -values (cf-values in accordance
with DIN 1055 Part 4) greater than 1.2 and wind surfaces greater than the
permissible wind surface (Aperm).
Formula:


√
1,2 ⋅ Aperm
vred = v ⋅
cf ⋅ A'

vred reduced permissible wind speed in m/sec

v permissible wind speed according to lifting capacity table in m/sec
cf actual aerodynamic power correction value

A’ actual wind surface of the load in m2/t

Aperm permissible wind surface of the load in m2/t

Earthing the load

B
Risk of accidents due to electrical shock!
Earth the load before crane operation
– near strong transmitters (radio/television transmitters, radio/television
stations, etc.),
– near high-frequency switchgears and
– in potentially stormy weather.

The load can become electrostatically charged even if the truck crane is
earthed; ➠ Earthing the truck crane, p. 13-11. This applies especially when
a hook block is used with sheaves made of synthetic material and non-
conductive load handling gear (e. g. plastic or manila ropes).

To prevent the electrostatic charging of the load, you will need:

– an electrically conductive metal rod inserted in the ground
(approx. 1.5 m in length),
– an electrically conductive cable (minimum cross section 16 mm2),
– an electrically conductive metal rod with insulated handle used to touch
the load.

B
01.02.2000

Risk of accidents due to electrical shock!

Ensure that the connection between the load and the ground is a faultless
electrically conductive connection!

12 - 34 2 084 548 en Operating Instructions GMK 6300

 Crane operation
12.3 Crane work with the main boom

• Connect one end of the cable to the metal rod that is to be inserted into
the ground. Hammer the metal rod at least 1 m into the ground.
Moisten the soil around the metal rod for better conductivity.
• Connect the other end of the cable to the metal rod with the insulated
handle.

B
Risk of accidents due to electrical shock!
The metal rod is to be held by the insulated handle only!

• Hold the metal rod by the insulated handle. Use the metal rod to touch
the load before touching the load with your hand.

12.3.2 Slewing ranges permitted for working with the crane

According to the lifting capacity table there are two permitted ranges for
crane work the 360° slewing range and the 0° to the rear working position.
– the 360° slewing range and
– the 0° working position to the rear.

360 slewing • Support the truck crane with the outrigger span required according to
range the Lifting capacity table.
• Select the 360° slewing range using the Permissable slewing range mem-
brane switch on the SLI or enter the required SLI code in accordance

H
with the Lifting capacity table; ➠ Entering values, p. 12-19.

The required outrigger span for the 360° slewing range depends on the
rigged counterweight. A table in section Slewing with rigged counterweight,
p. 13-61 shows the necessary outrigger spans.

Working position The superstructure must be locked before the crane is operated in the
0° to the rear working position 0° to the rear. Observe the maximum permitted tele-
scope status and outrigger span given in the Lifting capacity table.

• Support the truck crane.

• Turn the truck crane to the rear in the 0° position.
• Lock the superstructure; ➠ Mechanical superstructure lock, p. 12-6.
• Select the 0° slewing range using the Permissable slewing range membra-
ne switch on the SLI or enter the required SLI code in accordance with
the Lifting capacity table; ➠ Entering values, p. 12-19.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 12 - 35
Crane operation
12.3 Crane work with the main boom

G
The crane can overturn when the superstructure lock is released!
The superstructure must always be locked when you work with the crane
in the 0° position to the rear. This prevents the superstructure from over-
turning due to unfavorable effects (for example, inadvertent actuation of
the slewing gear or swinging loads) out of the 0° position which would
cause the truck crane to overturn or parts of the truck crane to be over-
strained. Before leaving the 0° to the rear working position you must
change the SLI code.

12.3.3 Hoists

Main hoist You may work with the main boom or the lattice extension using the hoist
rope on the main hoist.

G
Risk of accidents due to inadvertent operation of a hoist!
Always switch off the hoist that is not in use!
You may not turn the drum if the hook block is unreeved and you have
completely reeled in the hoist rope.
– If the hoist rope is inadvertently turned in the lowering direction,
the switching point of the lowering limit switch is displaced, resulting in
slack rope. This causes rope loops to form on the hoist drum which can
lead to load slipping and destruction of the hoist rope.
– If the hoist rope is inadvertently turned in the raising direction,
the switching point of the lowering limit switch changes, leaving less
than the required number of safety windings on the drum.

G
Accidents may occur if the load is lifted at a slant!
With a load the main boom bends and the hoist rope is no longer aligned
in a vertical position pointing upwards. Balance out the deflection by rai-
sing so that the load is lifted vertically upwards. In this way you prevent
the load dragging and injuring helpers or falling into the hoist rope at an
angle. Inform all helpers about this as well.

• Check whether the auxiliary hoist (additional equipment) is switched off.

C The Auxiliary hoist shutdown rocker switch on the left-hand control lever
must be pressed downward to prevent inadvertent actuation of the
auxiliary hoist.
• Switch on the main hoist.
ü Press the Deactivate main hoist rocker switch on the right-hand control
lever upward.
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 Crane operation
12.3 Crane work with the main boom

Lamp I of the display lamps Hoists is activated upon switching the main
hoist on.
If you would like to lift the load with the main hoist, lamp I for the main
hoist must illuminate.

If the I lamp flashes, switch over the indicator lamps; ➠ Switch over the
hoist gear indicator lamps, p. 12-22.

The value on the display Reeving is always valid only for the hoist of
/ n= which the lamp illuminates among the display lamps Hoists. When switch-
ing on a hoisting gear, a value will be shown which was last entered for
this hoisting gear.

Lifting: Pull the right-hand control lever back.

Lowering: Push the right-hand control lever forward.
You may regulate the speed of the main hoist by moving the control lever
and changing the engine speed using the accelerator.

You can set the maximum speed of the hoist gear on the Crane control dis-
@ play; ➠ Power unit speeds/critical load control menu, p. 12-83.

You can set a constant engine speed with the rocker switch Constant engine
å speed; ➠ p. 12-89.

With a degree of utilization of up to 50 % (lifted load maximum of 50 % of

the load bearing capacity according to the Lifting capacity table) you may
move the hoists also in fast speed.
Activate a higher speed with the Hoists fast speed foot-operated switch.
The fast speed for the main and auxiliary hoists (additional equipment) is
activated at the same time with the foot-operated switch; ➠ p. 12-78.

H The speed of the hoists is clearly increased by switching to fast speed

only if you have extended the control lever more than approx. 70 %.
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Operating Instructions GMK 6300 2 084 548 en 12 - 37
Crane operation
12.3 Crane work with the main boom

A hoist drum synchro (1) is installed in the

manual control lever. You will notice an
impulse on the hoist drum synchro when
the hoist drum rotates.

You can monitor the rope running on the drum using the mirror over the
hoist.

G
Risk of accidents when the load is suspended!
Never leave the crane cab while a load is suspended on the hook block.
Never turn the crane engine off while a load is suspended on the hook.
Always keep your hand close to the control levers while a load is sus-
pended on the hook so that you are able to react correspondingly at all
times.
Always put down the load before you stop work!

A lifting limit switch on the boom head deactivates the movements

K Raise main hoist, Raise auxiliary hoist and Extend telescoping out. The Lifting li-
mit switch shutdown warning lamp lights up when the switching point is
reached.
Leave the shutdown area by carrying out the movements Lower or Retract
telescoping.

G
Risk of accidents with overridden lifting limit switch!
Always leave the shutdown area after a lifting limit switch shutdown.
The shutdown must absolutely not be overridden during crane operation
and as long as a load is suspended on the hook. If you move the hook
block further against the boom with an overridden shutdown, the hoist
rope can tear and the load will uncontrollably fall to the ground.
01.02.2000

Further information about shutdown of the lifting limit switch; ➠ Lifting

limit switch, p. 10-61.

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 Crane operation
12.3 Crane work with the main boom

A lowering limit switch on the hoist prevents the hoist rope from being
completely reeled off. It deactivates the Lower movement when five turns
are left on the drum. For safety reasons, these five turns must remain
reeled on the drum.
Drive out of the shutdown area by performing the Lift movement.

G
Risk of accidents if the lowering limit switch is defective!
Do not carry out any crane work if the lowering limit switch is
– damaged,
– out of operation or
– improperly set.
Too much hoist rope would be reeled off and the required safety turns
would no longer be there.

H The switching point of the lowering limit switch must be checked if the
hoist rope is replaced. Five turns must remain on the rope drum if the
hoist rope is reeled off to the switching point, ➠ Maintenance Manual.

H The hoist rope is stiff in low temperatures. A weight must be added if the
reeved hook block repeatedly cannot be lowered.
You must operate the hoist slowly when reeling in the rope, as stiff rope
is difficult to wind.

You may use the Main hoist shutdown rocker switch on the right control
ü lever to prevent inadvertent actuation of the main hoist.
To do this, press the rocker switch downward.

You can display the operating hours and possibly the blocked functions of
> the hoist on the crane control display with the membrane switch Display
status; ➠ Menu Display status, p. 12-79.

Auxiliary hoist You may work with the main boom or the lattice extension using the hoist
(additional rope on the main hoist.
equipment)

G
Risk of accidents when working with auxiliary hoist!
Before working with the auxiliary hoist, read and follow all the safety
instructions in the Main hoist section; ➠ p. 12-36.
When working with the auxiliary hoist, all the safety instructions for
working with the main hoist also apply, along with the information in
this section.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 12 - 39
Crane operation
12.3 Crane work with the main boom

H If you run the auxiliary hoist rope over the left head sheave (additional
equipment), you must extend the main boom to a total length of at least
20 m before lifting a load.
Otherwise the rope angle exceeds the maximum permitted value.

• Check whether the main hoist is switched off to prevent unintentional

ü actuation.
The Main hoist shutdown rocker switch must be pressed down.
• Switch on the auxiliary hoist.
C Press the Auxiliary hoist shutdown rocker switch on the left-hand control
lever upward.
Lamp II of the display lamps Hoists is activated upon switching the
auxiliary hoist on.
If you want to lift the load with the auxiliary hoist, the II lamp for the auxi-
liary hoist must light.

If the II lamp flashes, switch over the indicator lamps; ➠ Switch over the
hoist gear indicator lamps, p. 12-22.

The value on the display Reeving is always valid only for the hoist of
/ n= which the lamp illuminates among the display lamps Hoists.

Lifting: Pull the left-hand control lever rearward.

Lowering: Push the left-hand control lever forward.
You may regulate the auxiliary hoist speed by moving the control lever
and by changing the engine speed using the accelerator.

H The auxiliary hoist is operated the same way as the main hoist (high-
speed, set driving gear speed, etc.).

Use the Auxiliary hoist shutdown rocker switch on the left-hand control
C lever to deactivate the auxiliary hoist to prevent inadvertent operation.
To do this, press the rocker switch downward.
01.02.2000

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 Crane operation
12.3 Crane work with the main boom

12.3.4 Derricking gear

The main boom can be inclined between –1,5° and +80°. The angle of the
main boom in relation to the horizontal position can be set by raising and
lowering the main boom.
The SLI switches off lowering of the boom, depending on the load size
and main boom length according to the Lifting capacity table.
Raising the boom out of a horizontal position and lowering it to the hori-
zontal with the completely retracted main boom is automatically cleared
by the SLI if it is permitted by the SLI rigging programs (Rigging pro-
grams; ➠ Lifting capacity tables)
A rigging code must be entered for other telescope statuses (also for

H
0/0/0/0/0).

For the outrigger span 8.70 x 2.68 metres, a rigging code must also be en-
tered when the main boom is retracted and raising and placing is only per-
mitted in the positions 0° to the rear or 180° to the front.

G
The truck crane may overturn when lifting loads!
Lifting loads by raising the boom is strictly prohibited as the SLI does not
function when this is carried out!

H Raising the boom is a movement which decreases the load moment; it is

not deactivated by the SLI. However, if excessively heavy loads are lifted
by raising the boom, the truck crane can overturn.

• Switch the derricking gear on.

Ü Push the Derricking gear shutdown rocker switch on the right-hand control
lever upward.
• Switch the right-hand control lever to the Derricking function.
_ Push the Derricking / telescoping preselection control lever function rocker
switch downward to do this.
The Derricking control lever function indicator lamp illuminates.
U
Lowering: (= lower boom) Push the right control lever to the right.
Raising: (= raise boom) Push the right control lever to the left.
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Operating Instructions GMK 6300 2 084 548 en 12 - 41
Crane operation
12.3 Crane work with the main boom

You may regulate the speed of the derricking gear by moving the control
lever and changing the engine speed using the accelerator.

You can set the maximum speed of the derricking gear for working with
@ the main boom and lattice extension on the Crane control display; ➠ Power
unit speeds/critical load control menu, p. 12-83.

You can set a constant engine speed with the rocker switch Constant engine
å speed; ➠ p. 12-89.

You can switch to fast speed with the fast speed derricking gear/telescoping
gear (arrow) foot-operated switch; ➠ p. 12-78.

When the two-stage swing-away lattice extension or boom extension

(both additional equipment) are being operated, the fast speed for the
derricking gear is blocked.

H When the boom is completely extended and in the steepest position and
you wish to lower the boom without a load, you must switch on the fast
speed to lower the boom so that the derricking gear can come out of the
dead centre position.

You can press the Derricking gear shutdown rocker switch downward to
Ü prevent unintentional actuation of the auxiliary hoist.

You can display the operating hours and possibly the blocked functions of
> the derricking gear on the Crane control display with the membrane switch
Display status; ➠ Menu Display status, p. 12-79.

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 Crane operation
12.3 Crane work with the main boom

12.3.5 Slewing gear

You can display the operating hours and possibly the blocked functions of
> the slewing gear on the Crane control display with the membrane switch
Display status; ➠ Menu Display status, p. 12-79.

Slewing gear
permanent brake

Apply the slewing gear permanent brake using the Slewing gear permanent
Y brake rocker switch on the left-hand control lever and deactivate the
Slewing function to prevent inadvertent actuation. To do this, press the
rocker switch downward.
The Slewing gear permanent brake indicator lamp illuminates when the
Y slewing gear permanent brake is applied.

S
The boom may buckle!
The slewing gear permanent brake should never be used to brake
slewing movement!
Do not apply the slewing gear permanent brake until the superstructure is
no longer slewing.

G
The crane can overturn when the superstructure lock is released!
The superstructure must always be locked when you work with the crane
in the 0° position to the rear. This prevents the superstructure from over-
turning due to unfavourable conditions (e. g., inadvertent actuation of the
slewing gear or swinging loads) out of the 0° position, which would cause
the truck crane to overturn.

Slewing

G
Risk of accidents due to slewing superstructure!
There is a risk of crushing due to slewing machine sections.
Actuate the horn before slewing the superstructure and make sure that
nobody is standing in the slewing range of the superstructure.
In this way you prevent people getting crushed between the slewing su-
perstructure and fixed objects or between the superstructure and the
carrier.

G
Risk of overturning with insufficient support!
Always support the truck crane on outriggers before rotating the super-
01.02.2000

structure. When the counterweight is rigged, the truck crane can overturn
rearward if the outrigger span is to small.

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Operating Instructions GMK 6300 2 084 548 en 12 - 43
Crane operation
12.3 Crane work with the main boom

• Check whether a sufficient outrigger span with which the superstructure

may be slewed is set for the rigged counterweight with the table in
section Slewing with rigged counterweight, p. 13-61.
• Set the maximum permissible slewing speed for the current rigging
mode; ➠ Maximum permitted slewing speed, p. 12-45.
• Release the mechanical superstructure lock before you slew the super-
structure; ➠ Mechanical superstructure lock, p. 12-6.
Slewing to the left: Push the left-hand control lever to the left.
Slewing to the right: Push the left-hand control lever to the right.

Slewing speed

S
The boom may buckle!
Accelerate and brake slewing speed only to such a degree that the load
does not sway!

The further you move the control lever to the right or left, the more
quickly the slewing gear slews.

The further you move the control lever back to the central position,
the slower the slewing movement becomes.

When you move the control lever back to the central position, the slewing
gear stays still.

Furthermore, you can change the slewing speed by:

– changing the engine speed with the accelerator,
– setting a constant engine speed; ➠ p. 12-89.

Tracking the When the slewing gear is tracked, the superstructure can adjust itself to
slewing gear outside forces (e. g. wind or when working with a second crane).

You must switch on the slewing gear freewheel to track the slewing gear.

• Press the foot-operated switch slewing gear freewheel (arrow).

As long as you keep the foot-operated switch pressed, the slewing gear is
tracked, if at the same time:
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– the left-hand control lever is in the central position and,

– the slewing gear permanent brake is switched off.

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 Crane operation
12.3 Crane work with the main boom

Maximum per- You must set the maximum permitted slewing speed before each job.
mitted slewing The maximum permitted slewing speed depends on:
speed – the working radius and
– the degree of utilization, i.e. the percentage of the permitted load
according to the Lifting capacity table which is lifted.

• Determine the maximum permitted slewing speed for your special job
from the following tables for the main boom, the boom extension and
the luffing jib.

Table for main boom

Degree of Degree of Degree of Degree of

Working radius utilization utilization utilization utilization
[m] 25 % 50 % 75 % 100 %

Adjustable, maximum slewing speed in %

10 100 50 40 30
20 50 40 30 25
30 30 25 20 20
40 15 15 15 15
50 10 10 10 10
60 10 10 10 10

Table for two-stage swing-away lattice extension and boom extension

Degree of Degree of Degree of Degree of
Working radius utilization utilization utilization utilization
[m] 25 % 50 % 75 % 100 %

Maximum slewing speed to be set in %

10 70 50 40 30
20 40 40 30 25
30 25 25 20 20
40 15 15 15 15
50 10 10 10 10
60 10 10 10 10
70 10 10 10 10
80 10 10 10 10
90 10 10 10 10
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Set this slewing speed by calling up the menu Power unit/critical load
@ control in the Crane control display; ➠ p. 12-83.

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Operating Instructions GMK 6300 2 084 548 en 12 - 45
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12.3 Crane work with the main boom

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12.3.6 Telescoping gear

Structure of the Most procedures which you initiate for the operation of the telescoping
chapter gear are afterwards carried out by the crane control and monitored. In the
process you receive acknowledgements, you can follow the procedure
and, at the right time, initiate further procedures.
For this it is important that you are not only familiar with the operation,
display, and control instruments of the telescoping gear, but also its
functioning. Then you can comprehend the procedures which the crane
control carries out in the boom while you move the control lever; you will
become familiar with the status displays and crane control more quickly.
Therefore the chapter is organized in the following sections:

– Description of functioning,
– Main boom fixed lengths, intermediate lengths, telescoping lengths,
– Telescope status,
– Notes on telescope-sequence,
– Function of the control lever,
– Example of procedures when telescoping
(further sections are refered to in this section).

H The last section and the sections following it belong together and
describe the actual telescoping procedure. Before you proceed according
to this section for the first time, you must know the basic information
from the previous sections. Only in this manner is a safe operation of the
telescoping gear possible.
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Operating Instructions GMK 6300 2 084 548 en 12 - 47
Crane operation
12.3 Crane work with the main boom

Description of The main boom consists of the non-telescoping section, four telescope
functioning sections and a single-level telescoping cylinder. The following diagram
shows the main boom in section with the telescoping cylinder.

In the diagram the main boom is completely retracted and the telescoping
cylinder is located in the foot section of telescope section I.

All telescope sections (I to IV) are rigged on the outside with locking pins
(1) which are pushed out of the telescope sections with springs (9). If a
bore (2) of the telescope section above it aligns with the corresponding
locking pin, the spring pushes the locking pin in at that point and the
telescope section is locked. All telescope sections can be locked at three
different points (on the fixed lengths) in the corresponding bores (2).

Levers are fixed to the locking pins of all telescope sections of which the
brackets (6) reach inward into the foot sections of the telescope section.
The brackets reach in all telescope sections the same distance into the
foot sections.
The piston rod (7) of the telescoping cylinder is fastened to the main
boom basic section. If the telescoping cylinder is telescoped, its head runs
(8) through the foot sections of telescope sections (I to IV). If the head (8)
is situated at a locking point (the head is situated at the locking point of
telescope section I), the mechanism (3) on the telescope cylinder snaps
into the bracket (6).

If the telescoping cylinder is located on the locking point, the bores (4)
also align on the inner sides of the telescope sections with the locking
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pins (5) of the telescoping cylinder.

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12.3 Crane work with the main boom

Telescoping cylinders and telescope sections can be locked and unlocked

at all locking points. In order to telescope, the telescoping cylinder must
be locked with the corresponding telescope section and the telescope
section must be unlocked.

To lock the telescoping cylinder, the locking

pins are (5) pushed into the bores (4) of the
telescope section by spring force.

In order to unlock the telescope section, a

hydraulic cylinder (2) is extended. The me-
chanism (3) transfers this movement to the
brackets (6) and retracts the locking pins (1)
against the spring force.

The telescope section is locked again after

telescoping, the procedure takes place in the
reversed sequence (as with unlocking).
When the telescoping cylinder is unlocked,
the locking pins are hydraulically retracted
against the spring force.

H The locking pin of the telescoping cylinder and the mechanism are moved
hydraulically. The necessary pressure for this is comes from a reservoir
which must be first be filled. Because of this, retardations of 2 to

H
3 seconds may occur.

A hydraulic/mechanical switch and the crane control prevent a telescope

section and the telescoping cylinder from being unlocked simultaneously.
A telescope section can be unlocked only when the telescoping cylinder is
locked and vice versa.

Main boom Main boom fixed length

fixed length,
All telescoping statuses where all telescope sections are locked are usual-
intermediate
ly called main boom fixed lengths. Higher load bearing capacities are per-
length,
mitted only when all telescope sections are locked.
telescoping
In the case of the GMK 6300, only those telescoping status with the
length
highest lifting capacities are permitted as main boom fixed lengths
because of the large number of possible locked telescoping statuses for
the same boom length.
There are thus a total of 28 main boom fixed lengths (➠ Lifting capacity
table). The lifting capacity values for the fixed lengths of the main boom
01.02.2000

are automatically monitored by the SLI.

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Operating Instructions GMK 6300 2 084 548 en 12 - 49
Crane operation
12.3 Crane work with the main boom

Main boom intermediate length

All telescoping statuses where all telescope sections are unlocked are
usually called main boom intermediate lengths.
In an unlocked telescoping status the whole load affects the telescoping
cylinder. This means that the permitted lifting capacitues are sometimes
considerably less than with main boom fixed lengths.
In the case of the GMK 6300, all locked telescoping statuses which do not
have the highest load bearing capacity with their main boom length are
also treated as main boom intermediate lengths. No higher loads are
therefore permitted for these locked telescoping statuses.

The lifting capacity values for the intermediate lengths of the main boom
are automatically monitored by the SLI.
Telescope the main boom to the required length before lifting the load!
With the lifting capacities which are given in the lifting capacity table for
main boom intermediate lengths, telescoping with a load is not possible!

Main boom telescoping length

There is a main boom telescoping length when the main boom is at a
main boom intermediate length and is also telescoped with a load.
The lifting capacity values for the telescoping length of the main boom
are in the same range as the lifting capacity values for the main boom in-
termediate lengths which are monitored by the SLI.
The telescopic load is restricted by:
– the angle of the boom and
– the lubrication of the sliding wear pad between the telescope sections.

S
The main boom should only be telescoped with a load if the job cannot
be done otherwise.

Telescope status The position of the telescope sections, i.e. which telescope section has
been telescoped how far, is called the telescope status.

The current telescope status is displayed:

– on the SLI and
– on the Crane control display.
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 Crane operation
12.3 Crane work with the main boom

This section deals with the status display of the telescope status on the
SLI, the status display of the telescope status on the Crane control display is
described starting at the section Example of procedures when telescoping.

If a telescope section is retracted or extended, both the length of the main

boom and the length of the respective telescope section change on the
display.

The main boom fixed length is displayed in decimals (e. g. 0.50) and the
main boom intermediate length and main boom telescoping length are

H
displayed as two-digit percent values (e. g. 47).

Intermediate lengths and telescoping lengths at 100 % are indicated by

the flashing display 1.0.

Example: Telescope status display for main boom fixed lengths

1 2 3 4
!0 =50 =00 =00 C0645

Telescope section I 100 % extended (fixed length)

Telescope section II 50 % extended (fixed length)

Telescope section III 0 % extended (fixed length)

Telescope section IV 0 % extended (fixed length)

The following percent values represent main boom fixed lengths:

Telescope section I 0 / 50 / 100 [%]

Telescope section II 0 / 50 / 100 [%]

Telescope section III 0 / 50 / 100 [%]

H
Telescope section IV 0 / 50 / 100 [%]

Not all locked telescope statuses are permitted as main boom fixed
lengths; ➠ p. 12-49.
The fixed lengths can be found in the Lifting capacity table.
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Crane operation
12.3 Crane work with the main boom

The decimal display (e. g. 0.50) follows only if all telescope sections are
telescoped to a fixed length. As soon as one or more telescope sections
are telescoped to a different length, all lengths count as main boom inter-
mediate lengths or main boom telescoping lengths.

The status display changes accordingly, as the following example demon-

strates.

Example: Telescope status display for main boom intermediate lengths

and main boom telescoping lengths.

1 2 3 4
000 067 100 100 C0645

Telescope section I 0 % extended (intermediate length)

Telescope section II 67 % extended (fixed length)

Telescope section III 100 % extended (fixed length)

Telescope section IV 100 % extended (fixed length)

The following percentage values represent main boom intermediate

lengths and main boom telescoping lengths:

Telescope section I 0 - 100

Telescope section II 0 - 100

Telescope section III 0 - 100

H
Telescope section IV 0 - 100

There can only ever be one telescope section at an intermediate length

(because only one telescope section can be unlocked).

H
The useful intermediate lengths can be found in the Lifting capacity table.

The maximum permissible lifting capacity also changes constantly in the

Maximum load status display.
Whenever the extending of a telescope section would lead to a telescope
status which is not permissible according to the Lifting capacity table, the
SLI switches this extending off as soon as the telescope section moves.
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12.3 Crane work with the main boom

Notes on The telescope sections can only be telescoped individually one after the
telescope- other.
sequence
When extending you must always extend the telescope section with the
highest numbering first, then the telescope section with the second
highest numbering, etc. (e. g. IV, III, II, I).
Retracting always takes place in the reversed sequence as extending.

Check before tele- The crane control calculates the displayed telescope status from the cur-
scoping for the rent status of the telescoping gear and the locking and unlocking
first time processes which have occurred and been saved.

Normally, the crane control recognises differences between current and

displayed telescope statuses and displays a corresponding error messa-
ge; ➠ Telescoping error message, p. 15-67.

If the values are deleted because of an accident (e. g. lightning strike), the
crane control can no longer calculate the current telescoping status and
an error message occurs.

S
Risk of damaging the telescoping gear!
After switching on the ignition before the first telescoping, always check
that the current telescope status is displayed in the crane control display.
After an accident, if the crane control is unable to correctly calculate the
current telescope status and no error message occurs, telescoping can
cause damage to the telescoping gear.

• After switching on the ignition, always check before the first telescoping
that the telescope status displayed in the crane control display matches
the current telecope status.
If the current telescope status is not correctly displayed, enter the current
telescope status; ➠ Entering telescope status after emergency operation, p. 15-80.
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Crane operation
12.3 Crane work with the main boom

Function of the This section only describes the functioning of the control lever and has
control lever general notes for telescoping. Before you telescope, you must fulfill cer-
tain requirements. Read the section Example of procedures when telescoping
for this; ➠ p. 12-56.

The SLI deactivates telescoping extension depending on the size of the

load and length of the main boom (angle between the main boom and the
horizontal position). Ensure that the boom has been sufficiently raised
before the main boom telescoping is extended.

• Switch on the telescoping gear.

Ö Push the Auxiliary hoist shutdown rocker switch upward.

• Switch the right hand control lever to the telescopic function.

_ To do this press the Preselection of derricking control lever function /
telescoping/derrick lattice extension rocker switch up.
The indicator lamp Telescoping gear switched on illuminates.
T

G
Risk of accidents from unexpected crane movement!
Make sure that the indicator lamp Telescoping gear switched on illuminates
before you move the control lever for telescoping.
This prevents accidents from the unexpected derricking of the main
boom and lattice extension.

Extend: Push the right-hand control lever to the right.

Retract: Push the right-hand control lever to the left.

H With certain telescoping states the SLI also shuts down the retraction of
the telescoping for safety reasons. In this case leave the shutdown area
by raising the boom or, if this is not possible, set the load down, tele-
scope to the next fixed length and lift the load again.

You may regulate the telescoping speed by moving the control lever and
changing the engine speed using the accelerator.
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 Crane operation
12.3 Crane work with the main boom

You can set the maximum speed of the telescoping gear for working with
@ the main boom and lattice extension on the Crane control display; ➠ Power
unit speeds/critical load control menu, p. 12-83.

In addition you can set a higher speed when extending by using the foot-
operated switch Fast speed derricking gear/telescoping gear (arrow).

You may set a constant engine speed using the rocker switch Constant
å engine speed.

The telescoping gear can be switched off by rocker switch (Telescoping gear
Ö shutdown) to prevent it from being operated accidentally.

H
To do this, press the rocker switch downward.

The distance between the hook block and the boom head also changes
during telescoping. Reel off the hoist rope when retracting and reel it on
when extending the telescoping.

S
Be careful not to damage the hoist rope!
Slack rope will occur if the hook block is allowed to touch the ground
while the boom is being retracted. This causes rope loops to form on the
hoist drum which can lead to load slipping and damage to the hoist rope.

H The telescoping movement is shut off if the hook block reaches the lifting
limit switch during extension of the main boom telescoping.

You can display the operating hours and possibly the blocked functions of
> the telescoping gear on the crane control display with the membrane
switch Display status; ➠ Display status menu, p. 12-79.
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Crane operation
12.3 Crane work with the main boom

Example of The procedures for telescoping with semi-automatic control are described
procedures when in the following sections.
telescoping You can also telescope to fixed lengths with the fully automatic control;
in the course of this the crane control regulates the procedures described
here automatically; ➠ Telescoping with fully automatic control, p. 12-73.
This section shows you the sequence of an entire telescoping procedure

H
for a better overview at the outset.

This section and the sections refered to here presuppose that you are
familiar with the functioning of the telescope system;
➠ Description of the functioning, p. 12-48.
The entire example cannot apply to all telescoping procedures, since the
start and end position of the telescoping gear is different for every proce-
dure. Nevertheless a part of the sequence of the telescoping procedure
described here applies to all telescoping procedures.

Read the sequence for this example and follow the cross-references in the
sections with the descriptions of what to do. These sections always take
up the following example at the end. You thus get an overview of all
necessary steps and can implement these for your special telescoping
procedure.

The following start and end states apply to this example:

– All telescopic sections are retracted and locked.
– The telescoping cylinder is locked to telescope section IV.
– The telescope sections II and III should be extended to 50 %.
– Telescope section I should be extended to an intermediate length
of 37 %.

Sequence of the exemplary telescoping procedure

1. Check the telescope status, the position of the telescoping cylinder
and the locking pin; ➠ Check the initial position, p. 12-57.

2. Unlock telescoping cylinder; ➠ p. 12-60.

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3. Move telescoping cylinder into the telescope section, the telescope

section which needs to be telescoped and lock it there (in our example
telescope section III); ➠ Extending / retracting telescoping cylinders,
p. 12-62.

4. Unlock telescope section for telescoping; ➠ Unlocking telescopic section,

p. 12-65.

5. Telescope telescope section to fixed length and lock; ➠ p. 12-67.

6. To telescope other telescope sections (in our example telescope sec-

tion II would be the next one) repeat Points 2 to 5 until all required
telescope sections have been telescoped to the required length.

7. If necessary, extend the last telescope section (in our example tele-
scope section I) to the necessary intermediate length;
➠ Telescoping telescope section to intermediate length, p. 12-71.

Check initial Before you telescope the main boom, you must check the following states:
position
– the current telescope status
(how far the telescope sections are telescoped),
– the position of the telescoping cylinder
(in which foot section the telescoping cylinder is located),
– the position of the locking pins
(whether telescope sections and cylinders are locked or unlocked).
Various displays on the front instrument panel define the current status of
the main boom.
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Operating Instructions GMK 6300 2 084 548 en 12 - 57
Crane operation
12.3 Crane work with the main boom

Check current telescope status

• Switch on the menu Display telescoping and teleautomatism. Press the
ä Display telescope status and teleautomatism membrane switch.
The entry TELESCOPE STATUS is in the first line of the menu, and the
entry SEMI-AUTOMATIC CONTROL in the third line. These two entries do
not change.
The current telescope status for telescope sections I to IV is indicated in
percentages in the second line from left to right.

As long as all telescope sections are locked,

the numerical values are separated by a dash,
and below, next to the entry TELE, there are
also two dashes.
TELESCOPE STATUS
The current extended length of the telescop-
– 0 – 0 – 0 – 0 – ing cylinder is indicated to the right in me-
SEMI-AUTOMATIC CONTROL tres. e. g., L: 1.10 m).
TELE: – – L: 1.10 m

If a telescope section is unlocked (e. g., Tele-

scope section III), the respective numerical
value is in brackets (><) in the second line.
Below, next to the entry TELE, the unlocked
TELESCOPE STATUS
telescope section is displayed (T1 to T4 for
– 0 – 0 > 0 < 0 – telescope sections I to IV).
SEMI-AUTOMATIC CONTROL To the right is the current telescope status as
a percentage (e. g., 0 %).
TELE: T3 L: 0%

In our example, the display would indicate the start position as it appears in the
first illustration. The main boom is completely retracted; therefore the display
shows 0 (%) for all telescope sections.
At the bottom left there are two dashes, and the current extended length of the
telescoping cylinder is L: approx. 0.88 m, since the head of the telescoping
cylinder is extended into the foot section of telescope section IV.
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12.3 Crane work with the main boom

Checking the position of the telescoping cylinder

The current telescope status is now known; the next thing you should do
is check in which telescope section the head of the telescoping cylinder is
located.

One of the display lamps Telescoping cylinder in foot section I, II, III or IV
Vefg displays the position of the telescoping cylinder.
The corresponding display lamp illuminates when the head of the tele-
scoping cylinder is at the locking point in the foot section of the respective

H
telescope section.

Definition: When the statement “The telescoping cylinder is in foot

section II” appears in the following chapters, this means that “the head”
of the telescoping cylinder is in the foot section.

In our example “Initial position” is defined as the following: The telescoping

g cylinder in telescope section IV is locked, thus the head of the telescoping
cylinder is there. The display lamp Telescoping cylinder in foot section IV would
illuminate accordingly.

Checking the position of the locking pins

If you know in which telescope section the telescoping cylinder is located,
check the positions of the locking pins as the last initial position.

Both indicator lamps Telescope section unlocked and Telescope section locked
jj display the position of the locking pins in the telescope section in which
the telescoping cylinder is located.

The red indicator lamp Telescope section unlocked illuminates when the tele-
j scope section is not locked to the telescope section above it.

The green indicator lamp Telescope section unlocked illuminates when the
j telescope section is locked to the telescope section above it.

Both indicator lamps Telescoping cylinder unlocked and Telescoping cylinder

ih locked display the position of the locking pins on the telescoping cylinder.

The red indicator lamp lights up when the telescoping cylinder is not
i locked.

The green indicator lamp illuminates when telescope cylinder is locked to

h the telescope section in which it is located.
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Operating Instructions GMK 6300 2 084 548 en 12 - 59
Crane operation
12.3 Crane work with the main boom

In our example the green indicator lamp telescope section locked would illumi-
jh nate and thus display that telescope section IV is locked to telescope section III
(it was presupposed that all telescope sections are locked to one another).
The green indicator lamp Telescoping cylinder locked would in addition illumi-
nate (it was presupposed that the telescoping cylinder is locked to IV).
Present state: – telescoping cylinder is locked in foot section IV –
The next objective: – Unlock telescoping cylinder –

Unlocking tele- Before you can move the telescoping cylinder from one telescope section
scoping cylinder into another telescope section, you must unlock the telescoping cylinder.
The locking pins on the telescoping cylinder retract when unlocking.
Prerequisites for the unlocking of the telescoping cylinder:
– The telescope section is locked; the green indicator lamp Telescope
j section locked illuminates.
– The telescoping cylinder is locked to the telescope section; the green
h
H
indicator lamp Telescoping cylinder locked illuminates.

If these prerequisites are not fulfilled, the unlocking procedure is on the

one hand blocked by a hydraulic/mechanical switch for safety reasons
and is on the other hand not released by the crane control.

Unlocking telescoping cylinder

• Select the unlocking of the telescoping cylinder; to do this, press the
. rocker switch Select locking/unlocking downward.

Now the red indicator lamp Telescoping cylinder unlocked flashes; the crane
i control thus confirms the selection.

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the right control lever toward retract or extend to unlock.
As soon as the locking pins move, the green indicator lamp Telescoping
h cylinder locked flashes in addition.

As soon as the locking pins are completely retracted, the red indicator
i lamp Telescoping cylinder unlocked illuminates.
The green indicator lamp Telescoping cylinder locked goes out.

If you continue to move the right control lever after the Telescoping cylinder
unlocked warning lamp lights up, the telescoping cylinder moves in the cor-
responding direction immediately.
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H If the locking process is not finished after about 10 seconds (warning

lamp Telescoping cylinder unlocked is not on), you can not retract the locking
pins because they are under load.
With the Telescoping cylinder at locking point indicator lamps you can see if
you need to retract or extend the telescoping cylinder to relieve the load.
If only the bottom indicator lamp lights up, you must extend the telesco-
8 ping cylinder.

8 If both indicator lamps or only the top indicator lamp light up, you must
retract the telescoping cylinder.
9

S
Risk of damaging the boom system!
If extending and retracting the telescoping cylinder several times does
not cause unlocking, you must not move the telescoping cylinder any
further against the stop.

If extending and retracting several times does not unlock the telescoping
cylinder:
– Lock the telescoping cylinder by pressing the Select locking/unlocking
rocker switch up and moving the control lever.
– Start the locking process again by pressing the Select locking/unlocking
rocker switch down and moving the control lever.

The process of unlocking applies to all telescoping procedures; thus the red
i indicator lamp Telescoping cylinder unlocked would also now illuminate in our
example. The display would display the length L = 0.88 m.
Current end state: – telescoping cylinder is locked in telescope section IV –
– The next target: – Moving telescoping cylinder in foot section III –
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12.3 Crane work with the main boom

Extending/ In order to telescope a telescope section you must first move the tele-
retracting tele- scoping cylinder into the foot section of the corresponding telescope
scoping cylinder section and lock it there.
and locking
You can select the locking before the telescoping cylinder has reached the
corresponding foot section. The crane control then locks the telescoping
cylinder in the first foot section which is reached when extending/
retracting.
That is why the exact time of the selection depends on whether the tele-
scoping cylinder:
– is to be moved and locked with an extended main boom
– or is to be moved and locked with a fully retracted main boom.

Before you telescope the telescoping cylinder with the selection, the
following prerequisites must be fulfilled:

– The telescope section in which the telescoping cylinder is located is

j locked, the green indicator lamp Telescope section locked illuminates.
– The lock between the telescoping cylinder and telescope section has
i been released, the red indicator lamp Telescoping cylinder unlocked illumi-
nates.

Moving and locking the telescoping cylinder with the main boom extended
This case applies when you move the telescoping cylinder back after
extending or retracting in order to telescope the next possible section.

Before you extend or retract the telescoping cylinder, the prerequisites at

the beginning of this chapter must be fulfilled.

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the telescoping cylinder; to do this, move the control lever in the
corresponding direction.
If the telescoping cylinder is moved without the telescope section, the

H
crane control always switches automatically to fast speed.

The following actions run parallel; you do not need to interrupt the
extending/retracting of the telescoping cylinder.

The telescope section begins to extend and the corresponding display

g lamp (e. g. Telescoping cylinder in foot section IV) flashes for the time being.
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As soon as this display lamp goes out, you can select the locking of the
telescoping cylinder.

• Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescoping cylinder locked flashes; the crane
h control thus confirms the selection.

While you are moving the telescoping

cylinder, the lower right status display for
the current extended length of the teles-
coping cylinder continuously changes
TELESCOPE STATUS (e. g. L: 7.63 m).
– 0 – 0 – 0 – 0 – In this way you can directly follow the
SEMI-AUTOMATIC CONTROL extending/retracting on the status display.

TELE: T3 L: 7.63 m

When the telescoping cylinder retracts into a foot section, the corres-
f ponding display lamp flashes (in the example Telescope cylinder in foot
section III).

The crane control now reduces the telescoping speed specified by the
control lever and initiates the locking process owing to the selection made:

1. Once the locking point has been reached, the corresponding display
f lamp (e. g. Telescoping cylinder in foot section III) lights up.

2. The locking pins are extended, and the red indicator lamp Telescoping
i cylinder unlocked flashes as long as the locking pins are moving.

3. As soon as the telescoping cylinder is locked, the green indicator lamp

h Telescoping cylinder locked lights up.
The red warning lamp Telescoping cylinder unlocked goes out.

• Bring the telescoping process to an end, and move the control lever to
the central position.
The retracting/extending of the telescoping cylinder with the main boom
extended has thus been finished.

Moving and locking the telescoping cylinder with the main boom fully

H
retracted

As long as the unlocked telescoping cylinder is situated in a foot section,

the crane control reduces telescoping speed specified by the control lever.
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Operating Instructions GMK 6300 2 084 548 en 12 - 63
Crane operation
12.3 Crane work with the main boom

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the telescoping cylinder; to do this, move the control lever in the

H
corresponding direction.

The following actions run parallel; you do not need to interrupt the
extending/retracting of the telescoping cylinder.

As long as the telescoping cylinder is situated in a foot section, the corre-

g sponding display lamp (e. g. Telescoping cylinder in foot section IV) flashes.
If the telescoping cylinder leaves this foot section, the display lamp goes
out and the display lamp of the next foot section flashes simultaneously
(e. g. Telescoping cylinder in foot section III).

If the display lamp of the foot section in which you would like to lock the
f telescoping cylinder (e. g. Telescoping cylinder in foot section III) is flashing,
you must select the locking within 3 seconds.

• Switch the rocker switch Select locking/unlocking to the central position to

.
H
do this.

Once you have waited longer than 3 seconds before you select the
locking, the telescoping cylinder has moved past the locking point. In this
case stop the extending/retracting (move control lever into the central po-
sition) and move the telescoping cylinder in the opposite direction until
the display lamp of the corresponding telescope section flashes again.
Now select the locking within 3 seconds.

The green indicator lamp Telescoping cylinder locked flashes; the crane
h control thus confirms the selection and initiates the locking process:

1. Once the telescoping cylinder has reached the locking point, the corre-
f sponding display lamp (e. g. Telescoping cylinder in foot section III) lights up.

2. The locking pins are extended, and the red indicator lamp Telescoping
i cylinder unlocked flashes as long as the locking pins are moving.

3. As soon as the telescoping cylinder is locked, the green indicator lamp

h Telescoping cylinder locked lights up.
The red indicator lamp Telescoping cylinder unlocked goes out.

• Bring the telescoping process to an end, and move the control lever to
the central position.
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 Crane operation
12.3 Crane work with the main boom

The retracting/extending of the telescoping cylinder with the main boom

fully retracted has thus been finished.

The section “Moving and locking telescoping cylinder with completely retracted
main boom” applies for our example. All telescope sections are fully retracted,
thus the telescoping cylinder is situated in adjacent foot sections.
The telescope cylinder should be moved from foot section IV directly to foot
section III.
The display lamps in this section conform to actuality in our example. You can
accept this section as an example.
New end state: – Telescoping cylinder is locked in foot section III –
The next objective: – Unlock telescope section III –

Unlock Before you can telescope a telescopic section, you have to unlock it. You
telescope section can only unlock the telescope section in which the telescoping cylinder is
situated. The locking pins of this telescope section are retracted by the
mechanism on the telescoping cylinder when unlocking.

Prerequisites for the unlocking of the telescope section:

– The telescoping cylinder is locked to the telescope section; the green
h indicator lamp Telescoping cylinder locked illuminates.
– The telescope section is locked; the green indicator lamp Telescope
j
H
section locked illuminates.

If these prerequisites are not fulfilled, the unlocking procedure is on the

one hand blocked by a hydraulic/mechanical switch for safety reasons
and is on the other hand not released by the crane control.

Unlocking telescope section

• Select the unlocking of the telescopic section; to do this, press the
. rocker switch Select locking/unlocking upward.

Now the red indicator lamp Telescope section unlocked flashes; the crane
j control thus confirms the selection.

As soon as the locking pins move, the green indicator lamp Telescope
j section locked flashes in addition.
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12.3 Crane work with the main boom

When the locking pins are retracted, the red indicator lamp Telescope
j section unlocked lights up.
The green indicator lamp Telescope section locked goes out.

As soon as the telescope section is unlocked,

the status display on the Crane control display
changes; the numerical value for the unlok-
ked telescope section is now in brackets.
TELESCOPE STATUS
The unlocked telescope section (e. g. T3) is
– 0 – 0 > 0 < 0 – displayed at the lower left.
SEMI-AUTOMATIC CONTROL To the right, its current telescope status in
percent (e. g. L: 0 %).
TELE: – – L: 7.63 m

H
Now the telescope section is unlocked and can be telescoped.

If the locking process is not finished after about 10 seconds (warning

lamp Telescoping cylinder unlocked is not on), you can not retract the locking
pins because they are under load.
Relieve the locking pins by slowly retracting or extending the main boom
until the green indicator lamp Telescope section locked also flashes.

S
Risk of damaging the boom system!
If extending and retracting several times does not cause unlocking, you
must not move the telescoping cylinder any further against the stop.

If extending and retracting several times does not unlock the telescoping
cylinder:
– Lock the telescope section by pressing the Select locking/unlocking rocker
switch up and moving the control lever.
– Start the locking process again by pressing the Select locking/unlocking
rocker switch down and moving the control lever.
The process of unlocking applies to all telescoping procedures; thus the red indi-
j cator lamp Telescope section unlocked would also now illuminate in our example.
Telescope section III is unlocked; the numerical value for telescope section III
would correspondingly appear on the display in brackets.
The unlocked telescope section III would be displayed as T3 in the lower line
and the current telescoping of 0 % next to it.
Present end state: – Telescope section III unlocked –
The next objective: – Extend telescope section III to 100 % –
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12.3 Crane work with the main boom

Telescoping tele-
scope section to

H
fixed length and
lock

Read the sections concerning the fixed, intermediate, and telescoping

lengths, the telescoping sequence and the functioning of the control lever
at the beginning of this chapter and observe the notes for telescoping;
➠ p. 12-47.
If you extend several telescope sections or want to work on a fixed length,
you must extend the telescope section to a fixed length and lock it there.
You can select the locking before the telescope section has reached the
fixed length. The crane control then locks the telescope section at the first
fixed length which is reached. Since every telescope section has three
fixed lengths, the point in time of the selection depends on whether the
telescope section:

– is to be locked at the fixed length reached first

– or is to be locked at the fixed length after the next.
Before you telescope the telescope section with the selection, the fol-
lowing prerequisites must be fulfilled:

– The telescoping cylinder is situated in the foot section of the telescope

f section which is to be telescoped. The corresponding display lamp
(e. g. Telescoping cylinder in foot section III) illuminates.
– The telescoping cylinder is locked to the telescope section which is to
h be telescoped; the green indicator lamp Telescoping cylinder locked illumi-
nates.
– The telescope section in which the telescoping cylinder is located is
j unlocked, the red indicator lamp Telescope section unlocked illuminates.

Locking the telescope section at the first fixed length reached

This case applies if you for example extend a fully retracted telescope
section to the middle fixed length and want to lock it there.

Before you telescope a telescope section, the prerequisites at the

beginning of this chapter must be fulfilled.

• Check if the indicator lamp Telescoping gear switched on is on.

T • Move the telescoping cylinder; to do this, move the control lever in the
corresponding direction.
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Crane operation
12.3 Crane work with the main boom

H The following actions for telescoping run parallel; you do not need to
interrupt the telescoping.

While you are telescoping the telescopic

section, the numerical value in brackets and
the value at the lower right on the display
continuously change.
TELESCOPE STATUS
– 0 – 0 > 20 < 0 –
SEMI-AUTOMATIC CONTROL In this way you can directly follow the tele-
scope status of the telescope section
TELE: T3 L.: 20.3 %
(e. g. T3) on the status display.

If the initial position was an intermediate length before telescoping, you

can immediately select the locking of the telescope section.

If the initial position was a fixed length before telescoping, you must wait
until the percent value for the telescope status has risen by 2 % before
selecting.

• Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescope section locked flashes; the crane control
j thus confirms the selection.

When the telescoping cylinder reaches the next fixed length, the crane
control reduces the telescoping speed specified by the control lever and
initiates the locking process owing to the selection made:

1. Shortly before reaching the locking point, the locking pins are pushed
j out and the red indicator lamp Telescope section unlocked also flashes.

2. The locking pins are pushed out at the locking point and the telescopic
j section is set down on the locking pin.
The green indicator lamp Telescope section locked first switches from flash-
ing to illuminating when this process has been completed.
The red indicator lamp Telescope section unlocked goes out.
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12.3 Crane work with the main boom

S
Be careful not to damage the telescoping cylinder!
Move the control lever until the green indicator lamp Telescope section lok-
ked is no longer flashing and is on. If necessary, move the telescope sec-
tion from side to side somewhat until the indicator lamp illuminates.
Only then is the locking process completed and the telescope section is
joined in a power dozing manner with the telescope section above it.
In this way you prevent the load from affecting the telescoping cylinder
when the crane is in operation and enable the release of a load for fixed
lengths.

• Bring the telescoping process to an end, and move the control lever to
the central position.
As soon as the telescope section is locked,
the numerical value for the telescope section
is no longer in brackets.
Both dashes are displayed again on the left
TELESCOPE STATUS
side of the lower line.
– 0 – 0 – 50 – 0 – The display to the lower right again changes
SEMI-AUTOMATIC CONTROL to the current extended length of the tele-
scoping cylinder (in the example L: 7,24 m).
TELE: – – L.: 7.24 m

Locking the telescope section at the next fixed length

This case applies when you want to telescope a telescope section from
e. g. 0 % to 100 % or vice versa.
Before you telescope a telescope section, the prerequisites at the
beginning of this chapter must be fulfilled.
• Check if the Telescoping gear switched on indicator lamp is on and tele-

H
T scope the telescope section.

The following actions for telescoping run parallel; you do not need to
interrupt the telescoping.

While you are telescoping the telescopic

section (e. g. telescope section III), the nume-
rical value in brackets and the value at the
lower right on the display continuously
TELESCOPE STATUS
change.
– 0 – 0 – 55 – 0 –
• Follow the telescoping process on the
SEMI-AUTOMATIC CONTROL status display (e. g. L: 60.4 %).
TELE: T3 L.: 60.4 %
• Wait until the first fixed length for this tele-
scope section is exceeded (e. g. up to
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55 %, the first fixed length for T3 is at 50

%).

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Operating Instructions GMK 6300 2 084 548 en 12 - 69
Crane operation
12.3 Crane work with the main boom

Now you can select the locking.

Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescope section locked flashes; the crane control
j thus confirms the selection.

When the telescoping cylinder reaches the next fixed length, the crane
control reduces the telescoping speed specified by the control lever and
initiates the locking process owing to the selection made:

1. Shortly before reaching the locking point, the locking pins are pushed
j out and the red indicator lamp Telescope section unlocked also flashes.

2. The locking pins are pushed out at the locking point and the telescopic
j section is set down on the locking pin.
The green indicator lamp Telescope section locked first switches from flash-
ing to illuminating when this process has been completed.
The red indicator lamp Telescope section unlocked goes out.

S
Be careful not to damage the telescoping cylinder!
Move the control lever until the green indicator lamp Telescope section
locked does not flash any more. If necessary, move the telescope section
from side to side somewhat until the indicator lamp illuminates.
Only then is the locking process completed and the telescope section is
joined in a power dozing manner with the telescope section above it.
In this way you prevent the load from affecting the telescoping cylinder
when the crane is in operation and enable the release of a load for fixed
lengths.

• Bring the telescoping process to an end, and move the control lever to
the central position.
As soon as the telescope section is locked,
the numerical value for the telescope section
is no longer in brackets.
Both dashes are displayed again on the left
TELESCOPE STATUS
side of the lower line.
– 0 – 0 – 100 – 0 – The display to the lower right again changes
SEMI-AUTOMATIC CONTROL to the current extended length of the tele-
scoping cylinder (e. g. L: 11.91 m).
TELE: – – L: 11.91 m
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12.3 Crane work with the main boom

In our example, the section “Locking the telescope section at the fixed length
reached first” applies. Telescope section III should be extended to 50 %, so you
can select locking as soon as the telescope section has been telescoped approx.
2 % from initial state.
The values in this section are suited to the example. You can accept this section
directly as an example.
Present end state: – Telescope section III extended to 50 % –
New objective: – Extend telescope section II –

In order to reach the end position of the example from page 12-56, you would
have to now extend telescope section II first. You would have to repeat the sec-
tions which are refered to in items 2 to 5 of the example on page 12-56. The
steps are the same as with extending telescope section III. The initial and end po-
sitions would simply have to be changed for telescope section II and the status dis-
plays would change accordingly. This is the case for every other telescoping process.

You can also telescope a telescope section without selecting the lock,
as described in the next section.

Telescoping tele- Before you telescope a telescope section to an intermediate length,

scope section to the following prerequisites must be fulfilled:
intermediate
length
– The telescoping cylinder is situated in the foot section of the telescope
V section which is to be telescoped. The corresponding display lamp
(e. g. Telescoping cylinder in foot section I) illuminates; ➠ Extending/
retracting telescoping cylinders and locking them, p. 12-62.
– The telescope section in which the telescoping cylinder is located is
j unlocked, the red indicator lamp Telescope section unlocked illuminates;
➠ Unlocking telescopic section, p. 12-65.
– The telescoping cylinder is locked to the telescope section; the green
h indicator lamp Telescoping cylinder locked illuminates.
• Check if the Telescoping gear switched on indicator lamp is on and tele-
T scope the telescope section.
While you are telescoping the telescope
section, the status display on the Crane
control display changes for the current tele-
scope status (e. g. for telescope section I).
TELESCOPE STATUS
> 37 > 50 – -0 – Extend the telescope section until the status
SEMI-AUTOMATIC CONTROL
display shows the desired intermediate
length in percent (e. g. L. 37 %).
TELE: T1 L.: 37 %
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Crane operation
12.3 Crane work with the main boom

The telescope status given in our example is therefore reached. The main boom
is now at the intermediate length (37 / 50 / 50 / 0) and you can lift according to
the corresponding capacity chart.

To reach on-the-road mode you must proceed in the reverse order, locking tele-
scope sections I, II, III and IV one after the other and then the telescoping cylin-
der in telescope section I.

Locking telescope section

If you retract the main boom fully without having selected the locking
during the last telescoped telescope section, you must lock this telescope
section before on-road driving.

• Switch the rocker switch Select locking/unlocking to the central position.

. The green indicator lamp Telescope section locked flashes; the crane control
j thus confirms the selection.

As soon as the locking pins move, the red indicator lamp Telescope section
j unlocked flashes.

When the locking pins have reached the end point, the green indicator
j lamp Telescope section locked illuminates.
The red warning lamp Telescope section unlocked goes out.

When all telescope sections are locked, the

two dashes are displayed on the bottom left.

The display to the lower right again changes

TELESCOPE STATUS
to the current extended length of the tele-
– 0 – 0 – 0 – 0 scoping cylinder (e. g. 0.00 m when the tele-
SEMI-AUTOMATIC CONTROL scoping cylinder is in the foot section of
telescope section I).
TELE: – – L: 0.00 m

H If you have retracted the main boom for on-road driving, you must now
lock the telescoping cylinder in telescope section I so that the axle loads
are in accordance with the values in the Driving mode table.
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Telescoping with To telescope to fixed lengths you can also use the fully automatic control
fully automatic (teleautomatic control). To do this enter the desired telescope status in
control a submenu on the display crane control system and then steer the control
lever out in the direction in which the telescoping should go. The locking
and unlocking processes are carried out automatically by the crane con-

H
trol system.

Before you use the fully automatic telescoping, you must have read the
entire telescoping gear section so that you can comprehend the locking
and unlocking processes that the crane control carriers out. With the fully
automatic control you can telescope the individual telescope sections
only to the 0 %, 50 % and 100 % lengths.
If you want to telescope one of the telescope sections to another length
(e. g. 70 %), you can telescope with the fully automatic control at first to
the next locking point (e. g. 50 %) and then telescope the last telescope
section further with the semi-automatic control (e. g. to 70 %).

You can only activate the submenu for entering the desired telescope
status if
– the Crane control display is in the Display telescope status and teleautomatism
menu and
– the telescoping gear is activated.
You can start the sub-menu independent of the current telescope status.

• Switch on the menu Display telescope status on the display if necessary.

• Switch the rocker switch Select locking/unlocking to the central position.
. • If necessary switch on the telescoping gear. The Telescoping gear switched
T on indicator lamp must light up.
Press the membrane switch Display telescope status and teleautomatic.
ä Now the sub-menu for the entry of the desired telescope status appears
on the Crane control display.

The entry SET TELEAUTOMATIC is in the

first line.
Telescope sections T1 to T5 are in the
second line, and in the line below this, the
SET TELEAUTOMATIC numerical value 0 is displayed for every tele-
> T1 < T2 – T3 – T4 – scope section.
– ● – 0 – 0 – 0 – In addition, the entry request (●) flashes on
the numerical value for T1.
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Crane operation
12.3 Crane work with the main boom

You can enter the desired telescope status for every telescope section
with the membrane switches Entry and view, located to the right, next to
the display.

You can only enter the value on which the entry request flashes anew.

• Press one of these two membrane switches as many times as necessary

+ until the entry request flashes on the numerical value which you would
like to enter.
* • You can select a higher or lower fixed length with these two membrane
: switches. The following values are available:
For T1 : 0 50 100
< For T2 : 0
For T3 : 0
50 100
50 100
For T4 : 0 50 100
• Press this membrane switch in order to switch off the menu.
ö The display switches to the Display telescope status and teleautomatism menu.
• Once you have entered the desired value, you have to start the teleauto-
Ö
H
matic. Press this membrane switch to do this.

If the four green light diodes above the first line flash three times after the
teleautomatic has been started, you have entered a telescoping which is
not permissible according to the Lifting capacity table. Furthermore, the
display shows the submenu for entering and you can enter a new per-
missible telescoping.

If you have entered a permissible telescope status, the teleautomatic is

started and the display changes to sub-menu Teleautomatic.

The menu shows the entry TELESCOPING in

the first line.
The current telescope status is displayed in
the second line.
TELESCOPING The third line shows the telescope status
– 100 – 0 – 0 – 0 – which you entered before. This telescope
– 60 – 100 – 100 – 100 – status now sets the crane control as the
objective.
TELE: – – L: 10.90 m The last line of the display is exactly as in
the Display telescope status and teleautomatism
menu.
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 Crane operation
12.3 Crane work with the main boom

The crane control now calculates the necessary telescoping sequence.

In order to start the telescoping, you must move the control lever in the
corresponding direction and hold it fast:

– If you want to extend first, move the right control lever to the right.
– If you want to retract first, move the right control lever to the left.
The crane control telescopes fully automatically only until a change of
direction is necessary; then the telescoping is interrupted and you must

H
move the control lever in a different direction.

The other extension of the control lever for changing the direction is only
necessary for extending a telescopic part. The telescoping cylinder moves
automatically in both directions between the telescopic parts when chang-
ing, irrespective of the direction steered by the control lever.
You can leave the menu at any time by pressing the rocker switch Select
. locking/unlocking either upward or downward.

You can change from the menu Display telescope status and teleautomatism
ä back to the submenu for entering the desired telescope status at any time.
To do this press the membrane switch Display telescope status and teleauto-

H
matism once.

You can also change to the submenu for entering the telescope status and
enter a new telescope status whilst the crane control carries out the fully-
automatic telescoping when, e. g. you have entered an incorrect telescope
profile.

Example of telescoping with teleautomatic

Assuming the current telescope status is

100 / 0 / 0 / 0, the desired telescope status should
be 50 / 100 / 100 / 100 and the telescoping cylin-
TELESCOPING der is locked in foot
section I.
– 100 – 0 – 0 – 0 –
The status display would then correspond to the
– 50 – 100 – 100 – 100 –
illustration to the left and the following tele-
TELE: – – L: 10.90 m scoping sequence is yielded:
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12.3 Crane work with the main boom

– T1 retract to 0 %
– T4 extend to 100 %
– T3 extend to 100 %
– T2 extend to 100 %
– T1 extend to 50 %

• Move the right control lever to the left in order to retract and hold it fast.

While you are holding the control lever, the crane control automatically carries
out the necessary locking and unlocking processes and fully retracts telescope
section I.

You can follow the process on the display and

the indicator and display lamps.

When the telescopic part is retracted (Value in

TELESCOPING
brackets = 0), the crane control system moves
– 0 – 0 – 0 – 0 – the telescoping cylinder into the next telescopic
– 60 – 100 – 100 – 100 – part to be extended (telescopic part IV) and
TELE: – – L: 1.10 m locks the telescoping cylinder into it.

When the display lamp for the telescoping cylinder in the foot section IV and the
gh indicator lamp Telescoping cylinder locked illuminates, the crane control system
stops all processes, as a change of direction in the telescoping is necessary.

• Move the right control lever to the right in order to extend and hold it fast.

While you are holding the control lever, the crane control automatically carries
out the necessary locking and unlocking processes and fully extends telescope
section V to II and telescope section I to 60 %.

When the specified telescope status has been re-

ached, the display changes to the menu Display
telescope status and teleautomatism and displays
TELESCOPING the current telescope status.
L: 9.31> m 50 < 0 – 0 – 0 –
SEMI-AUTOMATIC CONTROL

TELE: – – L: 6.54 m

H
The telescoping with fully automatic control is thus completed.

If you want to extend telescope section I to 70 %, for example, you can now
extend this telescope section further with the semi-automatic control.
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Lowering the In order to lower the partly extended boom to an angle smaller than that
main boom for permitted in the operating area, you must enter an SLI rigging code. The
maintenance rigging codes are found in the corresponding rigging curves of the Lifting

H
capacity table.

If the main boom is fully retracted and no load is raised, the SLI switches
automatically to the rigging code when the working range is left.

• Put down the load.

• If the main boom is not fully retracted, enter the appropriate SLI code
for the current rigging mode of the truck crane according to the Lifting
capacity table.
• Turn the superstructure in the necessary direction;
➠ Slewing with rigged counterweight, p. 13-61.

G
Risk of overturning with an outrigger span of 8.70 x 2.68 m!
With an outrigger span of 8.70 x 2.68 m the main boom may be set down
only in the 0° forwards or 180° to the rear positions.
If you place the boom to the side with this outrigger span, the truck crane
tips over even with the boom retracted.

G
Risk of overturning if SLI is overridden!
If the SLI switches off the lowering of the boom, the truck crane is in a
status in which the main boom can not be placed in a horizontal position
(e. g. a raised load or extended too far).
Do not override the SLI, put down the load if necessary and retract the
main boom.

• Lower the main boom to the horizontal position.

Telescoping the • Enter the corresponding SLI rigging code for the current rigging mode
main boom in of the truck crane according to the Lifting capacity table.
the horizontal
The maximum permitted telescope status for the current rigging mode
position
(counterweight, outrigger span, direction of rotation) is determined by the
SLI rigging code. If this telescope status is exceeded, the SLI switches off
the extending function.
• Put down the load.
• Extend the main boom only so far that the SLI switches off the exten-

H
ding function.
01.02.2000

If you continue to extend the main boom after an SLI shutdown, you can
get into areas in which you can not retract or raise.

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Crane operation
12.3 Crane work with the main boom

12.3.7 Fast speed

G
Accidents may occur if movements are suddenly accelerated!
Reduce the engine speed before switching on fast speed so that the mo-
vements are not accelerated too intensely. The truck crane could start to
rock and then overturn.

You can switch to fast speed for some crane movements in order to reach
a faster working speed. Depending on the crane movement, the fast
speed is switched to in different ways:
– with the foot-operated switch Fast speed derricking gear/telescoping gear or
– the foot-operated switch Fast speed hoisting gear.
The fast speed derricking gear/telescoping gear foot pedal (arrow) is used to
switch to fast speed for the crane movements telescoping and raising the
boom.

H During lowering of the boom, fast speed mode only supports the start-up
of the derricking procedure from steep boom positions; it does not increa-
se the derricking speed. When the boom extension or luffing jib (both ad-
ditional equipment) are in operation, the crane control blocks the fast
speed for the derricking gear; ➠ Derricking gear – high-speed, p. 12-42.

S
Make sure that the lifted load is no more than 50% of the maximum load
according to the. Lifting capacity table (degree of utilization maximum
50 %) before you move the hoists with fast speed!

With the foot-operated switch Fast speed hoisting gear you activate the fast
speed for the crane movement Raising/lowering main hoisting gear and
raising/lowering auxiliary hoist gear (additional equipment).

H When the luffing jib (additional equipment) is in operation the crane con-
trol blocks the fast speed for the auxiliary hoist.
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 Crane operation
12.3 Crane work with the main boom

S
Danger of build-up of slack rope!
Take care that slack does not form when the hoist is lowered!

H The slewing gear cannot be driven in fast speed.

12.3.8 Menus on the crane control display

You can call up various menus on the Crane control display. You receive
information about the power units from and can sometimes enter values
in these menus; error messages are also displayed here. You can select
five different menus directly:
– the menu Display states,
– the menu Power unit speeds/critical load control,
– the menu Control lever emergency operation,
– the menu Display telescope status and teleautomatism,
– the menu Enter telescope status after emergency operation.

Error messages and a sub-menu Emergency operation are displayed auto-

matically and with priority; ➠ Display of an error message, p. 12-87.
Whenever further sub-menus are arranged under a menu, you can call
these up from the open menu.

Not all menus are described in this section:

Menu Control lever emergency operation; ➠ p. 15-72.
Menu Enter telescope status after emergency operation; ➠ p. 15-80.
Sub-menu Emergency operation; ➠ p. 15-74.

Menu Display In this menu you can display the operating hours of all power units and
states possibly read off existing malfunctions. The operating hours of the crane
engine correspond to the superstructure operating hours, which are
specified in the maintenance manual.

• Select the menu; press the membrane switch Display states once to do so.
>
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Operating Instructions GMK 6300 2 084 548 en 12 - 79
Crane operation
12.3 Crane work with the main boom

The crane control display now switches to

the menu Display states and in the uppermost
line the message STATUS REPORT appears.
STATUS REPORT
The most recently selected menu item (here
DERRICKING GEAR derricking gear) appears in the second line.
STATUS : O.K
TIME : 3.27 h

You can call up different menu items after each other by repeatedly pres-
> sing the membrane switch Display status or

you can use both these membrane switches to switch between menu
: items in increasing or decreasing order.

< The following menu items are available:

– Engine (crane engine)
– System (for the crane control)
– Main hoist
– Auxiliary hoist (only with additional equipment)
– Derricking gear
– Telescoping gear
– Locking system (locking pins in the telescoping gear)
– Slewing gear
– Secondary power units (counterweight lifting gear/locking pins,
superstructure lock, incline crane cab)
– Critical load control

• Select the desired menu item (e. g., main hoist).

:
<
The total operating hours of the selected
power unit are displayed in the last line.
In this example the total operating time of
the main hoist amounts to 168 hours and
STATUS REPORT
27 minutes.
MAIN HOIST
STATUS : O.K The third line displays the status of the
selected power unit. There are two different
TIME : 168.27 h
status displays:
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 Crane operation
12.3 Crane work with the main boom

Status Significance
display

There are not malfunctions, the power unit is released by

O.K the crane control without restrictions.

One or more error messages have been acknowledged for

ERROR
this power unit and stored in the sub-menu Memory error.

Memory error sub-menu

You can call up the sub-menu memory error from this status display in
order to see already acknowledged error messages again.

Press this membrane switch next to the status display to do so.

+ The display now changes to the sub-menu Memory error.

The entry MEMORY ERROR is in the top line;

to the right of it is the number of the error
which was acknowledged (e. g. 1).
The second line shows the power unit
MEMORY ERROR
concerned (e. g. main hoist)
MAIN HOIST
J3502 : 01000000 Both lower lines display the error exactly like
the corresponding error message which was
acknowledged; ➠ Display of an error message,
STATUS : 01000001
p. 12-87.

You can call up further existing errors with both of these membrane
: switches next to the display. The errors are numbered consecutively and
the corresponding number of the error is displayed at the top right.
< Once the error with the number 1 has been reached and you press the
upper membrane switch again, the display changes back to the menu
Display states.

*öÖ To leave the Memory error submenu you can press one of the adjacent
membrane switches.
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Operating Instructions GMK 6300 2 084 548 en 12 - 81
Crane operation
12.3 Crane work with the main boom

Menu items with special displays

In the Engine menu item, the current engine
speed of the crane engine is displayed in the
third line. In this example the current engine
speed is 1000 revolutions per minute.
STATUS REPORT

MOTOR The speed display is updated when the

STATUS : 1000 UPM speed of the crane engine changes.

TIME : 227.35 h

If there is an error, the message ERROR appears as with the other menu

H
items in the third line.

You can switch on this display when setting a constant engine speed if
you would like to set the constant engine speed to a certain value
(e. g. 1300 rpm); ➠ Setting constant motor speed, p. 12-89.

The menu item Locking system gives informa-

tion on the mechanism on the head of the
telescoping cylinder and its locking pins.

STATUS REPORT In this menu item the last line shows how
LOCKING SYSTEM frequently the mechanism has controlled the
STATUS : O.K cycle Unlock telescope section.

CYCLES : 1727

The intervention of the critical load control

is displayed directly under the menu item
Critical load control (primarily for servvice
purposes).
STATUS REPORT
CRITICAL LOAD CONTROL In the third line there are three different entries:
STATUS : ON ON critical load control switched on
OFF critical load control switched off
❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ❘❘❘ ERROR error has occured

The bar graph in the last line shows to which percentage the performance
of the hydraulic pumps is throttled to (1 box is approx. 5 %; the diagram
shows approx. 40 %). The display is updated constantly. The bar display
shows 100 % if the critical load control CLC is switched off.
After STATUS the message ERROR appears if there is an error message.
The menu Display states remains switched on until you select another
@üäÄ
01.02.2000

menu with the corresponding membrane switch or until there is an error

message.

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 Crane operation
12.3 Crane work with the main boom

Menu Dis- In this menu you can see the current telescope status and the extended
play length of the telescoping cylinder.
telescoping
status and te-
leautomatic
• Select the menu. Press the membrane switch Display telescope status and
ä teleautomatic.
The display Crane control now changes in
the menu Display telescope status and teleauto-
matic; in the top line the message TELE-
SCOPING appears.
The display changes depending on the tele-
scoping status; this is described in more
– 0 – 0 > 20 < 0 – 0
detail in the section Telescoping gear;
TELESCOPING
➠ Example of procedures when telescoping,
TELE: T3 L:20.3% p. 12-56.

The menu Display telescoping status and teleautomatic remains switched on

@üäÄ until you select another menu with the corresponding membrane switch
or until there is an error message.

Power unit In this menu, you can enter the maximum speed of all power units.
speeds/critical
load control menu

• Select the menu; press the membrane switch Power unit speeds/critical
@ load control once to do this.
The crane control display now switches to
the menu Power unit speeds/critical load control;
the entry SPEED appears in the uppermost
line.
SPEEDS
SLEWING GEAR The most recently selected menu item (here
NORMAL : 95 % ← slewing gear) appears in the second line.

POINT : 45 %

You can call up different menu items after each other by repeatedly pres-
@ sing the membrane switch Display status or

You can use both these membrane switches to switch between menu
: items in increasing or decreasing order.

<
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Operating Instructions GMK 6300 2 084 548 en 12 - 83
Crane operation
12.3 Crane work with the main boom

You can call up the following menu items:

– Main hoist
– Auxiliary hoist (additional equipment)
– Derricking gear
– Telescoping gear
– Slewing gear
– Critical load control; ➠ p. 12-85

: Select the desired menu point (e. g., Telescoping gear).

< Displaying entered speeds

The menu displays what percent of the

maximum speed is set as maximum speed.
The displayed value behind the following
applies here:
SPEEDS
– NORMAL for operation with main boom
TELESCOPING GEAR
– POINT for operation with luffing jib, boom
NORMAL : 95 % ←
extension or telescopic swing-away lattice
POINT : 40 % extension (all additional equipment)

H The arrow to the right always refers to the value with which the crane
control calculates at the moment.

As soon as the lattice extension is electrically

connected, the arrow next to the value for
TOP SECTION changes and the maximum
speed of the auxiliary hoist, derricking gear,
SPEEDS telescoping gear and slewing gear is redu-
TELESCOPING GEAR ced to 70%.
NORMAL :––
←
POINT : 40 %

Entering the maximum speed

Before you can enter the new value for the maximum speed, you must
switch to entry mode.

• Press the Entry mode membrane switch to switch on the entry mode for
+ NORMAL.
01.02.2000

• Press this membrane switch to switch on the entry mode for POINT.
*

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 Crane operation
12.3 Crane work with the main boom

The entry request flashes in front of the two

numerical values (● e. g. with NORMAL, in
front of 95 %).
You can only newly enter the value which has
SPEEDS
the entry request in front of it.
TELESCOPING GEAR You can enter values from 10 % to 100 % for
NORMAL : ● 95 % ← NORMAL.
For luffing jib operation (additional equip-
POINT : 40 %
ment), the entry for POINT is limited to 70 %
(except for the main hoist).

• Press this membrane switch if you want to increase the value.

: Every time the button is pressed, the value increases by 5 %.
• Press this membrane switch if you want to decrease the value.
<
H
Every time the button is pressed, the value decreases by 5 %.

When you hold down the membrane switch, the value continuously
changes by 5 % intervals.

• Press this membrane switch if you want to set the value back to the
ö initial state.
Once you have entered the desired value, you have to save it.

H
• Press this membrane switch to save the new maximum speed.
Ö
The newly set speed is accepted by the crane control only if you have
saved it.
You can also enter both values (NORMAL and TOP SECTION) anew and
then save them together with enter.
You can no longer set the entry back with ESC after saving.

Switching on/off critical load control

Press the membrane switch Power unit

speeds/critical load control until the entry
CRITICAL LOAD CONTROL appears in
the second line.
SPEEDS
CRITICAL LOAD CONTROL Whether the critical load control is switched
STATUS : ON on (ON) or off (OFF) is displayed in the third
line behind STATUS.
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Operating Instructions GMK 6300 2 084 548 en 12 - 85
Crane operation
12.3 Crane work with the main boom

Before you can change the setting, you have to change to the entry mode.

• To do this press one of the two right membrane switches Entry and view,
+ Display and hold it down briefly.
Now the entry request flashes in front of the
entry in the third line (●).

Now you can change the entry.

SPEEDS

CRITICAL LOAD CONTROL

STATUS : ● ON

• Press this membrane switch in order to switch off the critical load
< control; the entry OFF appears in the third line.
• Press this membrane switch in order to switch on the critical load
: control; the entry ON appears in the third line.
Press this membrane switch to save the changed entry.
Ö The menu Power unit speeds/critical load control stays on until you select
>üäÄ another menu with the corresponding membrane switch or until there
is an error message.

Access emergency If the crane control no longer receives signals from a length indicator or
operation menu proximity switch, if the received signals from the locking pin statuses are
unrealistic, or if the crane control recognizes an error in a valve for the
locking mechanism, the following crane movements are switched off:
– retracting and extending,
– locking and unlocking telescoping cylinders,
– locking and unlocking telescope sections.

Furthermore, the following lamps have no function:

– Telescoping cylinder at locking point,
89 – Telescoping cylinder in foot section I to IV,
Vefg – Telescopic part locked, telescopic part unlocked,
jj – Telescoping cylinder locked Telescoping cylinder unlocked.
hi A corresponding error message is displayed on the Crane control display.

• Acknowledge the error message.

Ö
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 Crane operation
12.3 Crane work with the main boom

If the Display telescope status and teleautomatism menu was selected before
the error message occurred, the crane control switches directly to the
Access emergency operation menu.
The menu can be recognised by the messa-
ge ACCESS EMERGENCY OPERATION in the
third line.
The three-digit numeric code in the second
TELESCOPING GEAR
line displays which type of error has occurred;
STATUS :0 0 1 ➠ Deciphering the numeric code, p. 15-74.
ACCESS EMERGENCY OPERATION
In the last line there is the message
KEYCODE : __
KEYCODE and the entry request (—) flashes.

To start the emergency program, a key code must be entered in this line:
• Press the following membrane switches next to the display one after
the other:

Ö : < Ö

H
Each correct entry is confirmed on the display with a star (*).

If you press the wrong membrane switch more than once, the entries
which have already been confirmed (*) will also be erased and the key
combination must be entered again.

When the key combination has been correctly entered, the crane control
commences emergency operation and the following lamps are reactiva-
ted;
– Telescoping cylinder at locking point,
89 – Telescopic part locked, telescopic part unlocked,
jj – Telescoping cylinder locked Telescoping cylinder unlocked
hi
Display of an The crane control shows current errors with priority on the display Crane
error message control. As soon as there is an error, the display switches to the Error
message display.
The message ERROR MESSAGE appears in
the top line.
The power unit concerned is displayed in the
second line (e. g. the telescoping gear).
ERROR MESSAGE
The third line shows the designation of the
TELESCOPING GEAR part on which a malfunction occurred. Be-
hind that is a numerical code which descri-
01.02.2000

J3502 :00000010
bes the cause of the error.
STATUS :00000001

Operating Instructions GMK 6300 2 084 548 en 12 - 87

Crane operation
12.3 Crane work with the main boom

The numerical code in the last line describes the area in which the error
occurred.
Further information on the numerical code; ➠ Crane control error messages,
p. 15-61.

Acknowledging error messages

You can acknowledge an error message and thus return to the menu
which was selected before the error message occurred.

• Press the membrane switch Enter once to acknowledge; there are three
Ö possible reactions:
– If no further error message is in the queue, the display switches to the
menu which was selected before the error message occurred.
– If further error messages are in queue, the next error message appears
on the display. You can acknowledge all error messages one after the
other.
– If the error message was displayed because the crane control cannot
detect any lengths and positions (proximity switch or length indicator is
faulty or the line has been cut), the crane control switches to the sub-
menu Emergency operation after the acknowledgement; ➠ p. 15-74.

Calling up error messages again after acknowledging

All acknowledged error messages are saved in the sub-menu Error
memory. As long as the ignition remains switched on, you can call up the
acknowledged error messages again:

• To do this, switch to the menu Display states.

> • Call up the menu item for the power unit for which the error message
: appeared.

< Switch to submenu Error memory. Here you can see the acknowledged
+

H
error messages again.

The error memory is deleted each time the ignition is switch off. As long
as the cause of error is not eliminated, the error message appears after
switching on the ignition and is again stored in the error memory after
acknowledging. In this way you can also note the error messages later if
you have switched off the ignition, e. g. to contact GROVE Product
Support.
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 Crane operation
12.3 Crane work with the main boom

12.3.9 Setting a constant engine speed

You can set a constant engine speed for the crane engine from the crane
å cab using the rocker switch Constant engine speed.

You can read off the current engine speed of the crane engine from the
@ Crane control display on the status display Display states while setting;
➠ p. 12-82.
• Use the gas pedal to reach the desired rpm.
• Press the rocker switch Constant engine speed once downward to set the
å constant engine speed.
Now this rpm is set as the constant speed, and it will be maintained after
you remove your foot from the gas pedal.

If you wish to increase the constant engine speed, press the rocker switch
å upwards and hold it until you have reached ther desired speed.

If you wish to increase the engine speed, depress the gas pedal.
The preset engine speed will increase. When you take your foot off the
gas pedal, the rpm will sink again to the preset speed.

• In order to turn off the constant engine speed, remove your foot from
å the pedal and press the rocker switch Constant engine speed once down-
ward.
The motor speed will drop idling speed, and you can regulate speed with
the gas pedal again.
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Crane operation
12.3 Crane work with the main boom

12.3.10 Critical load control

The truck crane is equipped (standard) with a critical load control. The
critical load control system ensures that the crane engine does not stall
when the engine speed is low and more hydraulic power is demanded of
it simultaneously. You do not have to take over any steering tasks with
the accelerator here.

The critical load control takes into account the available engine power at
the set crane engine speed. It reduces the performance of the hydraulic
pumps automatically, when the hydraulic power demanded is greater
than the power of the crane engine at the time (e. g. when another crane
movement is switched on).

If the hydraulic power demanded exceeds the engine power, the critical
load control system reduces the performance of all variable displacement
pumps, in the correct relationship to the degree of deflection of the
respective control levers. The relationship of the working speeds remains
identical. It is not necessary to correct the movements of the control
levers.

If overloading occurs, the critical load control system ensures that the you
do not have to adjust the working speeds of several simultaneous crane
movements using the control levers to stop the crane engine from stalling.

If the critical load control does not work faultlessly owing to a defect and
the crane engine stalls because of this, or if individual power units can no
longer be controlled, you can switch off the critical load control; ➠ Power

H
unit speeds/critical load control menu, p. 12-83.

The slewing gear is not influenced by the critical load control.

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 Crane operation
12.3 Crane work with the main boom

12.3.11 Incline crane cab

In order to attain a more favourable sitting position while working at grea-

ter heights, you can incline the crane cab by up to 20° toward the rear.

G
Risk of accidents caused by falling objects in the crane cab!
Remove all loose objects (e. g. bags, bottles, etc.) from the crane cab so
that they cannot fall when inclining the crane cab. And close the door to
the crane cab before inclining.
In this way you prevent fluids from reaching the plug-in modules, that the
crane cab door opens by itself, or that unwanted operating errors caused
by fright occur.

Inclining crane cab to the rear

• Close the crane cab door.

• Press the rocker switch Incline crane cab downward.
: The crane cab inclines rearward as long as you hold the rocker switch
down until the end position of 20°.

Incline the crane cab back to the horizontal

• Press the rocker switch Incline crane cab upward.

: The crane cab inclines forward as long as you hold the rocker switch
down until the horizontal end position.
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Crane operation
12.3 Crane work with the main boom

12.3.12 Cooling the hydraulic oil

Standard The truck crane is equipped with a hydraulically driven oil cooler which is
oil cooler controlled via a thermostat. When the hydraulic oil reaches a temperature
of 55 °C, the oil cooler is switched on.

During normal crane operation the temperature of the oil must not exceed
80 °C.

• Monitor the Hydraulic system oil temperature status display during crane
°C operation.
20 100

C0388

If the hydraulic oil reaches a temperature of 80 °C, you must stop crane
operation and allow the oil to cool down with the crane engine running.

Additional The truck crane can be equipped with a second oil cooler as additional
oil cooler equipment. This second oil cooler is switched on parallel to the standard
installed oil cooler.

12.3.13 Possible movement combinations

Lifting / lowering main hoist can be carried out simultaneously with

– Lifting / lowering with an auxiliary hoist (additional equipment)
– Slewing
– Telescoping or derricking
All other possible combinations

You can use fast speed with the movements which can be carried out
simultaneously.
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 Crane operation
12.4 Driving with a rigged crane

12.4 Driving with a rigged crane

This section describes moving the truck crane with an installed counter-
weight but without a rigged lattice extension.

G
Risk of accidents!
It is forbidden to move the truck crane with a load on the hook.
Put the load down before you move the truck crane.
Secure the hook block so that it cannot swing.

G
Risk of overturning!
Before a rigged crane can be driven the superstructure must be locked
and the slewing gear permanent brake must be engaged.

G
Risk of accident if the truck crane is not completely visible!
While driving the equipped truck crane, always stay in visual or radio con-
tact with a banksman who additionally observes the parts which you can-
not see (e. g. the raised boom when the superstructure is rotated to the
rear).
This prevent accidents resulting from collisions with persons, other con-
struction equipment, ledges of buildings, cables or other objects.

12.4.1 Driving route

The route must be a flat, even surface. The level adjustment system can-
not compensate for uneven surfaces. If the surface pressure of the tyres
exceeds the permissible load on the ground, the surface pressure must be
increased using packing made of durable material (e. g. wooden planks).

S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ p. 6-9.
Do not reduce the tyre pressure!
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Operating Instructions GMK 6300 2 084 548 en 12 - 93
Crane operation
12.4 Driving with a rigged crane

12.4.2 Position of the boom

The vehicle may only be moved if certain conditions are met. The boom
may have to be moved to a specified position, depending on the installed
counterweight.

S
Damage may occur to the axle lines!
Always move the boom to the prescribed position before you move the
rigged truck crane. The permitted load on the axle lines will be exceeded
if the boom is in a position which deviates from the prescribed position.

• Set the appropriate SLI code for the rigging mode on the safe load indi-
11== cator. The SLI codes are found in the Lifting capacity table.
• Move the boom into the prescribed position. The prescribed boom posi-

H
tion is found in the following table.

If the SLI shuts down the lowering of the boom before the boom has
reached the prescribed position, you must adjust on the SLI the current
SLI rigging code for the actual rigging mode of the truck crane according
to the Lifting capacity table.

G
Risk of accidents if SLI is overridden!
Always set the SLI rigging code when you want to lower the partially
extended main boom below an angle permitted in the operating area.
Do not override the SLI; if the SLI is overridden, the truck crane works
without overload protection!

H
Boom
positions

You will find the table with the prescribed boom positions for driving with
a rigged truck crane with mounted lattice extension in the sections Driving
with rigged crane and rigged lattice extension or rigged boom extension in the
GMK 6300 Lattice extension operating manual.
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 Crane operation
12.4 Driving with a rigged crane

Boom positions without lattice extension:

Counter- Telescope status Boom Boom Axle load2) in t

weight (TelI/II/III/IV) angle in ° position1) front rear
in t

0 front 12.5 12.0

0 0/0/0/0
82 rear 6.5 15.0

0 front 10.0 15.5

8 0/0/0/0
82 rear 8.5 16.0

0.5 / 0 / 0 / 0 15 front 12.0 18.0

22
0/0/0/0 82 rear 12.0 18.0
1.0 / 0.5 / 0 / 0 15 front 19.0 18.0
36
0/0/0/0 82 rear 20.0 15.5

1.0 / 1.0 / 0 / 0 15 front 19.0 22.0

50
0/0/0/0 82 rear 19.5 21.5
- - front not permissible
80
0/0/0/0 75 rear 25.0 26.0
- - front not permissible
1003)
0/0/0/0 70 rear 28.5 29.0

1)
Boom position at rear = 0° position, boom over
truck crane rear edge
Boom position at front = 180° position, boom over
driver’s cab

2)
Axle load front: each on the 1st and 2nd axle lines
rear: each on the 3rd, 4th, 5th and 6th axle lines

3)
After the procedure, observe the instructions in the section After the
procedure with 100 t counterweight; ➠ p. 12-98.

H The axle loads specified refer to a driving mode with the basic unit inclu-
ding the 35 t hook block.
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Operating Instructions GMK 6300 2 084 548 en 12 - 95

Crane operation
12.4 Driving with a rigged crane

12.4.3 Driving the rigged truck crane

Locking the Before the truck crane is moved, the superstructure must be locked to the
superstructure carrier; ➠ Mechanical superstructure lock, p. 12-6.
and engaging the
slewing gear
permanent brake
• Lock the superstructure; the indicator lamp Superstructure locked must
! illuminate.
• Apply the slewing gear permanent brake and hence switch off the
Y slewing gear Slewing function to prevent inadvertent operation.
To do this, push down the Slewing gear permanent brake rocker switch.
The Slewing gear permanent brake indicator lamp lights up when the

H
slewing gear permanent brake is applied.

If the crane engine stops the slewing gear permanent brake is auto-
matically applied.

Retracting the • Retract the outrigger cylinders until the wheels are just above the ground.

G
outriggers
Risk of overturning!
Take care that the truck crane does not overturn when the outriggers are
being retracted!
Retract all the outrigger cylinders as uniformly as possible!

Switching over
the suspension
locking system
• Switch the suspension locking system off. Push up the Suspension locking
u system rocker switch. The Suspension locking system indicator lamp must
go out.
• Retract the outrigger cylinders until the truck crane is approximately at
on-the-road level.
• Activate the suspension locking system again. To do this push down
u the Suspension locking system rocker switch. The Suspension locking system
indicator lamp lights up when the suspension system is locked.
• Continue to retract the outrigger cylinders.

G
Risk of overturning!
To reduce the risk of the crane overturning do not raise the outrigger pads
01.02.2000

more than 5 to 10 cm off the ground. Leave the outrigger beams extended.

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 Crane operation
12.4 Driving with a rigged crane

Switching on se- Before driving with the rigged crane you must switch on separate steering:
parate steering
• Switch on the Level adjustment system key switch.

C0018

• Switch on separate steering by releasing the Separate steering rocker

b switch and pressing it down.

S
Damage may occur to steering linkage!
Before driving with the rigged crane always switch on separate steering
and steer the truck crane only when the vehicle is moving.
If separate steering is switched off or if you steer with the vehicle station-
ary the steering linkage may become damaged.

Driving

S
Risk of tyre damage!
Check the pressure in the tyres before the rigged truck crane is moved!
The truck crane may be moved only if tyre pressures are at the prescribed
levels; ➠ p. 6-8.
Do not reduce the tyre pressure!

S
Damage may occur to steering linkage!
Steer only when the vehicle is moving. The steering linkage can be dama-
ged if the steering is turned when the vehicle is stationary.

H The wind speed must be checked before the rigged truck crane is moved!
The same maximum permissible wind speeds apply as when working
with the crane; ➠ Effect of wind on crane operation, p. 12-32.

• Switch the transfer case to off-the-road gear to move the truck crane;
➠ Off-the-road gear, p. 6-36.
• Switch on driving range 1; ➠ Driving ranges of the automatic gearbox,
p. 6-17.
• Drive at only a very low speed!
• The turning radius should be as large as possible when turning corners!
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Operating Instructions GMK 6300 2 084 548 en 12 - 97
Crane operation
12.4 Driving with a rigged crane

• Steer the truck crane only when it is moving and avoid sudden steering
movements!
When the surface is uneven the truck crane must be raised with the outrig-
ger cylinders, horizontally aligned and then re-lowered; ➠ Retracting out-
riggers, p. 12-96 and Switching over suspension locking system, p. 12-96.

Extending the The truck crane must be on outriggers before beginning work with the
outriggers crane; ➠ Outriggers, p. 13-13.

G
Risk of overturning!
The truck crane must be raised until no wheels touch the ground!

After the proce- After the procedure with 100 t counterweight, the truck crane is in a rig-
dure with 100 t ging mode in which the front outrigger cylinders cannot lift the crane.
counterweight

S
Danger of causing damage due to axle loads being too high!
Do not lower the main boom as long as the truck crane is on wheels. If
you lower the boom, the rear axle lines will be overloaded and damaged.

Proceed in the following manner to support the truck crane:

• Move all outrigger beams to the span required for the job.
• Extend the outrigger cylinders until the wheels of the rear axle lines no
longer touch the ground.
• Set the code on the SLI for the intended job.
The rear axle lines are now without a load and you can lower the main
boom.

• Lower the fully retracted main boom to about 30°.

• Extend the outrigger cylinders until none of the wheels is touching the
ground.
• Align the truck crane horizontally with the outrigger; ➠ Outrigger,
p. 13-13.
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 Crane operation
12.5 Work break

12.5 Work break

12.5.1 Short work break

G
Risk of accidents when the load is suspended!
Never leave the crane cab while a load is suspended on the hook block.
Never turn the crane engine off while a load is suspended on the hook.
Always keep your hand close to the control levers while a load is suspen-
ded on the hook so that you are able to react correspondingly at all times.
Always put down the load before you stop work!

• Lock the slewing gear permanent brake by pushing down the Slewing
Y gear permanent brake rocker switch.
• Switch the crane engine off, turn the ignition key to the 0 position and
remove it.
• Ensure that no unauthorized persons can operate the truck crane.
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Operating Instructions GMK 6300 2 084 548 en 12 - 99

Crane operation
12.5 Work break

12.5.2 Work breaks lasting more than 8 hours

• Retract all telescope sections.

• Lower the boom onto the boom support.
• Lock the slewing gear permanent brake by pushing down the Slewing
Y gear permanent brake rocker switch.
• Switch the crane engine off, turn the ignition key to the 0 position and
remove the ignition key.
• Switch off all current consumers.

• Switch off the main battery switch.

H You may switch off the battery master switch even if the heater is still
running down. This does not interrupt the run-down period of the heater.

• Ensure that no unauthorized persons can operate the truck crane.

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 Crane operation
12.6 Crane cab heating and ventilation

12.6 Crane cab heating and ventilation

12.6.1 Heating the crane cab

A heat exchanger provides warmth for the crane cab using heat from the
engine coolant. Suction air for the heating system can be fresh air, recir-
culated air or mixed air with any desired amount of fresh air.

The suction air for the heating system is set

with the regulator Recirculated air / fresh air
mode (3):
Fresh air mode: regulator downward
Recirculated air: regulator upward
Mixed air: regulator in the inter-
mediate position
The air distribution in the crane cab is set
with the regulator Air distribution front
windshield / cab floor (2):
To the windscreen: regulator upward
To the cab floor: regulator downward
All nozzles: regulator in the
middle

The infinitely variable Temperature regulator (4) is used to set the desired
hot air temperature.
Cooler: Regulator upward
Warmer: Regulator downward
The knob Heater fan (1) is used to activate the fan.
The fan has the settings 0 (off), 1, 2 and 3 (maximum output).

S
In recirculated air mode, the heating system sucks in air through the black
grille below, behind the crane operator’s seat. Never cover the grille,
e. g. with items of clothing or bags!
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Operating Instructions GMK 6300 2 084 548 en 12 - 101

Crane operation
12.6 Crane cab heating and ventilation

12.6.2 Additional water heating system (additional equipment)

The engine-independent additional water heating system heats up the

crane engine’s coolant. The heat is generated by burning fuel from the
tank in the superstructure. The heating system is operated by onboard
electrics in the superstructure. The additional heating system may be
operated when the engine is stationary or running.

In the case of a stationary and cold engine, this can be preheated using
the additional heating system. The heating pump circulates the coolant
within the engine. The Temperature regulator in the crane operator’s cab
should be set up to the setting “Cold”.
If you set the regulator Temperature to “Warm” and turn on the fan as
described in section Heating the crane cab, p. 12-101, the crane cab will

H
heated at the same time.

If you operate the additional heating system while the crane engine is
switched off, the batteries will run down. The batteries must then be
recharged after shorter periods of time!

When the engine is running, the additional heating system supports the
preheating of the engine until the engine operating temperature is
reached.
The heat supply will be interrupted when the engine operating tempe-
rature is reached. The heating pump continues to run until, using the

H
rocker switch, the additional heating system is switched off.

When the engine operating temperature is reached, the additional heating

system should be switched off to prevent uncontrolled starting when the
engine temperature drops.

Switching on the
additional
heating system
To activate push down the Additional heating system rocker switch. The indi-
0 cator lamp in the rocker switch illuminates.

After a preheating period of approx. 15 seconds, automatic ignition takes

place. If the heating system does not trigger after 30 seconds, ignition is

H
aborted.

The indicator lamp in the rocker switch merely indicates that the switch has
been operated and that the heating system has been switched on or off.
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It does not indicate whether the heating system has been triggered.

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 Crane operation
12.6 Crane cab heating and ventilation

The heating system has ignited if:

– the air flowing from the fan vents is warming up (cab heating system) or
– the engine temperature rises (preheating the crane engine).

Once the heating system has triggered, a thermostat in the heater takes

H
over control of the heating system.

If a malfunction of approx. 10 seconds occurs while the heating is on, the

heating system will automatically shut down.

If you wish to restart the heating system, you must turn off the Additional
0 heating system rocker switch and turn it back on again.

Switching off the

additional
heating system
• To deactivate push up the Additional heating system rocker switch.
0 The indicator lamp goes out.
The heating pump will continue to run for approx. 3 minutes to cool

H
down the heater.

Turning off the battery master switch while the heater is cooling down
will not interrupt the cooling of the heater.

12.6.3 Additional heating system with timer (additional equipment)

The additional heating system with timer is operated in the same way as
the carrier; ➠ p. 6-60.
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Operating Instructions GMK 6300 2 084 548 en 12 - 103

Crane operation
12.6 Crane cab heating and ventilation

12.6.4 Ventilating the crane cab

• Push the regulator Temperature (4) as far

upward as possible (cold position).
• Push the regulator Recirculated air / fresh air
mode (3) as far upward as possible (fresh
air position).
• Push the regulator Air distribution wind-
screen / cab floor (2) to the central position
(all nozzles).
• Switch the heater fan knob (1) to level 3.

Various windows in the crane cab can also be opened for ventilation;
➠ Doors, keys, windows, p. 10-56.

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 Crane operation
12.7 Air-conditioning system (additional equipment)

12.7 Air-conditioning system (additional equipment)

The air-conditioning system is installed behind the crane operator’s seat.
It only works in recirculated air mode. The refrigerating agent compressor

H
is driven by the crane engine.

The air-conditioning system sucks the cabin air in through grilles.

Therefore do not cover the grilles with bags or items of clothing.

Notes for air conditioning the crane cab can be found in the section
Air conditioning, p. 12-106.

12.7.1 Switching on

• Turn the Fan knob to level 1, 2 or 3, depending on the output desired.

• Set the desired temperature with the Thermostat knob switch.

• Adjust the air outlet jets so that the cool air is mixed well with
the cabin air.

12.7.2 Switching off

• Turn the knob Fan to the 0 position.

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Operating Instructions GMK 6300 2 084 548 en 12 - 105
Crane operation
12.7 Air-conditioning system (additional equipment)

• Turn the Thermostat knob to the left as far as possible.

12.7.3 Air conditioning

How to ensure Avoid excessive cooling of the air in the cab.

pleasant air- For example, with an outside temperature of 40 °C the temperature inside
conditioning the cab should lie between 26 and 30 °C; in other words, the difference in
temperature should not exceed 10 °C to 14 °C. When the outside tempera-
ture is lower, you should select a correspondingly lower temperature diffe-
rence. Excessive cooling frequently results in physical discomfort, usually
only after you have left the cab.

Avoid exposing your body directly to cold air. Direct the air stream from
the nozzles in the cab floor so that the cold air mixes thoroughly with the
warm air in the cab. This produces an even temperature throughout the
cab and ensures cooling without a draught.

In the mixed air mode, operate the air-conditioning system with a low
proportion of fresh air in order to dehumidify the driver’s cab, while at the
same time ensuring a fresh supply of oxygen.

Keep adjusting the cooling system as needed. Initially, if the truck

crane has e. g. been parked in strong sunlight for a long time, the cooling
system should be operated at maximum cooling capacity and with the fan
on setting 3 with the crane engine running.
The crane cab door or at least the windows should be left open for a short
while to air thoroughly.
The process can be accelerated by increasing the engine speed of the
crane engine.

If you then continue to run the air conditioner, close the windows and
other air vents to ensure that the crane cab can be cooled adequately.

Once the desired inside temperature has been reached, set the fan to
level 2 again and reduce the cooling output with the knob Thermostat
accordingly. If only a low level of cooling is required, fan level 1 will
01.02.2000

be sufficient.

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 Crane operation
12.7 Air-conditioning system (additional equipment)

Dehumidifying On humid days at the turn of the season you can dehumidify the air in the
crane cab air driver’s cab by operating the air-conditioning system in a combined
heating and cooling mode. Operation of the heating system is described

H
in section Crane cab heating and ventilation, p. 12-101.

As this involves the heating and air-conditioning system functioning

“in opposition to each other”, dehumidifying produces little or no heat.

• Set the Temperature regulator of the crane cab heating system and the
Thermostat knob on the air-conditioning system to approximately the
same output.

H
• Switch on the fan.

The higher the level of heating and cooling selected the more efficiently
cab air becomes dehumidified.
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Operating Instructions GMK 6300 2 084 548 en 12 - 107

Crane operation
12.7 Air-conditioning system (additional equipment)

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 ____________________________________________________________________________________ 13
13 Rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1
13.1 Check lists for rigging work for crane operation with main boom 13 - 1
13.1.1 CHECK LIST: Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 1
13.1.2 CHECK LIST: Unrigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 4
13.2 Choosing a suitable site . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 7
13.2.1 Load bearing capacity of the ground and the outrigger . . . . . . . . . . 13 - 7
13.2.2 Safe distance from banks and pits . . . . . . . . . . . . . . . . . . . . . . 13 - 10
13.2.3 Safe distance from electrical lines . . . . . . . . . . . . . . . . . . . . . . 13 - 10
13.2.4 Earthing the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 11
13.3 Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 13
13.3.1 CHECK LIST: Extending the outriggers . . . . . . . . . . . . . . . . . . . 13 - 13
13.3.2 CHECK LIST: Retracting outrigger . . . . . . . . . . . . . . . . . . . . . . 13 - 15
13.3.3 Outrigger span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 17
13.3.4 Preparing the outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 20
13.3.5 Extending / retracting the outrigger beams . . . . . . . . . . . . . . . . . 13 - 23
13.3.6 Moving the outrigger pads into working / driving position . . . . . . . . . 13 - 28
13.3.7 Extending / retracting the outrigger cylinders . . . . . . . . . . . . . . . . 13 - 30
13.4 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 37
13.4.1 Counterweight sections and identification . . . . . . . . . . . . . . . . . 13 - 37
13.4.2 Counterweight versions . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 38
13.4.3 Slinging points on the counterweight sections . . . . . . . . . . . . . . . 13 - 41
13.4.4 CHECKLIST: Rigging the counterweight . . . . . . . . . . . . . . . . . . . 13 - 42
13.4.5 CHECKLIST: Unrigging the counterweight . . . . . . . . . . . . . . . . . 13 - 45
13.4.6 Placing the 8 t base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 48
13.4.7 Prepare the 8 t base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 50
13.4.8 Assembling the counterweight version . . . . . . . . . . . . . . . . . . . 13 - 53
13.4.9 Extending/retracting the lifting cylinders of the 8 t base plate or
lifting/lowering counterweight . . . . . . . . . . . . . . . . . . . . . . . . 13 - 56
13.4.10 Locking the counterweight on the turntable/releasing the locking pin . . 13 - 59
13.4.11 Slewing with the counterweight rigged . . . . . . . . . . . . . . . . . . . 13 - 61
13.5 Rigging work on the main boom . . . . . . . . . . . . . . . . . . . . 13 - 63
13.5.1 Hook block on the bumper . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 63
13.5.2 Hook block on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . 13 - 65
13.5.3 Reeving and unreeving the hoist rope . . . . . . . . . . . . . . . . . . . . 13 - 67
13.5.4 Possible reeving methods on the main boom . . . . . . . . . . . . . . . . 13 - 75
13.5.5 Anemometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - 79
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2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.1 Check lists for rigging work for crane operation with main boom

13 Rigging work
Once you have reached the site, you must carry out numerous rigging
tasks before you can begin crane work. Follow the instructions contained
in this check list!

If the truck crane has already been rigged on the site, proceed according
to the CHECK LIST: With rigged truck crane, p. 12-1.

13.1 Check lists for rigging work for crane operation with

H
main boom

This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

13.1.1 CHECK LIST: Rigging

1. Choose a suiteble site; ➠ p. 13-7.

2. Check whether the parking brake is locked (parking brake lever points
toward the rear).

C0027

3. Lower the truck crane as far as possible and align horizontally using the
level adjustment system; Switch on level adjustment system; ➠ p. 6-37.

4. Activate the suspension locking system; ➠ p. 13-20.

u
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Operating Instructions GMK 6300 2 084 548 en 13 - 1
Rigging work
13.1 Check lists for rigging work for crane operation with main boom

5. Support truck crane and align horizontally; ➠ p. 13-13.

6. Inspect the truck crane looking out in particular for any escaping fluids
(oil, fuel or water).

7. Check the position of the hoist ropes; ➠ p. 12-8.

8. Starting the crane engine; ➠ CHECK LIST: Starting the crane engine,
p. 11-1.

9. Releasing the superstructure lock; ➠ p. 12-6.

¥ 10. Pick up hook block
– from accompanying vehicle; ➠ p. 13-65,
– from the stop rod; ➠ p. 13-63.

11. Install the rope grab and reeve the hoist rope; ➠ p. 13-70.
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 Rigging work
13.1 Check lists for rigging work for crane operation with main boom

12. Install the lifting limit switch, connect and check whether the locking
has been cancelled; ➠ Lifting limit switch on the main boom – installing
the lifting limit switch, p. 13-72.

13. Attach lifting limit switch weight and fasten to hoist rope;
➠ Lifting limit switch on the main boom – lifting limit switch weight, p. 13-74.

14. Mount the anemometer (additional equipment); ➠ p. 13-79.

15. Rig the counterweight version according to the Lifting capacity table;
➠ CHECK LIST: Rigging the counterweight, p. 13-42.

16. Adjusting the mirrors; ➠ p. 12-8.

17. Set the SLI code specified in the Lifting capacity table for the respective
00== rigging mode on the SLI. If the rigging mode was entered for indivi-
dual components: compare the displayed rigging mode with the
actual one; ➠ p. 12-16.

18. Set the number of reeved ropes on the SLI; ➠ p. 12-16.

2
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Operating Instructions GMK 6300 2 084 548 en 13 - 3

Rigging work
13.1 Check lists for rigging work for crane operation with main boom

13.1.2 CHECK LIST: Unrigging

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Unrigging the counterweight; ➠ CHECK LIST: Unrigging the counter-

weight, p. 13-45.

2. Depending on the transportation of the hook block place this

– on a separate vehicle; ➠ p. 13-65.
– attach to the bumper; ➠ p. 13-63.

3. Turn the boom in the direction of driving.

4. Lock the superstructure.

!
5. Retract and set down boom.

6. Removing the rope grab; ➠ Install/remove rope grab, p. 13-69.

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 Rigging work
13.1 Check lists for rigging work for crane operation with main boom

7. All telescope sections are locked; ➠ Locking telescope, p. 12-72;

The telescoping cylinder is, depending on the driving mode, in telesco-
pic section I or IV ➠ Driving mode, p. 6-5.
- 0 -
HALF
TELE: - -I

8. Remove the anemometer; ➠ p. 13-79.

9. Retract the outrigger; ➠ CHECK LIST : Retracting outrigger, p. 13-15.

10. Switch off the suspension locking system; ➠ Check the suspension, p. 6-6.
u
11. Switch off the crane engine; ➠ Crane engine, p. 11-15.

12. Switch off the battery master switch when the truck crane is no longer
being used; ➠ Switch off the crane engine, p. 11-15.
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Rigging work
13.1 Check lists for rigging work for crane operation with main boom

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 Rigging work
13.2 Choosing a suitable site

13.2 Choosing a suitable site

The stability of the truck crane primarily depends on the condition of the
ground at the site. Please read the following section Load bearing capacity of
the ground and the outrigger carefully.

Use the Outrigger pressure table to determine the pressure that will be
applied to the ground by the outrigger pads for the intended work with
the crane.

Examine the actual load bearing capacity of the ground on the site. If
necessary, enlarge the surface area of the outrigger pads using suitable
packing material (➠ Enlarging the outrigger surface area, p. 13-9 in this
section). The permissible pressure on the ground under the outrigger
must not be exceeded.

The outrigger cylinders can only be used to compensate for a specific off-
road angle. It is therefore necessary to note the structure of the terrain.
Maximum possible levelling by lifting with outrigger cylinders;
➠ Technical data – supporting equipment, p. 15-19.
When choosing a site, ensure that there is sufficient distance between the
truck crane and banks, pits and electrical lines.
Refer to section Safe distance to banks and pits, p. 13-10, and section Safe
distance to electrical lines, p. 13-10.

13.2.1 Load bearing capacity of the ground and the outrigger

Choose the on-site location for your truck crane with care. In particular,
ensure that the ground can withstand the resulting outrigger pressure.
Choose a location that will facilitate the smallest possible radius and
ensure that no obstacles are within the slewing range of the crane.

Always extend all four outrigger beams to the width specified in the lifting
capacity table. Never move the superstructure out of transport position
without first locking the suspension and supporting the truck crane.

The outrigger pads transmit the supporting force to the ground. If the sur-
face pressure of the outrigger pads exceeds the permissible load bearing
capacity of the ground, you must enlarge the surface area of the outrigger
with packing made of durable material (e. g. wooden planks or steel
plates) (➠ Enlarging the surface area of the outrigger, p. 13-9 in this section).
Arrange the packing under each outrigger so that the outrigger pad
touches down in the centre of the outrigger surface area.
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Operating Instructions GMK 6300 2 084 548 en 13 - 7
Rigging work
13.2 Choosing a suitable site

The required surface area is calculated using the outrigger pressure and
the load bearing capacity of the ground.
The outrigger pressure for the intended use of the crane may be found in
the outrigger pressure table. Maximum outrigger pressure and size of the
outrigger pad; ➠ Technical data – supporting equipment, p. 15-19.
The following table contains approximate values for the load bearing

H
capacity of the ground.

Have the ground tested (e. g. using a ram probe) if you are unsure of the
load bearing capacity of the ground at the site.

Load bearing
APPROXIMATE VALUES FOR THE LOAD BEARING capacity
CAPACITY OF THE GROUND (t/m2)

Backfilled ground, not artificially compacted ground: 0 to 10

Vegetated, apparently untouched soil:

Mud, peat, marsh 0

Non-cohesive ground which fine to 15

is sufficiently firm: medium sand

coarse sand to 20
gravel

Cohesive ground: mushy 0

soft 4

stiff 10

semi-solid 20

hard 40

Rock with minimal fissures in in closed 150

sound, unweathered condi- succession of
tion and with favourable beds
strata:
massive or 300
columnar
formation

Calculate the required supporting surface area:

outrigger pressure (t)

surface area (m2 ) =
FG t IJ
01.02.2000

load bearing capacity of the ground

H m2 K

13 - 8 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.2 Choosing a suitable site

Always align the packing horizontally. Always align the truck crane
horizontally with the outrigger cylinders.

G
Risk of overturning when substructure or truck crane is at an angle!
Align the packing horizontally and align the truck crane horizontally with
the outrigger cylinders. In this way you prevent the outrigger pads slip-
ping from the angled substructure or the truck crane from having an unfa-
vourable centre of gravity owing to an incline and overturning when sub-
ject to a load.

Enlarging the Only use durable materials for the packing, such as
surface area of
the outrigger
– thick wooden planks or square timber made of hardwood (such as
bongossi, etc.),
– thick steel plates with soldered webs that prevent the outrigger pads
from slipping or
– wide steel profiles soldered together (girders) with soldered webs to
prevent the outrigger pads from slipping.

G
Accidents may occur if the crane overturns due to weak packing!
Thin boards or planks made of pine wood or bricks are not made to
withstand the resulting pressure and divert it into the ground.

Wooden planks and square timber must be at least 80 mm high.

They must be knotless and free of fractures.

Please note the illustration to the left when

constructing the packing.

The materials used must have the same

height in every layer.

The layers must be offset from the following

layer by 90°.

Consult your supervisor if you are in doubt.

01.02.2000

Operating Instructions GMK 6300 2 084 548 en 13 - 9

Rigging work
13.2 Choosing a suitable site

13.2.2 Safe distance from banks and pits

Set the crane a safe distance away from banks and pits. The distance also
depends on the type of soil, if the banks and pits are not supported.

As a rule of thumb:

If the soil is loose or backfilled, the distance (a)

must be twice as large as the depth of the pit
(b).

a=2xb

If the soil is vegetated or not loose, the distance

(a) must be as large as the depth of the pit
(b).

a=1xb

The safe distance is measured from the base

of the pit (c).

13.2.3 Safe distance from electrical lines

Always keep a safe distance from electrical lines when these are in the
working area of the truck crane. This applies in particular if these lines are
overhead cables that have not been shut off by an electrician or have not
been covered in the danger zone.

Voltage Minimum distance

up to 1 000 V 1m

over 1000 V up to 110 000 V 3m

over 110 000 V up to 220 000 V 4m

over 220 000 V up to 380 000 V 5m

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13 - 10 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.2 Choosing a suitable site

B
Risk of accident due to electrical shock!
Keep a safe distance away from overhead cables!
Observe the regulations of the country in which you are working!
If the voltage is unknown, maintain a distance of at least 5 m from the
cables!

If the crane should come into contact with the cable despite all pre-
cautions:
• Keep calm!
• Do not leave the crane cab!
• Tell anyone standing outside to stop whatever he is doing and not to
touch the crane under any circumstances!
• Move the crane out of the danger zone!
If it is necessary to leave the crane, do not touch the crane and the ground
simultaneously. Do not climb down from the crane operator’s cab: jump!

13.2.4 Earthing the truck crane

B
Risk of accidents due to electrical shock!
Earth the truck crane before operation
– near strong transmitters (radio/television transmitters, radio stations, etc.),
– near high-frequency switchgears,
– in potentially stormy weather.

The truck crane can become electrostatically charged. This applies in

particular if the truck crane is equipped with synthetic outrigger pads or
the outrigger pads are packed with insulated material (e. g. wooden
planks).

Earthing the To prevent the electrostatic charging of the truck crane, you will need:
truck crane
– an electrically conductive metal rod inserted in the ground
(approx. 1.5 m in length),
– an electrically conductive cable (minimum cross section 16 mm2),
– a screw clamp for welding work.

B
Risk of accidents due to electrical shock!
Ensure that the connection between the truck crane and the ground is a
faultless, electrically conductive connection!
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Operating Instructions GMK 6300 2 084 548 en 13 - 11

Rigging work
13.2 Choosing a suitable site

• Connect one end of the cable to the metal rod that is to be inserted into
the ground. Hammer the metal rod at least 1 m into the ground.
Moisten the soil around the metal rod for better conductivity.

B
Risk of accidents due to electrical shock!
Fasten the screw clamp for welding work on soldered parts of the main
boom or the superstructure only. Do not fasten the clamp to screwed on
parts such as valves, cover plates, engines, gear units, etc.!

• Connect the other end of the cable to the screw clamp for welding work
and fasten the clamp to the main boom or the superstructure.

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13 - 12 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

13.3 Outrigger

G
Risk of crushing due to extended outrigger!
You may actuate the outriggers only if you yourself or a banksman with
whom you are in visual contact have an unobstructed view of their
movements.

13.3.1 CHECK LIST: Extending the outriggers

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Align the truck crane horizontally with the level adjustment system;
➠ Preparing the truck crane for outrigger, p. 13-20.

2. Activate the suspension locking system; ➠ p. 13-20.

u
3. Tighten all four locking pins and plug into the holdings;
➠ Safety during crane operation – releasing outrigger; p. 13-22.

4. Move the outrigger pads into working position and lock them into
place; ➠ p. 13-28.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 13 - 13
Rigging work
13.3 Outrigger

5. Extend all outrigger beams to the necessary width of the desired

outrigger span;
➠ Outrigger span, p. 13-17,
➠ Extending the outrigger beams, p. 13-23.

6. Secure all outrigger beams against independent extension with the

locking pins; ➠ Safety for on-road driving, p. 13-22.

7. Enlarge the surface area of the outrigger if necessary; ➠ p. 13-9.

8. Extend outrigger cylinders until no wheels are touching the ground;

➠ p. 13-30.

9. Align the truck crane horizontally with the outrigger; ➠ p. 13-34.

G
The truck crane may overturn if improperly supported!
When working with the crane
– Extend the outrigger beams only to the permitted spans of 2.68 m,
6.00 m, or 8.50 m;
– Secure the outrigger beam with locking pins;
– Enlarge the surface area of the outrigger if necessary;
– Raise truck crane until no wheels are touching the ground;
– Align the truck crane horizontally.
01.02.2000

10. Before operating the crane, remove the ignition key from the driver’s
cabin and lock the driver’s cabin to prevent unauthorized use.

13 - 14 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

13.3.2 CHECK LIST: Retracting outrigger

H This checklist is not equivalent to a complete instruction manual. There

are accompanying handling instructions which are indicated by cross-
references. Observe the warning and safety information given there!

1. Depending on the transportation of the hook block place this

– on a separate vehicle; ➠ p. 13-65.
– attach to the bumper; ➠ p. 13-63.

2. Retract the outrigger cylinders completely; ➠ p. 13-32.

3. Tighten all four locking pins and plug into the holdings;
➠ Safety during crane operation – releasing outrigger; p. 13-22.

4. Retract outrigger beam; ➠ p. 13-26.

5. Secure all outrigger beams against independent extension with the

locking pins; ➠ Safety for on-road driving, p. 13-21.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 13 - 15
Rigging work
13.3 Outrigger

6. Move the outrigger pads into driving position and lock them into
place; ➠ p. 13-29.

7. Store the packing securely on the truck crane or on a separate vehicle.

G
Accidents may occur during on-road driving!
For on-road driving
– all outrigger beams and cylinders must be completely retracted,
– all outrigger pads must be retracted and secured and
– all outrigger beams must be secured with the pins.
The outrigger must not protrude from the outer limits of the vehicle.

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13 - 16 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

13.3.3 Outrigger span

You can set various outrigger spans with the outrigger. The outrigger
spans are given in meter x meter (e. g. 8.70 x 6.00 m). The first value
stands for the outrigger length between the front and rear outrigger
beams. It is always 8.70 m for the GMK 6300 truck crane.
The second value indicates the necessary width to which you must extend
the outrigger beams. The widths for the following outrigger spans are
permissible:
– Outrigger span 8.70 x 8.50 m
– Outrigger span 8.70 x 6.00 m
– Outrigger span 8.70 x 2.68 m.
– Outrigger span 8.70 x 8.50/2.84 m.
The prescribed width can be found in the lifting capacity table. An outrigger
cylinder is mounted to the end of every outrigger beam. The outrigger
cylinders are used to raise, lower and horizontally align the truck crane.

G
The truck crane may overturn if it is not properly supported!
Before the superstructure can be slewed, the truck crane must be
supported on all four outriggers with extended outrigger beams and the
outrigger beams must be secured against independent extension with the
locking pins! The wheels must not touch the ground!

Outrigger span Front span 8.50 m

8.70 x 8.50 m Rear span 8.50 m
8.70 m

Status display on the SLI

01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 13 - 17
Rigging work
13.3 Outrigger

Outrigger span Front span 6.00 m

8.70 x 6.00 m Rear span 6.00 m

8.70 m
Status display on the SLI

G
Risk of overturning when slewing with rigged counterweight!
Whenever the truck crane is on outriggers with the outrigger span
8.70 x 6.00 m, you may only slew the superstructure when a counter-
weight of a maximum of 50 t is rigged; ➠ Slewing with rigged counter-
weight, p. 13-61.

Outrigger span Front span 2.68 m

8.70 x 2.68 m Rear span 2.68 m
8.70 m

Status display on the SLI

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13 - 18 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

G
Risk of overturning with a rigged outrigger span of 8.70 x 2.68 m!
No counterweight may be rigged with this outrigger span. The truck
crane tips over when slewing with a rigged counterweight.
Raising and lowering the boom under the angle permitted in the working
range is only permitted in the superstructure poositions 0° to the rear or
180° forwards with the superstructure locked and with the corresponding
SLI rigging code set.
If you raise or lower the boom outside of these permitted positions, the
truck crane tips over even with the boom retracted.

Outrigger span Front span 8.50 m

8.70 x 8.50/2.84 m Rear span 2.84 m

8.70 m

G
Risk of overturning when slewing with rigged counterweight!
Whenever the truck crane is on outriggers with the outrigger span 8.70 x
8,50/2.84 m, you may only slew the superstructure when no counter-
weight is rigged (SLI entry = 0 t);
➠ Slewing with the rigged counterweight, p. 13-61.
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Operating Instructions GMK 6300 2 084 548 en 13 - 19

Rigging work
13.3 Outrigger

13.3.4 Preparing the outriggers

Aligning the Before supporting the truck crane it should be aligned horizontally and
truck crane lowered as far as possible.
horizontally
• Align the truck crane horizontally in longitudinal and lateral directions
using the level adjustment system; ➠ Switch on level adjustment system,

H
p. 6-37.

If the truck crane is situated on a low level, the distance of the outrigger
pads to the ground is small. If necessary, uniformly lift the truck crane
with the level adjustment system if you have to pack the outrigger pad or,
owing to the condition of the terrain, you extend a support against a hill.

Locking the The suspension must be locked in all axle lines when the truck crane is
suspension supported.

• Press down the Suspension locking system rocker switch in the driver’s cab
u to lock the suspension. The indicator lamp lights up when the sus-
pension is locked.

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 Rigging work
13.3 Outrigger

Safety for on- All four outrigger beams must be secured with the pins for on-road
road driving driving.

• Retract all four outrigger beams com-

pletely.
• Insert the pins (1) on all four outrigger
beams in the bores in the outrigger beam
box and the outrigger beam.
• Turn the pin so that it can not come out
(handle must point down).

G
Risk of accidents if outrigger beams slip out!
Always secure all of the outrigger beams with the locking pins for on-
road driving. This prevents the outrigger beams from falling out while
driving around corners, which could cause serious accidents.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 13 - 21
Rigging work
13.3 Outrigger

Safety during During crane operation, the outrigger beams must be secured with a pin
crane operation at all outrigger spans.
The outrigger beams must be released for extending and retracting.

S
Risk of accidents if outrigger beams are not secured!
The outrigger beams may move on their own due to the changing load
conditions when working with the crane. Secure the outrigger beams
against this by inserting locking pins into all four beams.

H The locking pins are always inserted in the same position, directly on the
support housing, regardless of the span.
On the right side, the locking pins are inserted from the front; on the left
side, the locking pins are inserted from the rear.
Securing the outrigger beams
• Take the pin (2) out of the holder (1) and fit
it into the bores in the outrigger beam box
and outrigger beam.
• Turn the pin so that it can not come out
(handle must point down).
The outrigger beam is now secured against
independent extension.

• Also secure the other outrigger beams.

Releasing the outrigger beams

• Turn the pin so that it can come out

(handle must point up).
• Pull the pins out of the bores (2) in the
outrigger beam box and outrigger beam
and fit it into the holder (1).
The outrigger beam can now be extended or
retracted.
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13 - 22 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

13.3.5 Extending / retracting the outrigger beams

Extending the The outrigger beams can be extended/retracted individually or in pairs.

outrigger beams The outrigger beams of one side of the vehicle can be actuated only by
means of the control box on the same side of the vehicle.

The control box for outrigger actuation (1) is

located on both sides of the carrier, behind
the steps.

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

S
The truck crane may overturn if improperly supported!
Always extend the outrigger beams only to the span of a permitted out-
rigger span (2.84, 6.00 m, 8.50 m) or retract them completely (2.68 m) and
secure the outrigger beams against independent retraction with the lock-
ing pin provided that it is possible.

H Before you can extend the outrigger beams, you must release them;
➠ Securing / releasing the outrigger beams, p. 13-22.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 13 - 23
Rigging work
13.3 Outrigger

• Press up the Preselection of direction of outrigger movement toggle switch.

C0120

• Press up the Preselection of outrigger cylinder / outrigger beam toggle switch.

C0121

Two speeds are available for extending the outrigger beams:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.
Slow outrigger movements:
C0119

• Press the Outrigger central toggle switch upward. The diesel engine
continues to run at idling speed.

• In addition, press the toggle switch for the desired outrigger beam
(e. g. front right).
• Extend all four outrigger beams to the necessary width of the desired
outrigger span; ➠ Outrigger span, p. 13-17.

H
C0122

You may also retract or extend the outrigger beams in pairs on the side
where you are positioned by pressing two respective toggle switches
simultaneously (e. g. the two toggle switches for front right and rear right).
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13 - 24 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

Outrigger span 8.70 x 8.50 m

The outrigger beams are extended as far as
possible with the width of 8.50 m and the
locking pins (1) can fit completely into the
bores in the outrigger housing and outrigger
beam.

Span 8.70 x 6.00 m

The bores (2) of the inner and outer out-
rigger beams align with the width of 6.00 m
and the locking pins (1) can fit completely
into the bores in the outrigger housing and
outrigger beam.

Outrigger span of 8.70 x 2.68 m

The outrigger beams are retracted as far as
possible with the span of 2.68 m and the
locking pins (1) can fit completely into the
bores in the outrigger housing and outrigger
beam.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 13 - 25
Rigging work
13.3 Outrigger

Outrigger span 8.70 x 8.50/2.84 m

The front outrigger beams are extended to
the width of 8.50 m and secured.;
➠ Outrigger span 8.70 x 8.50 m, p. 13-25.
With a width of 2.84 m (rear outrigger
beam), the outrigger beams must be exten-
ded to the extent that the strutting (2) of the
outer outrigger beam is extended to the ou-
ter edge (1) of the inner outrigger beam.
The travel way of the two supports is about
8 cm here.
In this position, the supports cannot be lok-
ked and the points of the arrow marks (3) are
at the edges of the inner outrigger beams.

G
Risk of overturning when the outrigger beams are not
uniformly extended!
Both front outrigger beams always have to be extended to the same
width and both rear outrigger beams always have to be extended to the
same width.
Check whether all outrigger beams are extended to the necessary width
and secure all outrigger beams with the locking pins, provided this is
possible.

Retracting the
outrigger beams

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

H Before you can retract the outrigger beams, you must release them;
➠ Securing / releasing the outrigger beams, p. 13-22.
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13 - 26 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

• Press down the Preselection of direction of outrigger movement toggle switch.

C0120

• Press up the Preselection of outrigger cylinder / outrigger beam toggle switch.

C0121

Two speeds are available for retracting the outrigger beams:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.

C0119
Slow outrigger movements:
• Press the Outrigger central toggle switch upward. The diesel engine
continues to run at idling speed.
• In addition, press the toggle switch for the desired outrigger beam
(e. g. front right).
• Retract all four outrigger beams completely.

H
C0122

You may also retract or extend the outrigger beams in pairs on the side
where you are positioned by pressing two respective toggle switches
simultaneously (e. g. the two toggle switches for front right and rear right).
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Operating Instructions GMK 6300 2 084 548 en 13 - 27

Rigging work
13.3 Outrigger

13.3.6 Moving the outrigger pads into working / driving position

Moving the
outrigger pads
into working
position

• Loosen the retaining bracket (1) and remo-

ve the bracket (2) from the bore holes on
the outrigger pad (3).
• Pull the outrigger pad outward as far as
possible.

• Push the bracket (3) through both of the

rear bores (2) in the outrigger pad so that
the bracket encompasses the head of the
outrigger cylinder.
• Secure the bracket using the retaining
pins (1).
• Also extend the other three outrigger
pads. Secure every outrigger pad with
a yoke and retaining pin.
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 Rigging work
13.3 Outrigger

Moving the
outrigger pads
into driving
position

• Release the retaining pin (1) and pull the

yoke (2) out of the bores in the outrigger
pad.

• Push the outrigger pad (2) right up to the

holding rod (4).
• Push the bracket (4) through the holders
(3) on the outrigger pad so that the bracket
encompasses the head of the outrigger
cylinder.
• Secure the pin with the retaining pin (2).
• Push also the other three outrigger pads
up to the holding rods. Secure every out-
rigger pad with a pin and retaining pin.
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Operating Instructions GMK 6300 2 084 548 en 13 - 29

Rigging work
13.3 Outrigger

13.3.7 Extending / retracting the outrigger cylinders

Extending the The outrigger cylinders can be operated individually, in pairs or all
outrigger cylinders together.

S
Danger of overturning if the load bearing capacity of the ground is too low!
Monitor the outrigger pressure and keep the load bearing capacity of the
ground in mind during crane work. If the ground does not have sufficient
load bearing capacity, you must support the outrigger pads with a sui-
table material.
In this way you prevent the ground giving way underneath the outrigger
pad and the truck crane falling into an incline and tipping; ➠ Increasing
the surface area of the outrigger, p. 13-9.

• Ensure that the packing of the outrigger pad is horizontally aligned.

Choose packing that will provide the outrigger cylinders with enough stroke

H
to align the truck crane horizontally and lift all wheels off of the ground.

The outrigger cylinders must have a remaining stroke of at least 25 mm in

order to carry out alignment corrections. The outrigger cylinders may not
be completely extended.

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

• Press up the Preselection of direction of outrigger movement toggle switch.

C0120

• Press down the Preselection of outrigger cylinder / outrigger beam toggle

switch.
01.02.2000

C0121

13 - 30 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

Two speeds are available for extending the outrigger cylinder:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.
Slow outrigger movements:
C0119

• Press the Outrigger central toggle switch upward. The vehicle engine
continues running at idling speed.

• In addition, press the toggle switch for the desired outrigger cylinder (e.
g. front right).
Extend all four outrigger cylinders one after the other until the outrigger
pads touch the ground.

C0122

• Continue to extend the outrigger cylinders in pairs, in order to raise the

H
truck crane until none of the wheels touches the ground.

You may also retract or extend the outrigger cylinders in pairs or together
by pressing two or all four respective toggle switches simultaneously
(e. g. front left and front right, to lower the truck crane forward).

S
Be careful not to damage the outrigger cylinder!
Move the outriggers as uniformly as possible on all four support points.
This prevents the outrigger cylinders from buckling due to one-sided
pressure.

H The electronic level in the crane cab only displays correct values when the
ignition has been turned off in the carrier. If the crane engine is started
from the superstructure, the display functions properly.

• Align the truck crane horizontally; ➠ p. 13-34.

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Operating Instructions GMK 6300 2 084 548 en 13 - 31
Rigging work
13.3 Outrigger

Retracting the
outrigger cylinders

G
Accidents may occur when outrigger movements are performed outside
of your field of view!
Block off the danger area of the moving outrigger beams before moving
them. Monitor the movements of the outrigger beams closely or have a
banksman with whom you are in visual contact monitor the movements
during operation.
No one may be in the danger zone of moving outrigger beams, not even
the banksman.

S
Risk of damage to the tyres!
Before retracting the outrigger cylinders walk around the crane and remove
all sharp and pointed materials which are under the tyres in this area.
This keeps the tyres from being punctured or damaged when the truck
crane is lowered.

• Press down the Preselection of direction of outrigger movement toggle switch.

C0120

• Press down the Preselection of outrigger cylinder / outrigger beam toggle

switch.

C0121

Two speeds are available for retracting the outrigger cylinders:

Quick outrigger movements:
• Press down the Outrigger central toggle switch. The speed of the diesel
engine is increased.

C0119
Slow outrigger movements:
• Press the Outrigger central toggle switch upward. The diesel engine
continues to run at idling speed.
In addition, press the toggle switch for the desired outrigger cylinder
(e. g. front right).
01.02.2000

C0122

13 - 32 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

Checking the Before working with the crane, you must horizontally align the truck crane

H
alignment of the with the support cylinders.
truck crane
The electronic level in the crane cab only displays correct values when the
ignition has been turned off in the carrier.

The current alignment of the truck crane is

displayed by two electronic levels on the
carrier.
1

The electronic level (1) is located on both

sides of the carrier in a control box behind
the steps.

888 888 The status display is activated in both con-

888 888
trol boxes as soon as you open the door of
one control box.

C0801

Reading the status display

Whenever the truck crane is higher on one side, the diodes in the
cruciform arranged girders (1 to 4) illuminate. Every girder stands for one
certain direction.

(1) The side of the truck crane opposite

you is higher than the side where you
1 are.
5
(2) The truck crane is higher to the right of
the status display than it is left of it.
2
(3) The side of the truck crane where you
are is higher than the side opposite
3 you.
4
(4) The truck crane is higher to the left of
the status display than it is right of it.

888 888 (5) The truck crane is horizontal.

888 888 C0802

01.02.2000

Diagonal inclines are displayed; the diodes on two girders next

to each other light up simultaneously.
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Operating Instructions GMK 6300 2 084 548 en 13 - 33
Rigging work
13.3 Outrigger

Switching over the measuring range

You may select one of two measuring ranges with the luminous diode
display:

Measuring range angle 0° to 5°

• Press the toggle switch Switch over measuring
range (2) downward.
A graduated collar (1) corresponds to a 1°
inclination.
1

Measuring range angle 0° to 1°

2 • Press the toggle switch Switch over measuring
range (2) upward.
A graduated collar (1) corresponds to a

888 888 0.2° inclination.

888 888 C0803

Measuring range angle 0° to 1° reacts very
sensitively. If the diodes on the girders illumi-
nate as much as possible, switch over to
measuring range angle 0° to 5° so that you
can follow the alignment with the outrigger
cylinders.

Aligning the When the boom is in the boom support:

truck crane hori-
• Align the truck crane horizontally with the outrigger cylinders until only
zontally
the square in the middle of the display illuminates in measuring range
angle 0° to 1°.
When the boom is retracted:
• Slew the superstructure to the 0° or 180° position. Align the truck crane
horizontally with the outrigger cylinders until only the square in the
middle of the display illuminates in measuring range angle 0° to 1°.

G
Danger of overloading the boom!
Always slew the superstructure to the 0° or 180° position before aligning
the truck crane horizontally with the boom raised. If the superstructure is
in another position, the electronic level detects the deformation of the frame
as an additional angle and the displayed value can deviate from the actu-
al value by up to 2°, and the truck crane is at an incline. The side load of
the boom increases when working at this incline and the boom can
01.02.2000

become overloaded.

13 - 34 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.3 Outrigger

Outrigger pres- The outrigger pressure display is located on both sides in the control
sure display (addi- boxes, under the status display of the electronic level.
tional equipment) The status display is activated in both control boxes as soon as you open

H
the door of one control box.

When the support cylinder is retracted as far as it will go, the values of the
outrigger pressure display do not correspond to the actual outrigger
pressure. An optimal display can be obtained when the movement Retract
support cylinder has last been driven (not to its limits).

There are four digital displays which display the outrigger pressure in
pounds (klbs); the following illustration shows the displays in the left con-
trol box.

Reading the status displays

Status displays (1, 4) in the upper row
display the outrigger pressures in the out-
1 rigger cylinders on the side opposite you.
4
Status displays (2, 3) in the lower row

888 888 display the outrigger pressures in the out-

rigger cylinders on the side where you are.

888 888 Both of the status displays on the right (1, 2)

display the outrigger pressure in the out-
rigger cylinders to your right.

Both of the status displays on the left (3, 4)

2 display the outrigger pressure in the out-
3 rigger cylinders to your left.
C0807

If you, for example, are before the status displays on the left side, as the
illustration shows. The following arrangement applies:
Display (1): Outrigger pressure right rear
Display (2): Outrigger pressure left rear
Display (3): Outrigger pressure left front
Display (4): Outrigger pressure right front.

H The crane is well aligned when the outrigger pressures in both of the
front outrigger cylinders are about the same and when the outrigger
pressures in both of the rear outrigger cylinders are about the same.
But the horizontal alignment with the electronic level is definitive for the
correct state for working with the crane.
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Operating Instructions GMK 6300 2 084 548 en 13 - 35

Rigging work
13.3 Outrigger

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13 - 36 2 084 548 en Operating Instructions GMK 6300

 Rigging work
13.4 Counterweight

13.4 Counterweight

13.4.1 Counterweight sections and identification

Counterweight For the GMK 6300 truck crane, the counterweight versions are assembled
sections from 8 counterweight sections:

– One 8-t base plate with four lifting cylinders

– Three 14-t counterweight sections with different recesses
– Two 15-t counterweight blocks (additional equipment)
– Two 10-t counterweight blocks (additional equipment)

Identification The truck crane and the accompanying counterweight parts are labelled
with the same serial number.

S
Interchanging counterweight parts is dangerous!
Operate the truck crane using only counterweight sections belonging to
the truck crane. The truck crane and the counterweight parts are labelled
with the same serial number.
Other or additional counterweight sections may not be installed.

Counterweight sections
The serial number (1) is located on all
counterweight sections and counterweight
blocks which are over the weight indication.
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Operating Instructions GMK 6300 2 084 548 en 13 - 37
Rigging work
13.4 Counterweight

13.4.2 Counterweight versions

G
Risk of accidents!
Combine the counterweights with each other only in the way prescribed
in this chapter and in the Lifting capacity table. Other variations are not
permitted.
If other versions are used, the truck crane is no longer protected against
overloading by the SLI.

G
Risk of overturning when slewing with rigged counterweight!
You may only slew the superstructure with rigged counterweight if a suffi-
ciently large outrigger span is rigged. Take the required outrigger span
from the table in the section Slewing with rigged counterweight, slewing
p. 13-61 and stabilize the truck crane accordingly before slewing the super-
structure. In this way you can aviod the truck crane overturning to the rear.

The counterweight sections of the GMK 6300 can be assembled into

6 different counterweight versions.

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 Rigging work
13.4 Counterweight

8.0 t

8.0-t base plate

22.0 t

14.0-t counterweight section

8.0-t base plate

36.0 t

14.0-t counterweight section

14.0-t counterweight section
8.0-t base plate

50.0 t
14.0-t counterweight section
14.0-t counterweight section
14.0-t counterweight section
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8.0-t base plate

Operating Instructions GMK 6300 2 084 548 en 13 - 39

Rigging work
13.4 Counterweight

80.0 t
(additional equipment)

14.0-t counterweight section

14.0-t counterweight section
14.0-t counterweight section
8.0-t base plate
2 x 15-t counterweight blocks

100.0 t
(additional equipment)

14.0-t counterweight section

14.0-t counterweight section
14.0-t counterweight section
8.0-t base plate
2 x 15-t counterweight blocks
2 x 10-t counterweight blocks

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 Rigging work
13.4 Counterweight

13.4.3 Slinging points on the counterweight sections

Four slinging points each are imbedded in

the 8-t base plate and the 14-t counterweight
sections.

Two slinging points each are imbedded in

the 15-t and 10-t counterweight blocks
(additional equipment).

• For slinging, use the supplied securing

equipment, which is adapted to the va-
rious heights of the slinging points.

G
Risk of accidents if used incorrectly!
Only attach the various counterweight sections to the appropriate
slinging point and use lifting gear with sufficient lifting capacity.
Only lift the counterweight sections individually. The slinging points are
not designed for lifting counterweight sections placed on top of each
other.
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Operating Instructions GMK 6300 2 084 548 en 13 - 41

Rigging work
13.4 Counterweight

13.4.4 CHECKLIST: Rigging the counterweight

H This checklist is not a complete operating manual. There are accompany-

ing instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Prerequisites – The truck crane is stabilized with the outrigger span required for crane
work according to the Load capacity chart; ➠ Outrigger span p. 13-17.
– SLI is set to actual rigging mode with 0 t counterweight; ➠ Enter values,
p. 12-19.
– The locking pins on the turntable are retracted; ➠ Lock/release the lock for
the counterweight at the turntable, p. 13-59.

1. Lift 8-t base plate from the separate vehicle and place it onto the coun-
terweight platform; ➠ Place 8-t base plate on the counterweight platform,
p. 13-48.

2. Swing out and pin safety hook on the 8-t base plate;
➠Preparing the 8t base plate – swinging safety hook in/out, p. 13-50.

More on rigging the 8-t counterweight at point 6.

3. Depending on the counterweight version required, lift one, two or

three 14-t counterweight sections onto the 8-t base plate with the
truck crane; ➠ Assembling the counterweight combination, p. 13-53.

Continue rigging up to 50-t counterweight at point 6.

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 Rigging work
13.4 Counterweight

4. For 80 t counterweight, lift the two 15-t counterweight blocks one after
the other from the separate vehicle with the truck crane and attach
them in the holdings of the upper 14-t counterweight section;
➠ Assembling the counterweight combination, p. 13-55.

5. For 100 t counterweight, lift each of the two 10-t counterweight blocks
from the separate vehicle with the truck crane and hang them in the
holders on the two 15-t counterweight blocks; ➠ Assembling the coun-
terweight combination, p. 13-55.

6. Slew the superstructure to the rear.

7. Lock the superstructure; ➠ Mechanical superstructure lock, p. 12-6.

!
8. Establish the hydraulic connection to the 8-t base plate;
➠ Preparing the 8-t base plate – establishing/disconnecting hydraulic connecti-
on, p. 13-51.

9. Check whether the locking pins are retracted; ➠ Mechanically locking

the counterweight, p. 13-60.

10. Extend the lifting cylinders on the 8-t base plate to lift the counter-
weight; ➠ Extending/retracting the lifting cylinder of the 8-t base plate or hoi-
sting/lowering the counterweight, p. 13-56.
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Operating Instructions GMK 6300 2 084 548 en 13 - 43
Rigging work
13.4 Counterweight

11. Mechanically lock the counterweight to the turntable; ➠ Mechanically

locking the counterweight, p. 13-60.

12. Retract lifting cylinders on the 8-t base plate;

➠ Extending/retracting the lifting cylinder of the 8-t base plate or hoisting/lo-
wering the counterweight, p. 13-56.

13. Select the current rigging mode with the newly rigged counterweight
00== version at the SLI or enter the corresponding SLI code; ➠ Enter values,
p. 12-19.

14. Only unlock the superstructure if the truck crane is stabilized with an
¥ outrigger span of at least 8.70 x 6.00 m;
➠ Mechanical superstructure lock, p. 12-6.
➠ Slewing with rigged counterweight, p. 13-61.

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 Rigging work
13.4 Counterweight

13.4.5 CHECKLIST: Unrigging the counterweight

H This checklist is not a complete operating manual. There are accompany-

ing instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Prerequisites – The truck crane is stabilized with the outrigger span required for crane
work according to the. Load capacity chart on outriggers; ➠ Outrigger
span p. 13-17.
– The SLI is set to the current rigging mode with the currently rigged
counterweight; ➠ Enter values, p. 12-19.
– The hydraulic connection on the 8-t base plate is established;
➠ Preparing the 8-t base plate – establishing/disconnecting hydraulic connec-
tion, p. 13-51.
1. Slew the superstructure to the rear; ➠ Slewing with rigged counter-
weight, p. 13-61.

2. Lock the superstructure; ➠ Mechanical superstructure lock, p. 12-6.

!
3. Extend lifting cylinders on the 8-t base plate up to the counterweight
platform; ➠ Extending/retracting the lifting cylinder of the 8-t base plate or
hoisting/lowering the counterweight, p. 13-56.

4. Unlocking the counterweight; ➠ Unlocking counterweight; ➠ p. 13-60.

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Operating Instructions GMK 6300 2 084 548 en 13 - 45
Rigging work
13.4 Counterweight

5. Retract lifting cylinders on the 8-t base plate to lower the counter-
weight; ➠ Extending/retracting the lifting cylinder of the 8-t base plate or hoi-
sting/lowering the counterweight, p. 13-56.

6. Disconnect the hydraulic connection from the 8-t base plate;

➠ Preparing the 8-t base plate – establishing/disconnecting hydraulic connec-
tion, p. 13-51.

7. Select the current rigging mode with the newly rigged counterweight
00== version at the SLI or enter the corresponding SLI code;
➠ Enter values, p. 12-19.

8. Unlock superstructure; ➠ Mechanical superstructure lock, p. 12-6.

¥
For a maximum 50 t counterweight, continue at point 11
9. For 100 t counterweight, lift each of the two 10-t counterweight blocks
from the holder in the 15-t counterweight blocks with the truck crane
and place them onto the separate vehicle; ➠ Slinging points on the coun-
terweight sections, p. 13-41.

10. For 100 t and for 80 t counterweight, lift each of the two 15-t counter-
weight blocks from the holders in the 14-t counterweight sections with
the truck crane and place them onto the separate vehicle; ➠ Slinging
points on the counterweight sections, p. 13-41.
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 Rigging work
13.4 Counterweight

11. Depending on the counterweight version rigged, lift two or three

14-t counterweight sections, one after the other, from the 8-t base
plate with the truck crane and place them onto the separate vehicle;
➠ Slinging points on the counterweight sections, p.. 13-41.

12. Swing the safety hook on the 8-t base plate into position and secure it;
➠ Preparing the 8-t base plate – swinging safety hook in/out, p. 13-50.

13. Place the 8-t base plate onto the separate vehicle with the truck crane.
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Operating Instructions GMK 6300 2 084 548 en 13 - 47

Rigging work
13.4 Counterweight

13.4.6 Placing the 8 t base plate

Select the current rigging mode with 0 t counterweight on the SLI or enter
00== the corresponding SLI code.

G
Danger – free-standing truck crane may overturn!
Stabilize the truck crane before lifting the counterweight section onto the
carrier.

G
Risk of crushing when placing the counterweight sections!
Ensure that helpers maintain sufficient clearance from the 8.0 t counter-
weight section with all parts of their bodies during placement.
Remove all objects which could become clamped or crushed from the
counterweight platform!s

G
Risk of crushing when rotating the superstructure!
Anyone who climbs onto the carrier using the hook-on ladder on the left
hand side is in the slewing range of the superstructure.
Make sure that nobody uses this access ladder (e. g. a helper) whilst you are
lifting a counterweight section from the separate vehicle onto the carrier.

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 Rigging work
13.4 Counterweight

On the counter- During rigging or for transport, the 8.0 t base plate is placed onto the
weight platform counterweight platform using the truck crane. This is used there during
rigging for mounting further counterweight sections. The entire counter-
weight is hoisted onto the turntable with its four lifting cylinders.

Four guide plates (1) which fix the position

of the counterweight section are welded
onto the counterweight platform.
There are also four mountings (2) as support
points for the lifting cylinders when lifting
the counterweight.

• Sling the 8.0 t base plate on the intended

slinging points; ➠ Slinging points on the
counterweight sections, p. 13-41.
• Lift the 8.0 t base plate from the other
vehicle using the truck crane and set it
down between the guide plates (1).
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Operating Instructions GMK 6300 2 084 548 en 13 - 49

Rigging work
13.4 Counterweight

13.4.7 Prepare the 8 t base plate

There is a swinging safety hook on the 8 t base plate which hooks into a
bracket on the turntable and stabilizes the counterweight.
The 8 t base plate is also equipped with two hydraulic connections which
connect the lifting cylinders with the crane’s hydraulic system.

When rigging and unrigging the counterweight, you must swing the
safety hook to the appropriate position and connect or disconnect the
connection to the crane’s hydraulic system.

Swinging the The safety hook is swung out to rig and swung back in for transport.
safety hook If the 8 t base plate is lying on the counterweight platform, the safety
in/out hook is on the side which points to the turntable.

Swinging out
• Pull the pin on the handle (1) from the
bore hole (2).
• Swing out the safety hook (4) by 90°.
Now the bore hole in the safety hook aligns
with the hole (3) in the base plate.

• Insert the pin in the bore hole (3).

Swinging in
• Withdraw pin (3) from the bore hole.
• Swing in the safety hook (4) as far as
possible.
• Insert the pin (1) into the bore hole (2).

H Always swing out the safety hook before stacking the 14-t counterweight
sections onto the base plate. After stacking the 14-t counterweight secti-
ons, the pin on the safety hook is no longer accessible.
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 Rigging work
13.4 Counterweight

Connecting/dis- The lifting cylinders in the 8 t base plate lift the entire counterweight to
connecting the turntable and lower it onto the counterweight platform. To do this,
the hydraulic two hydraulic connections to the crane’s hydraulic system must be con-

H
connection nected.

The connection to the 8 t base plate is made with a quick release locks.
Half couplings which belong together are colour coded.

The connecting cables of the crane’s hydraulic system are tightly screwed
to the turntable on one side and located on the rear left of the turntable.
With the superstructure turned to the rear, you can reach this area with
the hook-on ladder on the right-hand side.

Establishing the hydraulic connection

• Remove the connection line (2) from the
holder (1) on the turntable.
• Remove the caps from the half couplings
on both connection lines.
• Put the two connection lines in the pou-
ches (3) of the counterweight receiver in
such a way that the connection lines so not
fall out.
• Remove the protective caps from the hal-
ves of the two half couplings (4) at the
base plate.
• Connect the connection lines with the cor-
responding coupling halves on the base
plate (note colour marking!).
The hydraulic connection has now been es-
tablished.
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Operating Instructions GMK 6300 2 084 548 en 13 - 51
Rigging work
13.4 Counterweight

Disconnect the hydraulic connection;

• Detach the connection lines (2) from the
coupling halves (4) at the base plate.
• Place the protective caps on the both half
couplings (4) at the base plate.
• Take the two connection lines out of the
pouches (3) of the counterweight receiver.
• Put the cap on the connection lines (2).
• Wrap the connection line (2) back on the
holder (1) on the turntable.
The hydraulic connection has now been dis-
connected.

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 Rigging work
13.4 Counterweight

13.4.8 Assembling the counterweight version

To assemble the counterweight version, the 8 t base plate must be lying

on the counterweight platform; ➠ Place 8 t base plate onto counterweight plat-
form, p. 13-48.
For the counterweight versions 22 t, 36 t, and 50 t, one, two or three 14-t
counterweight sections are stacked onto the 8-t base plate. For the coun-
terweight versions 80 t and 100 t, up to four counterweight blocks (additio-
nal equipment) are also attached. The truck crane is used to lift the
individual counterweight sections.

G
Danger – free-standing truck crane may overturn!
Stabilize the truck crane with the outrigger span required for working
with the crane, before you slew the superstructure and lift the counter-
weight sections; ➠ Outrigger span, p. 13-17.

G
Accidents may occur due to falling counterweight parts!
Hoist the counterweight sections and counterweight blocks only indi-
vidually. The holders for the lifting gear are not designed for hoisting
sections/blocks placed on top of each other; ➠ Slinging points on the
counterweight sections, p. 13-41.
Always attach the counterweight blocks slowly and only vertically from
above. This prevents overloading and the possibility of the attachment
plates breaking off. When attaching the counterweight blocks, ensure that
no persons are located under the counterweight.

G
Risk of accidents due to slewing superstructure!
Nobody else may be in the slewing range of the superstructure or in the
range of the counterweight platform when the counterweight sections are
being placed on the carrier.

Assemble the necessary counterweight version with the truck crane.

Always start with the 22 t counterweight version and continue in steps un-
til the necessary counterweight version is assembled.
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Operating Instructions GMK 6300 2 084 548 en 13 - 53
Rigging work
13.4 Counterweight

22 t counterweight version
• Hoist the 14-t counterweight section with
the four rounded recesses (1) for the lifting
cylinder onto the 8-t base plate.

36 t counterweight version
• Hoist the 14-t counterweight section,
which is only equipped with the two rectan-
gular recesses (1) for the carrier weight,
onto the 22 t counterweight version.

50 t counterweight version
• Lift the 14-t counterweight section with the
side recesses (1) for the 15-t counterweight
blocks onto the 36 t counterweight version.
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 Rigging work
13.4 Counterweight

80 t counterweight version
• Attach the counterweight block above the
upper 14-t counterweight section so that
the attachment plates are located vertically
above the recesses (1).
• Attach the counterweight block to the re-
cesses (1) slowly.

100 t counterweight version

S
Counterweight may overturn if the rigging sequence is incorrect!
When installing, always attach both 15-t counterweight blocks before you
attach a 10-t counterweight block and, during removal, always remove
both 10-t counterweight blocks before you remove a 15-t counterweight
block.
If you attach both blocks on one side first, the entire counterweight will
tip and fall from the carrier and can injure you or other people.

• Attach the two 10-t counterweight blocks

in the recesses (1) of the 15-t counter-
weight blocks.
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Operating Instructions GMK 6300 2 084 548 en 13 - 55

Rigging work
13.4 Counterweight

13.4.9 Extending/retracting the lifting cylinders of the 8 t base plate

or lifting/lowering counterweight

There are four lifting cylinders on the 8 t base plate. These lifting cylin-
ders lift the entire counterweight to the turntable during rigging and lower
it back onto the counterweight platform during unrigging.

G
Risk of crushing during lifting and lowering of the counterweight!
Remove all objects which could become clamped or crushed from the
counterweight section before lifting the 8 t base plate!
Keep sufficient clearance from the counterweight platform so that the
8.0 t base plate cannot crush your feet or other limbs when lowering.

S
Risk of damage when raising the counterweight!
Always check whether the warning lamp counterweight unlocked lights up
before you lift the counterweight version with the lifting cylinders. Only if
the warning lamp lights up are both hasps in unlocked position.
You thus prevent the supporting frame of the 8 t base plate moving
against the hasps when lifting and damaging the hasps or supporting
frame; ➠ Locking / unlocking counterweight, p. 13-59.

G
Risk of accident if the counterweight falls!
When the counterweight is locked to the turntable, always check that the
safety cock is closed before moving the lifting cylinder; ➠ Safety cock,
p. 13-58.
In this way, you avoid unintensionally unlocking a counterweight because
of confusing controls.

H You can only extend/retract the lift cylinder if the 8 t base plate is connec-
ted to the crane’s hydraulic system and the stop cock is open;
➠ Preparing the 8 t base plate – connecting/disconnecting the hydraulic connec-
tion, p. 13-51.
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 Rigging work
13.4 Counterweight

To extend and retract the lifting cylinders,

there is a mobile switch unit (1) at the lower
left of the turntable.

Extend the lifting When the lift cylinders extend

cylinders
– the 8.0 t base plate is lifted from the counterweight platform to the
turntable and the safety hook latches into the holder on the turntable
during rigging.
– If the lifting cylinders are to be moved downwards into the cylinder
mountings on the counterweight platform during unrigging with the
8.0 t base plate locked on the turntable.
• Turn the Release switch unit switch to the right and hold it there.
• Press the Extend lifting cylinder / lift counterweight switch and hold it until:
– when rigging the counterweight is fully raised or
– when unrigging the lift cylinders are moved inot the cylinder mount
and support the counterweight.
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Operating Instructions GMK 6300 2 084 548 en 13 - 57
Rigging work
13.4 Counterweight

Retract hoist When the lifting cylinders retract

cylinder
– the lifting cylinders are retracted into the base plate during rigging if it
is locked to the turntable.
– the 8 t base plate with the entire counterweight is lowered onto the
counterweight platform during unrigging.
• Turn the switch Pressure build-up switch unit to the right and hold it.
• Press the Extend lifting cylinder / lower counterweight switch and
hold it until:
– when rigging the lift cylinders are fully retracted or
– when unrigging the counterweight is fully lowered.

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 Rigging work
13.4 Counterweight

13.4.10 Locking the counterweight on the turntable/releasing the

locking pin

If the 8-t base plate has been lifted onto the turntable, it must be locked
there for crane operation. There are locking pins on both sides of the
main hoist for this purpose, which are moved into the corresponding
holes on the carrier frame of the 8-t base plate. The locking pins are
extended and retracted with the hydraulic cylinders.

G
Risk of overturning when slewing with rigged counterweight!
If you have locked the counterweight on the turntable, you may only slew
the superstructure if a sufficient outrigger span is rigged. Take the
required outrigger span from the table in the section Slewing with rigged
counterweight, p. 13-61 and stabilize the truck crane accordingly before
slewing the superstructure. In this way you can avoid the truck crane over-
turning to the rear.

Safety tap The hydraulic cylinders are blocked with a safety tap so that the locking
pins cannot be retracted with the counterweight rigged causing the coun-
terweight to fall.

Before you can extend and retract the lok-

king pins, you must open the safety tap (2).
The safety tap is opened if the handle is
parallel to the cable.

If the safety tap is open, the locking pins (3)

can be extended and retracted with the mobi-
le switch unit (1).

G
Danger of accidents when the safety tap is open!
Always close the safety tap if the counterweight is locked to the turntable.
In this way, you prevent the counterweight from falling down because of
unintentional actuation of the locking pins.
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Operating Instructions GMK 6300 2 084 548 en 13 - 59
Rigging work
13.4 Counterweight

Locking the coun- To mechanically lock the counterweight, the locking pins are extended.
terweight The 8-t base plate must be completely lifted.

• Open the safety tap; ➠ Safety tap, p. 13-59.

• Turn the Pressure build-up switch unit switch to the right and hold it there.
• In addition, press the Extend locking pins switch and hold it down until
the Counterweight locked indicator lamp lights up in the switch.

The indicator lamp lights up only when both locking pins (1) are extended
through the bore holes in the support frame and the mountings on the
turntable.

• Close the safety tap.

G
Risk of accidents from falling counterweights!
Always close the safety tap if the counterweight is locked to the turntable.
This prevents the unintentional retracting of the locking pins (caused for
example, by mistaking switches), which could result in the entire counter-
weight to fall to the ground.

Unlocking the The locking pins have to be retracted in order to release the lock.

G
counterweight
Risk of accidents from falling counterweight!
Ensure that the hydraulic cylinders of the 8-t base plate are extended com-
pletely into the cylinder holders of the counterweight platform and stabi-
lize the counterweight before you retract the locking pins. In this way you
can avoid the counterweight falling when the locking pins are retracted.

• Open the safety tap; ➠ Safety tap, p. 13-59.

• Turn the Pressure build-up switch unit switch to the right and hold it there.
• In addition press the Retract locking pins switch and hold it down until
the Counterweight released indicator lamp lights up in the switch.

The warning lamp lights up only after the two locking pin (1) have been
completely retracted.
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 Rigging work
13.4 Counterweight

13.4.11 Slewing with the counterweight rigged

You may only slew the superstructure with rigged counterweight if the
truck crane is stabilized with a sufficiently largeoutrigger span. If this mini-
mum outrigger span is not observed, the truck crane can overturn to the
rear.
The following table shows, depending on counterweight and outrigger
span, whether slewing the superstructure is permitted or whether the
superstructure must be locked after rigging the counterweight.

Rigged outrigger span

8.70 x 8.50 m 8.70 x 6.00 m 8.70 x 8.50/2.84 m 8.70 x 2.68 m

Slewing only
permitted if the
main boom has
0t Slewing permitted Slewing permitted Slewing permitted been raised to an
inclination
permitted in the
operating area.

8t

22 t Slewing permitted

36 t Rigging mode not

permissible;
Slewing permitted Rigging mode not
Slewing only slewing not
permitted if the permissible permissible,
50 t radius slewing not
is at least permissible
3.0 m

80 t Superstructure has to be locked to the

Slewing permitted rear in the 0° working position,
100 t Slewing not permitted

G
Risk of overturning when slewing with too little outrigger span!
Check using the table whether sufficient outrigger span is set for the
rigged counterweight before you unlock and slew the superstructure.
Only turn the superstructure if the truck crane is sufficiently stabilized.
In this way you can avoid the truck crane overturning to the rear during
slewing because of too much counterweight mass.
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Rigging work
13.4 Counterweight

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 Rigging work
13.5 Rigging work on the main boom

13.5 Rigging work on the main boom

13.5.1 Hook block on the bumper

The hook block must either be on a separate vehicle, attached to the front
bumper or tied to a separate vehicle depending on how the truck crane is
rigged; ➠ Hook block on separate vehicle p. 13-65.

Picking up the When the 35 t hook block is rigged, it is attached to the front bumper with
hook block a holding rope.

S
Accidents may occur if your view is obstructed!
Have someone guide you when releasing the hook block from the
holding rope beacause the view of the hook block is obscured by the
driver’s cab.

• Enter the rigging code for the current rigging mode of the truck crane
00== on the SLI.

• Slacken the hoist rope and raise the main

boom simultaneously.
• Lower the main boom until the boom head
is situated vertically above the hook block.
• Disconnect the hook block from the re-
taining rope (1).
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Operating Instructions GMK 6300 2 084 548 en 13 - 63
Rigging work
13.5 Rigging work on the main boom

Attaching the The hook block must be reattached to the attachment plates on the front
hook block bumper with the holding rope for on-road driving.

G
Accidents may occur if your view is obstructed!
The reeved hook block rope lines obstruct your view on the roadway.
The number of legally permissible rope lines can differ depending on the
country in which you are working.
During on-road driving, the hook block may be reeved up to a maximum
of four fall according to EU regulations.

G
Risk of accidents from undesired swinging of the hook block!
If the holding rope for the hook block breaks during tightening of the
hoist rope, the hook block suddenly swings forward.
Therefore ensure that the banksman or other persons always stand at a
safe distance to the side of the hook block. Noone may be in front of the
hook block during tightening of the hoist rope.

H Do not attach the hook block to the front towing coupling! The reason for
this is, if a breakdown should occur, you would have to transfer the hook
block to the attachment plates before you could attach the tow-rod to the
towing coupling.

• Raise the hook block until it is directly

above the holding rope.
• Lower the hook block until you can hook
the holding rope (1) into the load hook of
the hook block.
• Lower the main boom onto the boom
support and pull the hoist rope taut using
the hoist so that the hook block is securely
in place.

H If the lifting limit switch switches off during tightening of the hoist rope,
you can override the shutdown of the lifting limit switch with the key
switch Override from the crane cab, or the banksman must pull the rope at
the lifting limit switch by hand; ➠ Overriding the shutoff system of the lifting
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limit switch, p. 10-61.

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 Rigging work
13.5 Rigging work on the main boom

13.5.2 Hook block on a separate vehicle

Picking up the
hook block

G
Risk of overturning!
Support the truck crane on outriggers before rotating the superstructure;
➠ Outriggers, p. 13-13.

S
Be careful not to damage the other vehicle!
Only lift the hook block from the separate vehicle when the boom head is
located directly above the hook block! This prevents the hook block from
swaying and avoids damage to the vehicle.

S
Be careful not to damage the hoist rope!
Do not ease down too much hoist rope when picking up and reeving the
hook block so as to prevent slack rope!
Slack rope causes rope loops to form on the hoist drum which can lead to
load slipping and destruction of the hoist rope.

• Slew the superstructure and lower the main boom until the boom head
is directly over the hook block.
• Reel off the hoist rope.
• Reeve the hoist rope; ➠ Reeving the hoist rope, p. 13-70.
• Lift the hook block off the separate vehicle.
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Operating Instructions GMK 6300 2 084 548 en 13 - 65
Rigging work
13.5 Rigging work on the main boom

Setting down the

hook block and
securing the

H
hoist rope for
on-road driving

We recommend that you transport the hook block on a separate vehicle in

a holder in such a manner as to make it possible for you to reeve the hoist
rope directly onto the hook block.

• Fully retract the main boom and reel the hoist rope on until the hook
block is suspended approx. 1 m below the boom head.
• Lower the main boom and place the hook block on the separate vehicle.
• Remove the rope holding rods on the boom head from the bores.
• Remove the holding rods from the bores in the hook block and fold the
guards down.
• Remove the lifting limit switch weight from the hoist rope.
• Remove the rope end clamp from the bracket on the boom head or
hook block.
• Unreeve the hoist rope. Unreeving is possible when the rope end clamp
is fastened.
• Re-insert the rope holding rods into the boom head bores. Secure the
rods into place using the retaining pins.
• Fold up the guards on the hook block again and insert the holding rods
into the bores. Secure the rods into place using the spring cotter pins.
• Lower the main boom onto the boom support.
• Attach the rope end clamp with holding ropes and shackles to the

H
attachment plates of the front bumper.

Do not attach the rope end clamp on the front towing coupling! Other-
wise, in case of a breakdown, you must remove the rope end clamp and
attach it on the attachment plates before you can attach the tow-rod in the
towing coupling.

• Wind up the hoist rope until it is slightly taut.

The hoist rope is now secured for driving.

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 Rigging work
13.5 Rigging work on the main boom

13.5.3 Reeving and unreeving the hoist rope

The hoist rope can be reeved differently depending on the required lifting
capacity.
The load bearing capacity of the crane depends, among other things, on
the tractive force of the hoist and the number of reevings on the hook
block. The load bearing capacity is never greater than the tractive force of
the hoist times the number of rope lines between the boom head and the
hook block (minus the amount of friction);
➠ Possible reeving methods on the main boom, p. 13-75.
Loads over 195 t can only be raised using supplementary equipment.
When determining the required lifting capacity, please note that the
weight of the hook block and the lifting tackle must be added to the load!
The actual useful load is therefore less than the value specified in the
table!

Rope end clamp A rope end clamp is fastened to the end of the hoist rope. It can be
fastened to the end of the hoist rope before reeving; reeving may also be
carried out when a rope end clamp is attached.
If the hoist rope is loaded, the rope end
clamp always aligns itself so that the point
(2) at which the carrying rope (1) ends in the
rope end clamp is on the same axis (X-X) as
the slinging point (3) (pulling axis).
• Always thread the hoist rope so that the
carrying rope runs alonng this pulling axis
and is not kinked when under a load.
The hoist rope is correctly threaded if it runs
into the rope clamp at position (2) and the
free end projects out of the rope end clamp
at position (4).

G
Accidents may occur if the load falls!
Only thread the hoist rope as described in this section (free end at
position (4)). If you thread the hoist rope any other way, the rope can
bend or become damaged upon loading. When operating the crane, the
load could fall to the ground.
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Operating Instructions GMK 6300 2 084 548 en 13 - 67
Rigging work
13.5 Rigging work on the main boom

The rope end clamp and rope wedge are labelled with their respective
size and corresponding rope diameter. Ensure that the rope wedge
inserted into the rope end clamp is labelled with the same size and rope
diameter as the rope end clamp.

G
Accidents may occur if the load falls!
If you use a rope wedge which does not belong to the rope end clamp.
The hoist rope slips out of the rope end clamp during crane operation
and the load crashes uncontrolled to the ground.

• Insert the hoist rope and rope wedge (3)

into the rope end clamp (2).
• Secure the rope clamp (1) to the loose end
of the rope.
The rope clamp provides additional safety
and prevents the hoist rope from slipping
out of the rope end clamp.

• Pull the rope end taut until the hoist rope

fits snugly in the rope end clamp.

H Observe the regulations of the country in which you are working when
attaching the rope clamp!

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 Rigging work
13.5 Rigging work on the main boom

Installing/remo- You have to remove the rope grab for on-road driving so that an overall
ving rope grab height of the truck crane of 4 m is not exceeded.
You must re-install the rope grab for working with the crane.

Transport mounting
There is a transport mounting for the rope
grab on the left side of the basic section. The
rope grab with its sheaves (1) is located in
the mounts (2) and is secured in the holdings
(3) with the pins.

• Remove the safety elements from the pins.

• Press the rope grab together at the top and
remove it from the transport mounting.

Installing the rope grab

2 1 Always install the rope grab so that the roll

(1) points toward the basic section.
3
4 • To do this, insert the plugs (3) through the
provided holdings (2).
• Secure the rope grab on both sides with
the safety device (4).
Removing the rope grab
• Remove the safety elements (4) from the
plugs (3).
• Pull the plugs (3) from the holdings (2) on
both sides.
C0957 • Reattach the rope grab in transport moun-
ting.
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Operating Instructions GMK 6300 2 084 548 en 13 - 69
Rigging work
13.5 Rigging work on the main boom

Reeving the The rope holding rods on the boom head must be removed before you
hoist rope can reeve the hoist rope with rope end clamp attached. The rods prevent
the hoist rope from slipping out of the rope pulley.

The two guards on either side of the hook block must be folded down.

• Loosen the retaining pins and remove the

rope holding rods (1) to (4) from the bore
holes on the boom head.

• Unreel the hoist rope and, while doing

1 this, guide it through under the rope
grab (1).

If the ropes are reeved by both hoists, you

must also run the auxiliary hoist rope under
the rope grab. Also use the rope grab when
working with lattice extensions.

C0956
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 Rigging work
13.5 Rigging work on the main boom

• Loosen the spring cotter pins (3) and re-

move the holding rods (1) and (2) from the
bores in the hook block.
• Fold the guards on either side of the hook
block down.
The hoist rope may now be reeved.

Depending on the reeving method used, the rope end clamp is secured
either on the boom head or on the hook block; ➠ Possible reeving methods
on the main boom, p. 13-75.
The rope end clamp is attached to the boom head if the number of lines is
even (two, four, six, etc.). The rope end clamp is attached to the hook
block if the number of lines is odd (one, three, five, etc.).

• To reeve, guide the rope from the outer-

most sheave on the head of the boom into
the hook block from the front.
• Guide the rope upwards from the back
over the next sheave on the boom head,
etc.
• Secure the rope end clamp to the bracket
on the boom head (1) or the hook block (2)
depending on the reeving. Secure the bolt
with a retaining pin.
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Operating Instructions GMK 6300 2 084 548 en 13 - 71
Rigging work
13.5 Rigging work on the main boom

• Fold both guards on the hook block back

up and insert the holding rods (1) and (2)
in the bore holes. Secure the rods into
place using the spring cotter pins.

• Reinsert the rope retaining rods (1), (2) and

(3) into the bores on the boom head.
Secure the rods into place using the
retaining pins.

Lifting limit The lifting limit switch must be mounted on the main boom during crane
switch on the work with the main boom. The lifting limit switch weight must be
main boom attached and the hoist rope must be attached.
If no anchor-to-bracket-switch is installed on the main boom, remove the
switch from the two-stage swing-away lattice extension, if necessary. For
operation with the main boom and two-stage swing-away lattice exten-
sion, the same anchor-to-bracket-switch is used; ➠ Lifting limit switch on
lattice extension, p. 14-64.
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 Rigging work
13.5 Rigging work on the main boom

Installing lifting limit switch

• Release the retaining pin (1) and place the
holder (3) with the lifting limit switch on
the grip (2).
• Secure the holder with the retaining pin (1).
• Connect the lifting limit switch at the
socket (4) on the distributor box.

S
Risk of damage if the lifting limit switch is blocked!
The lifting limit switch must not be blocked. If the lifting limit switch is
blocked, remove the blockage.
If the lifting limit switch is blocked, the hook block can catch on the
bottom of the main boom head when hoisting, and the hook block, main
boom head and hoist rope can be damaged.

Check the blockage and remove it if necessary

• Check whether the lifting limit switch is
blocked:
The lifting limit switch is blocked if the
plastic cap (2) is on the socket (1) and the
wire cable (3) is threaded into the plastic cap.

• If the lifting limit switch is blocked, remove

the blockage. To do so, pull the wire cable
(3) and thread it out of the plastic cap (2).
• Remove the plastic cap from the socket (1)
and insert it into the holder (4) on the
lifting limit switch.
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Rigging work
13.5 Rigging work on the main boom

Attaching and mounting the lifting limit

switch weight
Before working with the crane, you must
mount the lifting limit switch weight and
attach it to the hoist rope.

• Mount the lifting limit switch weight on the

shackle (1).

• Pull the retaining pin (1) on the lifting limit

switch weight upward and fold out the two
sides of the weight.

• Close the two halves of the weight around

the last rope line leading upward.
• Pull the retaining pin (1) upwards and
close the two sides of the weight together.
Ensure that the retaining pin locks into
place and the two halves of the weight are
securely attached to each other.
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 Rigging work
13.5 Rigging work on the main boom

13.5.4 Possible reeving methods on the main boom

Possible reeving methods on the two-stage swing-away lattice extension

(additional equipment) and boom extension (additional equipment);
➠ GMK 6300 Lattice extension operating manual.

H The maximum load bearing capacity of the hook blocks does not corre-
spond to the maximum load bearing capacity of the GMK 6300 together
with the respective hook block. This load bearing capacity depends on the
wire cable, reeving and friction force and is less; ➠ Reeve/unreeve hoist
rope, p. 13-67.

9-pulley hook block

max. Load bearing capacity of the hook block 200 t
max. Lifting capacity with the GMK 6300:
for 18-fall reeving 193 t
for 17-fall reeving 183 t
for 16-fall reeving 172 t

17-fall 16-fall
18-fall
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Operating Instructions GMK 6300 2 084 548 en 13 - 75

Rigging work
13.5 Rigging work on the main boom

7-pulley hook block

max. Load bearing capacity of the hook block 160 t
max. Lifting capacity with the GMK 6300:
for 15-fall reeving 160 t
for 14-fall reeving 151 t
for 13-fall reeving 141 t
for 12-fall reeving 130 t

15-fall 14-fall 13-fall 12-fall

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 Rigging work
13.5 Rigging work on the main boom

5-pulley hook block

max. Load bearing capacity of the hook block 125 t
max. Lifting capacity with the GMK 6300:
for 11-fall reeving 120 t
for 10-fall reeving 109 t
for 9-fall reeving 98 t
for 8-fall reeving 88 t

11-fall 10-fall 9-fall 8-fall

3-pulley hook block

max. Load bearing capacity of the hook block 80 t
max. Lifting capacity with the GMK 6300:
for 7-fall reeving 77 t
for 6-fall reeving 66 t
for 5-fall reeving 55 t
for 4-fall reeving 44 t

7-fall 6-fall 5-fall 4-fall

1 4 1 1 5
7 5 9
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Operating Instructions GMK 6300 2 084 548 en 13 - 77

Rigging work
13.5 Rigging work on the main boom

1-pulley hook block

max. Load bearing capacity of the hook block 35 t
max. Lifting capacity with the GMK 6300:
for 3-fall reeving 32 t
for 2-fall reeving 22 t
for 1-fall reeving 11 t

3-fall 2-fall 1-fall

1-fall

Hook tackle
max. Hook tackle load bearing capacity 12 t
max. Load bearing capacity with the GMK 6300 11 t
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 Rigging work
13.5 Rigging work on the main boom

13.5.5 Anemometer

When operating the main boom you should install the anemometer onto
the holder on the main boom head.

5 6
• Fit the anemometer (1) onto the holder (4)
4 on the main boom head.
• Turn the anemometer so that the bores (5)
and (6) in the anemometer and holder are
aligned with each other.
• Insert the retaining pin (3) into the bore.
• Check for movement of the anemometer.
The anemometer must return to a vertical
position after being swung outwards.
3
1 • The connecting flange (2) is connnected at
2 the terminal box on the main boom head.

H
C0437

Lay the cable in such a way that it cannot be chafed or crushed.

• Connect the plug of the connecting cable

to the socket (1) of the terminal box on the
head of the main boom.

H The anemometer must be removed before unrigging the main boom.

The retaining pin remains in the holder.
01.02.2000

If the anemometer is not to be plugged into the two-stage swing-away lat-

tice extension, it must be stored away safely.

Operating Instructions GMK 6300 2 084 548 en 13 - 79

Rigging work
13.5 Rigging work on the main boom

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 ____________________________________________________________________________________ 14
14 Auxiliary hoist assembly/disassembly . . . . . . . . . . . . . 14 - 1
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane . . . 14 - 3
14.1.1 CHECKLIST: Mounting with auxiliary crane . . . . . . . . . . . . . . . . . 14 - 3
14.1.2 CHECKLIST: Dismounting with auxiliary crane . . . . . . . . . . . . . . . 14 - 6
14.2 CHECKLISTS: Mounting/dismounting with counterweight
lifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 9
14.2.1 CHECKLIST: Mounting with counterweight lifting gear . . . . . . . . . . . 14 - 9
14.2.2 CHECKLIST: Removal with counterweight lifting gear . . . . . . . . . . . 14 - 12
14.3 Rigging work during mounting/dismounting . . . . . . . . . . . . 14 - 15
14.3.1 Slinging points and transport . . . . . . . . . . . . . . . . . . . . . . . . 14 - 15
14.3.2 Attaching and reeving the guy unit . . . . . . . . . . . . . . . . . . . . . 14 - 18
14.3.3 Lift auxiliary hoist to the main hoist with auxiliary crane . . . . . . . . . 14 - 21
14.3.4 Locking the auxiliary hoist / releasing lock . . . . . . . . . . . . . . . . . 14 - 22
14.3.5 Establishing/disconnecting the hydraulic connection . . . . . . . . . . . . 14 - 23
14.3.6 Establishing/disconnecting electrical connection . . . . . . . . . . . . . . 14 - 24
14.3.7 Lifting/lowering the auxiliary hoist with the counterweight . . . . . . . . 14 - 25
14.3.8 Checking that the auxiliary hoist is functioning properly . . . . . . . . . 14 - 28
14.3.9 Transport protection for the upper sheave . . . . . . . . . . . . . . . . . 14 - 29
14.3.10 Permitted utilization options for the auxiliary hoist . . . . . . . . . . . . . 14 - 30
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2 084 548 en Operating Instructions GMK 6300

 Auxiliary hoist assembly/disassembly

14 Auxiliary hoist assembly/disassembly

The GMK 6300 truck crane can be equipped with two different auxiliary
hoists as additional equipment. Only one auxiliary hoist can be mounted
on the truck crane at one time.
No auxiliary hoist may be mounted for on-road driving with a maximum
of 12 t axle load.

An auxiliary hoist is available for operation

with all lattice extensions (boom extension,
luffing jib, heavy load lattice extension, or au-
xiliary single-sheave boom top – all as addi-
tional equipment).

You recognize this auxiliary hoist by the hol-

ders (1) for the bottom sheave, which is re-
quired for operation with the luffing jib.

With the second auxiliary hoist, only opera-

tion with the heavy load lattice extension or
the auxiliary single-sheave boom top (both
additional equipment) is possible.

This auxiliary hoist has no holders for the

bottom sheave and less hoist cable.

H This chapter describes only the mounting and dismounting of the auxi-
liary hoists (additional equipment). Information on other rigging work for
operation with luffing jib which also concerns the auxiliary hoist can be
found in the chapter Luffing jib in the GMK 6300 lattice extension operating
manual.
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Operating Instructions GMK 6300 2 084 548 en 14 - 1
Auxiliary hoist assembly/disassembly

There are two ways to mount/dismount:

– With an auxiliary crane
– With counterweight lifting gear (only with additional equipment).

With the first method, the auxiliary hoist is lifted to the truck crane with an
auxiliary crane and bolted there.
In the second option, the auxiliary hoist is placed on the supplied folding
carrier of the top counterweight section with the truck crane or an auxilia-
ry crane and lifted onto the main hoist together with the counterweight by

H
the counterweight lifting cylinders and bolted there.

The assembly of the two auxiliary hoists (additional equipment) is diffe-

rent. For this reason, not all work steps in the checklists for the auxiliary
hoist for mounting and dismounting have to be followed for the operation
with the auxiliary single-sheave boom top or the heavy load lattice exten-
sion.

There are checklists for both mounting/dismounting methods. Proceed ac-

cording to the checklist which corresponds to the desired method.
➠ CHECKLISTS: Mounting/dismounting with auxiliary crane, p. 14-3.
➠ CHECKLISTS: Mounting / dismounting with counterweight lifting gear,
p. 14-9.

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 Auxiliary hoist assembly/disassembly
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane

14.1 CHECKLISTS: Mounting/dismounting with auxiliary

crane

14.1.1 CHECKLIST: Mounting with auxiliary crane

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Prerequisites – The superstructure is turned to the front and locked.

– The main boom is in the boom support.

If the auxiliary hoist is rigged for operation with the auxiliary single-
sheave boom top or the heavy load lattice extension, only points 1
through 7 have to be carried out.

1. Auxiliary hoist is slung on auxiliary crane; ➠ Slinging points, p. 14-15.

2. Remove safety pin and pull out the fastening pin at the main hoist.

3.. Lift auxiliary hoist to the main hoist using the auxiliary crane and bolt
it there;
➠ Lift the auxiliary hoist with the auxiliary crane onto the main hoist,
p. 14-21.
➠ Lock the auxiliary hoist / release lock , p. 14-22.
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Operating Instructions GMK 6300 2 084 548 en 14 - 3
Auxiliary hoist assembly/disassembly
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane

4. Establish the hydraulic connection; ➠ p. 14-23.

5. Establish the electrical connection; ➠ p. 14-24.

6. Check that the auxiliary hoist is functioning properly; ➠ p. 14-28.

7. If loads are to be lifted with the auxiliary hoist, reeve the hoist rope
and connect the lifting limit switch; ➠ Permissible utilization options for
the auxiliary hoist, p. 14-30.

The following points must only be carried out if the auxiliary hoist is
rigged for operation with a luffing jib.

8. If necessary, attach the lower sheave of the guying device for the luf-
fing control arm on the auxiliary hoist; ➠ Secure and reeve the guy unit –
lock the bottom sheave, p. 14-19.

9. If necessary, reeve the upper and lower sheaves of the guy unit for
the luffing control arm; ➠ Secure and reeve the guy unit – reeve the top /
bottom sheave, p. 14-19.
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 Auxiliary hoist assembly/disassembly
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane

10. Remove the transport protection between the upper sheave and the
auxiliary hoist; ➠ Transport protection for the upper hook block, p. 14-29.

H For other rigging work, (e. g. attaching the guy unit to the luffing control
arm), which also concerns the auxiliary hoist is described in the chapter
on the luffing jib; ➠ Attaching the upper hook block to the luffing control arm,
in the GMK 6300 Lattice extension operating manual.
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Operating Instructions GMK 6300 2 084 548 en 14 - 5

Auxiliary hoist assembly/disassembly
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane

14.1.2 CHECKLIST: Dismounting with auxiliary crane

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Prerequisites – The superstructure is turned to the front and locked.

– The main boom is in the boom support.
– The auxiliary hoist rope is rolled up on the drum.
– For operation with the luffing jib, the guy unit for the luffing control
arm is attached to the auxiliary hoist on the shelf; ➠ release the upper
hook block from the luffing control arm, in the GMK 6300 Lattice extension
operating manual.
1.. Disconnect electrical connection; ➠ p. 14-24.

2. Disconnect the hydraulic connection; ➠ p. 14-23.

3. Auxiliary hoist is slung on auxiliary crane; ➠ Slinging points, p. 14-15.

4. Loosen locking pin connection and set auxiliary hoist onto the separa-
te vehicle with the auxiliary crane; ➠ Locking the auxiliary hoist / Relea-
sing the locking pin, p. 14-22.
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 Auxiliary hoist assembly/disassembly
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane

5. Insert fastening pin for transport into the holders on the main hoist
and secure with the safety pin.

6. Check the transport position of the auxiliary hoist;

➠ Transport, p. 14-16.
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Auxiliary hoist assembly/disassembly
14.1 CHECKLISTS: Mounting/dismounting with auxiliary crane

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 Auxiliary hoist assembly/disassembly
14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear

14.2 CHECKLISTS: Mounting/dismounting with

H
counterweight lifting gear

For mounting/dismounting of the auxiliary hoist, the top 14

t-counterweight section must be equipped with folding carriers
(additional equipment).

14.2.1 CHECKLIST: Mounting with counterweight lifting gear

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Prerequisites – The truck crane is stabilized with the required outrigger span for crane
work according to the Lifting capacity table; ➠ Outrigger span, p. 13-13.
– At least 50 t is rigged and the counterweight version is lowered onto
the counterweight platform;
➠ CHECKLIST: Rigging the counterweight, p. 13-42.
– The current rigging code of the truck crane is entered in the SLI;
➠ Setting the rigging mode, p. 12-16.

If the auxiliary hoist is rigged for operation with the auxiliary single-
sheave boom top or the heavy load lattice extension, only points 1 to
3 and 5 to 12 have to be carried out.

1. Unfold folding carriers on the top 14 t counterweight section;

➠ Fold out/in folding carrier, p. 14-25.

2. Sling auxiliary hoist onto truck crane or auxiliary crane; ➠ Slinging

points and transport, p. 14-15.
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Operating Instructions GMK 6300 2 084 548 en 14 - 9
Auxiliary hoist assembly/disassembly
14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear

3. Set auxiliary hoist with the truck crane or auxiliary crane onto the fol-
ding carriers of the top 14 t-counterweight section; ➠ Place the auxi-
liary hoist on the folding carrier, p. 14-26.

4. If the auxiliary hoist is rigged for operation with a luffing jib, attach
the lower sheave of the guying device for the luffing control arm on
the auxiliary hoist if necessary; ➠ Secure and reeve the guy unit – lock
the bottom sheave, p. 14-19.

5. Turn the superstructure to the rear and lock it in place;

! ➠ Superstructure lock, p. 12-6.

6. Remove safety pin and pull out the fastening pin at the main hoist.

7. Lift auxiliary hoist with counterweight onto the main hoist;

➠ Hoisting the auxiliary hoist with counterweight, p. 14-25.

8. Bolt auxiliary hoist onto main hoist; ➠ Locking the auxiliary hoist / Relea-
sing the locking pin, p. 14-22.
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 Auxiliary hoist assembly/disassembly
14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear

9. Establish the hydraulic connection; ➠ p. 14-23.

10. Establish the electrical connection; ➠ p. 14-24.

11. Checking that the auxiliary hoist is functioning properly; ➠ p. 14-28.

12.. If loads are to be lifted with the auxiliary hoist, reeve the hoist rope
and connect the lifting limit switch; ➠ Permissible utilization options for
the auxiliary hoist, p. 14-30.

The following points must only be carried out if the auxiliary hoist is
rigged for operation with a luffing jib.

13. If necessary, reeve the upper and lower sheaves of the guy unit for
the luffing control arm; ➠ Secure and reeve the guy unit – reeve the top/bot-
tom sheave,, p. 14-19.

14. Remove the transport protection between the upper sheave and the
auxiliary hoist; ➠ Transport protection for the upper hook block, p. 14-29.

H For other rigging work, (e. g. attaching the guy unit to the luffing con-
trol arm), which also concerns the auxiliary hoist is described in the
chapter on the luffing jib; ➠ Attaching the upper hook block to the luffing
control arm, in the GMK 6300 Lattice extension operating manual.
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Auxiliary hoist assembly/disassembly
14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear

14.2.2 CHECKLIST: Removal with counterweight lifting gear

H This checklist is not equivalent to complete operating instructions. There

are accompanying instructions, which are indicated by cross-references.
Observe the warning and safety information given there!

Prerequisites – The truck crane is stabilized with the required outrigger span for crane
work according to the. Lifting capacity table Required outrigger span on
outriggers; ➠ Outrigger span, p. 13-13.
– At least 50 t counterweight is rigged and the folding carriers on the top
counterweight section are folded out;
➠ CHECKLIST: Rigging the counterweight, p. 13-42.
– The current rigging code of the truck crane is entered in the SLI;
➠ Setting the rigging mode, p. 12-16.

1. Turn the superstructure to the rear and lock it in place;

! ➠ Superstructure lock, p. 12-6.
2.. Disconnect electrical connection; ➠ p. 14-24.

3. Disconnect the hydraulic connection; ➠ p. 14-23.

4. Extend the lifting cylinder of the 8-t base plate into the counterweight
platform; ➠ Extending/retracting the lifting cylinder of the 8-t base plate,
p. 13-56.
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 Auxiliary hoist assembly/disassembly
14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear

5. Retract locking pin between counterweight and turntable; ➠ p. 13-59.

6. Release the pin connection between the auxiliary hoist and the main
hoist; ➠ Locking the auxiliary hoist / Releasing the locking pin, p. 14-22.

7. Lower auxiliary hoist with the counterweight; ➠ Lowering the auxiliary

hoist with counterweight, p. 14-27.

8. If the auxiliary hoist is being lifted onto the separate vehicle with the
¥ truck crane, release the superstructure lock and turn the superstructu-
re to the rear; ➠ Superstructure lock, p. 12-6.

9. Sling auxiliary hoist onto truck crane or auxiliary crane; ➠ Slinging

points, p. 14-15.

10. Place the auxiliary hoist onto the separate vehicle with the truck crane
or auxiliary crane; ➠ Locking the auxiliary hoist / Releasing the locking pin,
p. 14-22.
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Operating Instructions GMK 6300 2 084 548 en 14 - 13
Auxiliary hoist assembly/disassembly
14.2 CHECKLISTS: Mounting/dismounting with counterweight lifting gear

11. Insert fastening pin for transport into the holders on the main hoist
and secure with the safety pin.

12. Check the transport position of the auxiliary hoist; ➠ Slinging points
and transport, p. 14-16.

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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3 Rigging work during mounting/dismounting

14.3.1 Slinging points and transport

Slinging points Depending on the installation method, you must sling the auxiliary hoist
onto auxiliary crane or the truck crane.

The auxiliary hoist is equipped with four slin-

ging points (1, 2) for operation with all lattice
extensions.

• Sling the auxiliary hoist only on the slin-

ging points (1, 2).
The slinging points are designed so that the
auxiliary hoist can be lifted together with the
reeved guying device for the luffing control
arm;
➠ Attaching and reeving the guy unit, p. 14-18.

The auxiliary hoist is equipped with four slin-

ging points (1, 2) for operation with auxiliary
single-sheave boom top or heavy load lattice
extension.

• Sling the auxiliary hoist only on the slin-

ging points (1, 2).
The slinging points are arranged in such a
way that the auxiliary hoist can be complete-
ly lifted.

G
Risk of accidents if used incorrectly!
Only sling the auxiliary hoist onto the slinging points intended for this
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purpose. Always use lifting gear with sufficient load bearing capacity;

Operating Instructions GMK 6300 2 084 548 en 14 - 15

Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

Transport The auxiliary hoist must be dismounted and placed on a separate ve-
hicle for transport on public streets with a permissible axle load of
max. 12 t.

S
Risk of accidents from slipping load!
Attach the auxiliary hoist onto the separate vehicle so that it cannot slip
off. Insert the hydraulic hoses and the electrical cable into the dummy
connection and secure the reeved guy unit on its resting place.

G
Risk of accidents from damaged auxiliary hoist rope!
Ensure that the hoist rope is not damaged during loading of the auxiliary
hoist. This avoids loads falling from the luffing jib.

• Load the separate vehicle so that the load is distributed evenly on the
axles.
Transport the auxiliary hoist only on a separate vehicle with sufficient
load capacity and loading area; ➠ Transport dimensions and weights in the
GMK 6300 Lattice extension operating manual.

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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

Bring the auxiliary hoist into the following transport position.

For both auxiliary hoists:

– The electrical plug is in the dummy socket (4); ➠ p. 14-24.
– The hydraulic connections fit at the dummy connections (5);
➠ 14-23.
– The auxiliary hoist is attached to the separate vehicle.
– The bolts to attach onto the main hoist are in the holes in the main
hoist and are secured with locking pins.

In addition, for the auxiliary hoist for operation with luffing jib:
– The bottom sheave of the guying device for the luffing control arm is
bolted to the auxiliary hoist (6); ➠ p. 14-18.
– The upper sheave (1) is reeved and attached to the auxiliary hoist with
the staining screws (2); ➠ p. 14-29.
– The rope end clamp is either attached to the bottom sheave (7) or to the
holder (3) if the upper and lower sheaves are not mounted.

In addition, for the auxiliary hoist for operation with the heavy load
lattice extension or the auxiliary single-sheave boom top:
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– The rope end clamp is fastened to the holder (3).

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Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.2 Attaching and reeving the guy unit

The auxiliary hoist is connected to the luffing control arm with a guy unit
for operation with a luffing jib. Before mounting the auxiliary hoist you

H
must attach the guying device to the auxiliary hoist and reeve it.

You do not need to remove the guying device for transport on a separate
vehicle. The guying device is transported while attached to the auxiliary
hoist and reeved; ➠ Transport, p. 14-16. You only need to unreeve the
guying device when the auxiliary hoist rope is replaced or when you want
to reeve a hook block on the auxiliary hoist.

The guy unit consists of:

– The upper sheave (1)

– The lower sheave (2)
– The holder on the auxiliary hoist (3)
– The fastening pin (4) with safety pins

H If you rig the auxiliary hoist with an auxiliary crane, you can attach the
guying device and reeve it after the auxiliary hoist is attached to the main
hoist.
If you rig the auxiliary hoist without an auxiliary crane, you must attach
the guy unit before the auxiliary hoist is attached to the main hoist becau-
se you cannot later reach the rigged auxiliary hoist with the truck crane.
To reeve the guy unit, the auxiliary hoist must be attached to the main
hoist and must be electrically and hydraulically connected. It is therefore
advisable to always rig the guy unit with an auxiliary crane.
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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

Lock the • Remove the safety pin and pull the two attachment bolts from the hol-
lower sheave der on the auxiliary hoist.

• Sling the lower sheave (1) at the slinging

points with an auxiliary crane and hang it
on the holder (2).
• Align the lower sheave so that the front
holes align and insert an fastening pin (3)
through the front holes.

• Lower the lower sheave with the auxiliary

crane until the rear bore hole (1) align and
insert the other attachment pin through
the rear bore holes.
• Secure the two fastening pin with the safe-
ty pins.

Reeving the You must unreel the auxiliary hoist rope to reeve the upper and lower
upper/lower sheaves. Therefore, before reeving the upper sheave:
sheaves – The auxiliary hoist must be bolted onto the main hoist.
– The electrical connection must be established.
– The hydraulic connection must be established.
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Operating Instructions GMK 6300 2 084 548 en 14 - 19
Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

G
Risk of accidents from too little reeving!
The auxiliary hoist rope is designed so that it is possible to operate the
luffing jib with quintuple reeving. Therefore, always reeve the hoist rope
between the upper and lower sheaves five times. This avoids the hoist
cable from becoming overloaded with little reeving and breaking during
luffing jib operation.

• Unreel the auxiliary hoist rope (4). Ensure

that the hoist cable is between the retai-
ning rods (3) and the cable drum.
• Sling the upper sheave (1) onto the auxilia-
ry crane and hang it over the lower sheave.
• Remove the locking pins and the cable re-
taining rods and rolls (2) and (5) on the up-
per and lower hook blocks.
You must remove the cable end clamp to ree-
ve the auxiliary hoist. Remove the cable
clamp and pull out the hoist cable with the
anchor wedge; ➠ Cable end clamp, p. 13-67.

• Reeve the auxiliary hoist rope according to

the diagram at the left. (The upper three
wheels represent the upper sheave, the lo-
wer two represent the lower sheave.)
• Run the hoist rope from below over the
first wheel into the upper sheave.
• Run the hoist rope from above over the
first wheel into the lower sheave and go
from underneath into the next wheel of
the upper sheave.
• Repeat the procedure until the hoist rope
is reeved five times.
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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

• Reattach the cable end clamp to the auxi-

liary hoist rope and observe the note in the
Cable end clampsection ➠ p. 13-67.
• Attach the cable end clamp to the holder
(1) on the lower sheave.
• Attach the rope holding rods (2) with the
rope holding rolls to the bottom hook
block and secure the cable retaining rods
with the retaining pins.
• Secure the rope on the upper hook block
as well.

14.3.3 Lift auxiliary hoist to the main hoist with auxiliary crane

If you wish to lift the auxiliary hoist to the main hoist with the counter-
weight; ➠ p. 14-25.

• Check whether the attachment bolts are pulled from the holder on the
main hoist.

• Sling the auxiliary hoist onto an auxiliary crane; ➠ Slinging points ,

p. 14-15.
• Lift the auxiliary hoist to the main hoist
with the auxiliary crane. When doing this,
ensure that:
– the two hooks (3) grip into the holders
- on the main hoist and that
– the holders of the main hoist and
- auxiliary hoist align with each other at
positions (1) and (2)

• Correct the position of the auxiliary hoist if

necessary.
• Hold the auxiliary hoist in this position.
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Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.4 Locking the auxiliary hoist / releasing lock

The auxiliary hoist is attached to the main hoist at the bottom with two
bolts and held onto the main hoist at the top with two hooks.

Locking the auxiliary hoist

• If necessary, correct the position of the au-
xiliary hoist with the auxiliary crane or the
counterweight lifting gear so that the hol-
ders and mountings on the main and auxi-
liary hoist align.
• Insert the two bolts (1) and (2) through the
bracket and holders at the auxiliary and
main hoist.
• Secure the bolts with securing pins (3).

Releasing the locking pins

G
The bolt connection may only be disconnected if the auxiliary hoist is
slung onto an auxiliary crane or if it is on the folding carriers of the coun-
terweight.

• Relieve the load on the bolt connection by lifting or lowering the auxi-
liary hoist with the auxiliary crane or the counterweight lifting gear.
• Remove the retaining pin and hammer the two bolts (1) and (2) inward
through the brackets and holdings on the auxiliary and main hoist.

H
The bolts fall onto the counterweight section.

After lifting or lowering the auxiliary hoist insert both fastening pins back
into the mountings on the main hoist and protect them for on-road
driving with the securing plugs.
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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.5 Establishing/disconnecting the hydraulic connection

The auxiliary hoist is connected to the hydraulics of the truck crane by

three hoses with quick couplings.

Establishing the hydraulic connection

• Unscrew the three hydraulic hoses from the dummy connections (4, 5,
6) and screw them onto the connections (1, 2, 3).
The connections (1) and (2) and the associated quick couplings on the ho-
ses are colour coded and the connection (3) is smaller.

Breaking the hydraulic connection

• Unscrew the three hydraulic hoses from the connections (1, 2, 3) and
screw them onto the dummy connections (4, 5, 6).
Ensure that the connections (1, 2, 3) are protected against dirt with the
seal caps.
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Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.6 Establishing/disconnecting electrical connection

The auxiliary hoist is connected to the electrical supply of the truck crane
by an electrical line with a plug.

Establishing the electrical connection

• Remove the plug from the dummy socket (2) and insert it into the sok-
ket (1) on the main hoist.

Disconnecting electrical connection

• Remove the plug from the socket (1) on the main hoist and insert it into
the dummy socket (2).
• Close the cover on the socket (1) so that it is protected against dirt.

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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.7 Lifting/lowering the auxiliary hoist with the counterweight

H If you wish to lift the auxiliary hoist to the main hoist with the counter-
weight, the top 14-t counterweight section must be equipped with folding
carriers (additional equipment).

Folding the fol- The folding carriers are folded out to lift the auxiliary hoist and remain fol-
ding carriers in ded out during crane work. After the auxiliary hoist is removed, the fol-
and out ding carriers must be folded back in.

G
Risk of accidents from projecting folding carrier!
Always fold the folding carriers in if the auxiliary hoist is rigged or if the
14-t counterweight section is being transported.
This keeps overhanging folding carriers from injuring persons when the
superstructure rotates and keeps them from being damaged during
transport.

Folding out the folding carriers

• Fold back the folding carrier (2) onto the
holder (1).
• Also fold out the other folding carrier
toward the rear.

Fold the folding carrier in

• Fold the folding carrier (2) on the bracket
(1) forward.
• Also fold up the other folding carrier.
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Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

Place the You can place the auxiliary hoist onto the folding carrier with an auxiliary
auxiliary hoist crane or the truck crane.
onto the
folding carrier

• Sling the auxiliary hoist; ➠ Slinging points,

p. 14-15.
• Set down the auxiliary hoist so that the co-
nical feet (4) of the auxiliary hoist stick into
the bore holes (1) and the flat feet (3) are
on the mountings (2).

Lifting the When the auxiliary hoist is in the holders of the folding carrier, you can
auxiliary hoist lift it together with the counterweight.

• Check whether the two attachment bolts are pulled out of the holders
on the main hoist.

• Read the information in the Extending/retracting the lifting cylinder of the 8-t
base plate section; ➠ p. 13-56, before you hoist the auxiliary hoist.
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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

• Turn the Pressure build-up switch unit switch to the right and hold it there.
• In addition press the Extend lifting cylinders/lift counterweight switch on the
moving control unit and hold it down until the auxiliary hoist is lifted
with the counterweight and the bores are aligned on the main and auxi-
liary hoist.

H If the bore holes on the main and auxiliary hoist do not align after lifting
and a correction by lowering is not possible, you can align the auxiliary
hoist with the adjustment screws on the feet.

Lowering the Before you lower the auxiliary hoist with the counterweight, check
auxiliary hoist whether:

– The electrical connection is detached.

– The hydraulic connection is detached.
– The bolt connection between the main and auxiliary hoist is detached.

• Read the information in the Extending/retracting the lifting cylinder of the

8-t base plate section; ➠ p. 13-56, before you lower the auxiliary hoist.
• Turn the Pressure build-up switch unit switch to the right and hold it there.
• In addition press the Retract lifting cylinders / lower counterweight switch and
hold it down until the counterweight is lowered fully onto the counter-
weight platform.
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Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.8 Checking that the auxiliary hoist is functioning properly

After mounting the auxiliary hoist you must check that it functions pro-
perly when the control lever is extended and check the functioning of the
hoist drum synchro.

Switch on the auxiliary hoist. To do this, press up the Auxiliary hoist shut-
C down rocker switch on the left control console.

• Move the control lever alternating forward and back and let the auxi-
liary hoist run for about one half revolution in each direction.
• Check whether the direction of rotation for the particular control lever
position corresponds with the following specifications.
Control lever to the front: auxiliary hoist rope will be unreeled

Control lever to the rear: auxiliary hoist rope will be reeled

• Take care that slack does not form when checking.

Check the slewing indicator for jib for proper functioning. You have to feel
a pulse on the slewing indicator (1) when the auxiliary hoist is rotating;
➠ Main hoist, p. 12-36.

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 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.9 Transport protection for the upper sheave

If the upper sheave remains reeved during transport, it must be protected.

Two clamping screws are attached to the auxiliary hoist for this purpose.

Secure for transport

• Unscrew the clamping screw (2) until it co-
mes apart and insert the hook (3) into the
eye (1) of the upper sheave.
• Tighten the clamping screw until the hook
(3) can no longer slide out of the eye (1)
and the upper hook block cannot chafe
against the hoist rope during transporta-
tion.
• Secure the upper sheave with the straining
screw on the other side as well.

Detaching transport protection

• Unscrew the straining screw (2) until it comes apart and remove the
hook (3) from the eye (1).
• Fold the straining screws outwards so that they do not rub against the
hoist rope drum or the hoist rope.
• Detach the clamping screw on the other side as well.
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Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

14.3.10 Permitted utilization options for the auxiliary hoist

Not all utilization options are authorized with the auxiliary hoist. Two-
hook operation on the boom extension and two-hook operation on the
main boom head without additional equipment are prohibited.

G
Danger of accidents during two-hook operation!
Hoisting loads with two hooks is only permitted for turning loads with the
heavy load lattice extension or the auxiliary single-sheave boom top
(both additional equipment), as described in the GMK 6300 Lattice extensi-
on operating manual.
No hook block may be reeved on the main boom during operation with
the boom extension.

Use of the auxiliary hoist is permitted only in the following cases:

– For operation with the luffing jib;
– As a replacement for the main hoist; ➠ see paragraph at the bottom of
this page;
– During alternating operation with main hoist and auxiliary hoist on the
main boom; ➠ p. 14-31;
– For two-hook operation when turning loads with the heavy load lattice
extension, the auxiliary single-sheave boom top or the telescopic swing-
away lattice extension (all additional equipment).

Replacement for Each of these two auxiliary hoists can be used as a replacement for the
the main hoist main hoist in
– Main boom operation
– Operation with heavy load lattice extension (additional equipment)
– Operation with the auxiliary single-sheave boom top
(additional equipment)
– Operation with the telescopic swing-away lattice extension
(additional equipment)

Only the auxiliary hoist for operation with all lattice extensions can be used as
a replacement for the main hoist for operation with the boom extension.
• To do so, reeve the auxiliary hoist rope in the same way as the main
hoist rope; ➠ Reeve/unreeve hoist rope, p. 13-67.
• Attach the lifting limit switch and the lifting limit switch weight exactly
as for operation with the main hoist; ➠ Lifting limit switch at the main

H
boom, p. 13-72.

If you run the auxiliary hoist rope over the left head sheave (additional
01.02.2000

equipment), you must extend the main boom to a total length of at least
20 m before lifting a load. Otherwise the rope angle exceeds the maxi-
mum permitted value.

14 - 30 2 084 548 en Operating Instructions GMK 6300

 Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

Alternating opera- If the truck crane is equipped with a second head sheave (additional equip-
tion with the ment) on the main boom, you can reeve the auxiliary hoist rope and the
main and auxilia- main hoist rope on the main boom (or on the main boom and auxiliary
ry hoists single-sheave boom top) at the same time and work alternately with one
hoist or the other.
For this mode there is a socket for connecting a second lifting limit switch
on the right side of the main boom.

G
Danger of accidents during two-hook operation!
During alternating operation the load must always hang on only one
hook block. If you sling the load on both hook blocks but lift it with only
one of the blocks, you are already in the non-permitted two-hook mode
which is no longer secured by the SLI.

• Connect both lifting limit switches.

• Place the appropriate lifting limit switch weight on each of the two hoist
ropes.
The respective hoist with which the load is to be lifted must be set on the
SLI before operation. Proceed as follows:
• Switch off both hoists. The Hoisting gear indicator lamps on the SLI go out.
üC • Switch on the hoist with which you wish to lift the load.
The respective Hoisting gear indicator lamp lights up.
• Enter the reeving of the hoist with which the load is to be lifted in the
" n= Reeving display.

The correct hoist is now set on the SLI and crane operation is secured by
the SLI. The maximum load is reduced by the weight of the second hook

H
block.

For further information about switching the Hoist indicator lamps;

➠ p. 12-22.

H If you unreeve a hoist rope again and pull the plug of the lifting limit
switch from the terminal box or the socket, you must insert the short-cir-
cuit plug there. Otherwise the crane control system detects a shutdown of
the lifting limit switch, the warning lamp Lifting limit switch shutdown lights
up and all load moment increasing motions are switched off.
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Operating Instructions GMK 6300 2 084 548 en 14 - 31

Auxiliary hoist assembly/disassembly
14.3 Rigging work during mounting/dismounting

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01.02.2000

14 - 32 2 084 548 en Operating Instructions GMK 6300

 ____________________________________________________________________________________ 15
15 Malfunctions on the superstructure . . . . . . . . . . . . . . . 15 - 1
15.1 Superstructure emergency stop device . . . . . . . . . . . . . . . . 15 - 1
15.2 Troubleshooting for malfunctions that occur during
crane operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 3
15.3 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
15.3.1 Plug-in modules and consoles . . . . . . . . . . . . . . . . . . . . . . . . 15 - 5
15.3.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 7
15.3.3 SLI fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 13
15.4 Troubleshooting and malfunction correction . . . . . . . . . . . . . 15 - 15
15.4.1 Crane engine malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 15
15.4.2 Main hoist malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 17
15.4.3 Auxiliary hoist malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 19
15.4.4 Derricking gear malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 21
15.4.5 Telescoping gear malfunctions . . . . . . . . . . . . . . . . . . . . . . . . 15 - 22
15.4.6 Slewing gear malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 25
15.4.7 Counterweight lifting gear / lock malfunctions . . . . . . . . . . . . . . . 15 - 26
15.4.8 Hydraulic system / hydraulic oil cooler malfunctions . . . . . . . . . . . 15 - 27
15.4.9 Crane control malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 28
15.4.10 Malfunctions on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 29
15.4.11 Retraction emergency operation . . . . . . . . . . . . . . . . . . . . . . 15 - 44
15.4.12 Switching the fan thermostat to emergency operation . . . . . . . . . . . 15 - 60
15.5 Crane control error messages . . . . . . . . . . . . . . . . . . . . . . 15 - 61
15.5.1 Error messages about control units . . . . . . . . . . . . . . . . . . . . . 15 - 61
15.5.2 Error messages about power units . . . . . . . . . . . . . . . . . . . . . . 15 - 62
15.5.3 Telescoping error messages . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 67
15.5.4 Changing the connections in the control units . . . . . . . . . . . . . . . 15 - 68
15.5.5 Control lever emergency program . . . . . . . . . . . . . . . . . . . . . . 15 - 72
15.5.6 Emergency operation submenu . . . . . . . . . . . . . . . . . . . . . . . 15 - 74
15.5.7 Entering telescope status after emergency operation menu . . . . . . . . 15 - 80
01.02.2000

Operating Instructions GMK 6300 2 084 548 en

 01.02.2000

2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.1 Superstructure emergency stop device

15 Malfunctions on the superstructure

15.1 Superstructure emergency stop device

The GMK 6300 truck crane is equipped with two emergency stop devices
on the superstructure. With these devices you:

– can turn off the crane engine even when outside the crane cab
(e. g. with an ignition lock malfunction or when access to the crane cab
is blocked);
– can turn off the crane control when a crane movement can not be
switched off (e. g. when there is a crane control malfunction).

Switching off the You can turn off the crane engine from outside the crane cab by switching
crane engine off the battery master switch.

The battery master switch (1) is located on

the right-hand side of the superstructure, un-
der the battery box behind the side plate,
and is accessible from below.

• Switch off the main battery switch. Turn

the selector handle so that it can be pulled
off.
The crane engine switches off.
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Operating Instructions GMK 6300 2 084 548 en 15 - 1
Malfunctions on the superstructure
15.1 Superstructure emergency stop device

Crane control In an emergency you can switch off the crane control with the Crane
emergency stop control emergency stop switch. The switch is located on the middle plug-in
switch module in the crane cab.

G
Risk of overload if used improperly!
The Crane control unit emergency stop switch is only intended for the emer-
gency when the crane functions cannot be braked or stopped by the
corresponding control lever movements. Never use this switch to brake
crane movements in normal crane operation.
The sudden stopping of the crane movement can lead to an overload of
the truck crane at high working speeds and unfavourable combinations
between the working position and rigging mode.

• Press the Crane control emergency stop switch. The switch clicks in.
The crane engine is immediately switched off; the crane functions are
abruptly stopped.

G
Risk of accidents when the load is suspended!
If a load is on the hook after the emergency stop, you must ensure that
no persons are in the danger area under the suspended load. Secure the
danger area if necessary if the fault cannot be rectified without delay and
you leave the work site.

Releasing crane functions again

As long as the Crane control emergency stop switch is engaged, the crane
functions remain blocked. Proceed as follows to check if the crane control
works normally after a new start:

• Turn off the ignition.

• Turn the Crane control emergency stop switch until it disengages.
• Let go off all control levers and start the crane engine again.

H
• Check if the crane movements are carried out as normal.

If the crane movements are not carried out as normal or if you need to
carry out an emergency shut down, notify the GROVE Product Support
responsible.
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 Malfunctions on the superstructure
15.2 Troubleshooting for malfunctions that occur during crane operation

15.2 Troubleshooting for malfunctions that occur during

crane operation
If a malfunction occurs:
• Keep calm!
• If possible put down the load immediately. Retract the main boom
completely and set it down on the boom support.
• Use warning signs in the crane cab to prevent unauthorized use of the
truck crane. Remove the ignition key.
• Inform your supervisor.

G
Risk of accidents when the load is suspended!
Under no circumstances is repair work to be carried out with a suspended
load!

You may override the SLI to set down the load if SLI malfunctions occur.
Observe the warning and safety information in the section SLI overriding
when doing so; ➠ p. 12-30.

G
Risk of accidents!
Do not perform any crane movements that may increase the size of the
load moment when a load is on the hook block and the SLI is overriden.

• Try to repair the malfunction. Notify your local GROVE Product Support
if you cannot repair the problem yourself.

Load cannot be • Secure the danger zone using cordons and assigned personnel.
lowered
• Notify qualified repair personnel or local GROVE Product Support.

G
Accidents may occur due to inappropriate emergency operation!
Only trained, qualified personnel may carry out an emergency operation
if unrigging requires the manual operation of solenoid valves.
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Operating Instructions GMK 6300 2 084 548 en 15 - 3

Malfunctions on the superstructure
15.2 Troubleshooting for malfunctions that occur during crane operation

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01.02.2000

15 - 4 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.3 Electrical system

15.3 Electrical system

15.3.1 Plug-in modules and consoles

Plug-in module
Pos. name in the Function
elec. circ. diag.
1 1.2 D Monitoring crane engine and hydraulic
system /spotlight / windscreen washing
system / additional heating system
(additional equipment)
2 5D Display, input and emergency stop for
crane control / telescoping gear / operating
mode selection (only with additional
equipment with luffing jib)
3 6D Anemometer (additional equipment) /
switchable display for electronic spirit level
/ superstructure lock / warning and
indicator lamps for luffing jib / Display for
01.02.2000

shutting down lifting limit switch/ outrigger

pressure display

s
Operating Instructions GMK 6300 2 084 548 en 15 - 5
Malfunctions on the superstructure
15.3 Electrical system

Plug-in module
Pos. name in the Function
elec. circ. diag.
1 7D Sets constant crane engine speed

2 +BE 630. KR Control lever for telescoping, derricking

and main hoist /
main hoist shutoff, derricking gear,
telescoping gear /
control level function change-over
derrick ↔ telescoping
3 +BE 630. KL Control lever for slewing gear, auxiliary
hoist (additional equipment) /
switches off auxiliary hoist /
fast speed for hoists /
slewing gear permanent brake /
inclines crane cab
4 Safe load indicator (SLI)
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15 - 6 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.3 Electrical system

15.3.2 Fuses

S
Risk of fire!
Never repair a blown fuse with a nail, with wire, aluminium foil or other
materials which conduct electricity.
Always replace defective fuses only with fuses of the indicated ratings.

The fuses are divided into the groups F1 to F13.

The fuse groups F1 to F9 can be accessed

from outside by opening the flap on the front
of the crane cab (8 mm hexagon spanner).

Each group consists of six fuses:

The following tables show the designations

of the individual fuses, their strength and
function. The designations 1 to 6 in the
following tables correspond to the order
from left to right (fuse 1 is always the left
fuse).

Designation in Rating (A) Function

circuit diagram:
F1

1 20 Crane engine E-control

2 10 Crane engine diagnostic plug

3 10 Flame start system

(additional equipment)

4 15 No function

5 10 Crane cab ceiling lamp,

cigarette lighter

6 10 No function
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Operating Instructions GMK 6300 2 084 548 en 15 - 7
Malfunctions on the superstructure
15.3 Electrical system

Designation in Rating (A) Function

circuit diagram:
F2

1 10 No function
2 10 No function
3 10 No function
4 10 No function
5 10 No function
6 15 No function

Designation in Rating (A) Function

circuit diagram:
F3

1 10 Indicator and warning lamps for

engine, hydraulic system, flame start
system
2 15 Windscreen wiper/washing system
discs
3 10 ECOS pressure switch/sensor
4 10 Control lever, high-speed derricking
and telescoping gear and hoisting
gear, slewing gear brake,
superstructure lock
5 10 Crane engine diagnostic plug
6 10 Flame start system

Designation in Rating (A) Function

circuit diagram:
F4

1 5 Switches and indicator lamps

2 15 Working spotlight, switches and
indicator lamps for working spotlight
and shutdown of derricking gear /
telescoping gear / main hoist
3 5 Horn, Switch and indicator lamps for
auxiliary hoist shutdown, Slewing gear
permanent brake and crane cab incline
4 5 Crane cab heating
5 15 Crane cab electronic level,
SLI pre-warning/shutdown,
01.02.2000

lattice extension (additional equipment)

6 10 SLI deactivation, Anchor-to-bracket-
switch shutdown,
Dead man’s switch, Seat contact

15 - 8 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.3 Electrical system

Designation in Rating (A) Function

circuit diagram:
F5

1 15 Crane control power supply

2 15 Crane control power supply

3 15 Crane control power supply

4 15 Crane control power supply

5 15 Crane control power supply

6 15 Crane control power supply

Designation in Rating (A) Function

circuit diagram:
F6

1 10 Main hoist shutoff,

main hoist drum synchro

2 10 Shutdown for auxiliary hoist,

auxiliary hoist slewing indicator

3 10 Derricking gear shutdown

telescoping gear shutdown,
telescoping cylinder/telescopic section
lock

4 10 Control lever initial position

5 10 Slewing gear

6 10 No function
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Operating Instructions GMK 6300 2 084 548 en 15 - 9
Malfunctions on the superstructure
15.3 Electrical system

Designation in Rating (A) Function

circuit diagram:
F7

1 10 SLI

2 10 Proximity switch telescoping cylinder

lattice extension (additional equipment)

3 5 No function

4 10 Crane control display

emergency operation crane control

5 10 Crane control, switch unit

counterweight hoist unit

6 10 Crane engine E-control

Designation in Rating (A) Function

circuit diagram:
F8

1 20 Crane cab heating

2 15 Radio, voltage transformer

3 15 No function

4 5 Crane control unit 0

5 5 Crane control unit 1

6 5 Crane control unit 2

Designation in Rating (A) Function

circuit diagram:
F9

1 20 No function

2 5 No function

3 15 No function

4 10 No function
01.02.2000

5 5 Central lubrication system

6 10 No function

15 - 10 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.3 Electrical system

H The fuse groups F 10 to F 13 are located in the battery box. These fuse
groups consists of only one fuse each.

• Open the front lower service flap.

The fuse groups are attached to a mounting
plate.
– The two fuses F 10 and F 11 are in
terminal box (1).
– The two fuses F 12 and F 13 are in
terminal box (2).

Terminal Designation in Rating Function

box circuit diagram: (A)

F10 50 Superstructure
1 central fuse
F11 50

F12 20 For all consumers still

supplied with current when
2
the battery master switch is
F13 20
off.
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Operating Instructions GMK 6300 2 084 548 en 15 - 11

Malfunctions on the superstructure
15.3 Electrical system

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15 - 12 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.3 Electrical system

15.3.3 SLI fuses

On the SLI you will find a fuse for the central unit and several fuses for the
SLI outlets.
All outlets are individually protected by fuses. If one of the fuses is
defective you can no longer carry out the corresponding crane function.

Replacing fuses

S
Risk of fire!
Never repair a blown fuse with a nail, with wire, aluminium foil or other
materials which conduct electricity.
Always replace defective fuses only with fuses of the indicated ratings.

EKS 3 To change a fuse you need to remove the

SLI plug-in module.

• Remove the four retaining bolts at the

corners of the front plate of the SLI
plug-in module and pull out the plug-in
module.
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Operating Instructions GMK 6300 2 084 548 en 15 - 13
Malfunctions on the superstructure
15.3 Electrical system

The fuses are on the back of the plug-in

module and are labelled S I 1 to S I 13.

The following table shows the assignment of

fuses. If a fuse is defective the relevant crane
movement can not be carried out.

Designation in Rating (A) Function

circuit diagram:

SI1 5 SLI internal

SI2 5 SLI shutdown display

SI3 5 Lift main hoist shutdown

SI4 5 Shutdown lowering

SI5 5 Shutdown extending

SI6 5 Lift auxiliary hoist shutdown

SI7 5 Shutdown raising

SI8 5 Shutdown retracting

SI9 5 Lower auxiliary hoist shutdown

S I 10 5 Lowering the lattice extension

S I 11 5 SLI early warning display

S I 12 5 Raising the lattice extension

H
S I 13 5 SLI central unit

If the fuse on an SLI outlet fails again, notify your local GROVE Product
Support.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4 Troubleshooting and malfunction correction

15.4.1 Crane engine malfunctions

Malfunction Cause Action

Engine does not start (starter Battery master switch not Switch battery master switch
motor does not turn over) switched on on; ➠ p. 11-7.
Ignition switched off Switch on ignition;
➠ p. 11-12.
Engine does not start Batteries not charged enough Charge batteries
(starter motor turns over) Fuel tank empty 1. Fill fuel tank,
➠ p. 11-9.
2. Bleed fuel system,
➠ Crane engine
operating manual
Malfunction in the motor 1. Turn off ignition.
electronics (Motor electronics 2. Wait one minute.
warning lamp lights up) 1. Check if the warning lamp
lights up.
If the warning lamp does not
light up: start!
If the warning light does light
up, repeat the
process. If the engine still
does not start, inform GROVE
Product Support.
Fuse F1/1 or F7/6 defective Check fuse, replace if
necessary; ➠ p. 15-7.
Flame-start system indicator Check fuses and replace if
lamp does not go on, fuse necessary; ➠ p. 15-7.
F1/3 faulty
Engine coolant temperature Coolant level too low Top up coolant
too high Outside of heat exchanger Clean outside of heat
(warning lamp lights up) dirty exchanger
V-belt slack on coolant pump Tighten V-belt, refer to crane
on engine engine operating manual
Engine oil pressure too low Engine oil level too low Check oil level, fill if
necessary; ➠ p. 11-4 and
Maintenance manual
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Operating Instructions GMK 6300 2 084 548 en 15 - 15
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Engine can not be turned off Malfunction in the electronics Turn off engine with
with the ignition key emergency stop device,
➠ p. 15-1
Indicator lamp Crane engine Crane engine air filter is dirty Replace crane engine air filter
air filter lights up

Indicator lamp Flame start Problem with flame-start Inform GROVE Product
system lights up when crane system Support and have the flame-
engine is running start device checked.

Motor electronics warning Malfunctions in the motor electronics cause engine

lamp goes on during driving, performance to decrease continuously. The engine will not
the engine performance gets switch off, however so lowering the load and unrigging the
worse and worse truck crane can still be done.
Coolant level too low, Coolant level; ➠ p. 11-8;
Oil level too low, Oil level; ➠ p. 11-4;
Air filter dirty. Air filter;
➠ Maintenance manual
V-belt too loose Check V-belt tension;
➠ Operating manual Mercedes-
Benz
Plug or cable on the control Check plug on control unit
unit loose (near the diagnostic plug);
➠ p. 10-58.
Cabling behind the Check cable, Notify GROVE
accelerator damaged Product Support of any
damage

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.2 Main hoist malfunctions

Malfunction Cause Action

Main hoist not functioning Rocker switch Shutdown main Switch off rocker switch
or malfunctioning (lifting, hoist switched on Shutdown main hoist
lowering or fast speed not
Fuse F3/4 SS or Check fuse, replace if
functioning)
F6/1 SS defective necessary
Dead man’s switch not Press dead man’s switch
activated
Fuse F4/2 SS or F4/3 SS Check fuse, replace if
defective necessary; ➠ p. 15-7.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-87.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 15-61.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 15-2.
Main hoist lowering not func- Lowering limit switch Leave shutdown area,
tioning (in addition, check all triggered Lift main hoist
causes in the “Main hoist not
functioning” section!)
Main hoist lifting not Lifting limit switch triggered Leave shutdown area, lower
functioning (warning lamp on) main hoist
(in addition, check all causes
SLI shutdown Leave shutdown area;
in the “Main hoist not func-
tioning” section!)
(warning lamp on) ➠ p. 12-13.
Fuse F4/6 SS or F7/1 SS Check fuse, replace if
defective necessary; ➠ p. 15-7.
Lifting limit switch On one side of the main Fit in the short-circuit plug or
shutdown warning lamp boom there is neither a lifting connect second lifting limit
lights up, lift function is blok- limit switch nor a short-circuit switch
ked but the lifting limit plug connected to the
switch weight is not lifted terminal box
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Operating Instructions GMK 6300 2 084 548 en 15 - 17

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Lifting, lowering or fast speed Corresponding function is Acknowledge error message

do not function blocked by the crane control once; ➠ p. 12-87.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 15-62.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-79.
Lifting does not function Fuse on corresponding SLI Replace if necessary;
outlet defective ➠ p. 15-7.
No lifting or lowering, or pos- Maximum speed set too low Increase maximum speed on
sible only at very low speed the display Enter power unit
speed; ➠ p. 12-83.
Lifting or lowering function Malfunction on the crane Stop the movement with the
can not be switched off control Crane control emergency stop

H
switch; ➠ p. 15-2.

If a malfunction occurs, first check whether it applies in both directions of

movement.
In this case also check the causes listed in the Main hoist not functioning
section!

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.3 Auxiliary hoist malfunctions

Malfunction Cause Action

Auxiliary hoist not Rocker switch Shutdown Switch off rocker switch
functioning or malfunctioning auxiliary hoist switched on Shutdown auxiliary hoist
(lifting, lowering or fast speed Fuses F3/4 SS or F4/2 SS or Check fuses, replace if
not functioning) F6/2 SS defective necessary; ➠ p. 15-7.
Dead man’s switch not Press dead man’s switch;
activated ➠ p. 10-62.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-87.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 15-61.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 15-2.
Auxiliary hoist lowering not Lowering limit switch Leave shutdown area,
functioning (Also check all triggered Lift main hoist
causes in the “Auxiliary hoist
not functioning” section!)
Auxiliary hoist lifting not Lifting limit switch triggered Leave shutdown area,
functioning (Also check all (warning lamp on) Lower the auxiliary hoist
causes in the “Auxiliary hoist SLI shutdown Leave shutdown area
not functioning” section!) (warning lamp on)
Fuse F4/6 SS or F7/1 SS Check fuse, replace if
defective necessary; ➠ p. 15-7.
Lifting limit switch On one side of the main Fit in the short-circuit plug or
shutdown warning lamp boom there is neither a lifting connect second lifting limit
lights up, lift function is blok- limit switch nor a short-circuit switch
ked but the lifting limit plug connected to the
switch weight is not lifted terminal box

Lifting, lowering or fast speed Corresponding function is Acknowledge error message

do not function blocked by the crane control once; ➠ p. 12-87.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 15-62.
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Operating Instructions GMK 6300 2 084 548 en 15 - 19
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Corresponding function is Switch off ignition briefly then

blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-79.
No lifting or lowering, or pos- Maximum speed set too low Increase maximum speed on
sible only at very low speed the display Enter power unit
speed; ➠ p. 12-83.
Lowering does not function Fuse on corresponding SLI Replace if necessary;
outlet defective ➠ p. 15-13.
Lifting or lowering function Malfunction on the crane Stop the movement with the
can not be switched off control Crane control emergency stop

H
switch; ➠ p. 15-2.

If a malfunction occurs, first check whether it applies in both directions of

movement.
In this case also check the causes listed in section Auxiliary hoist not
functioning!

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.4 Derricking gear malfunctions

Malfunction Cause Action

Derricking gear not func- Dead man’s switch system Press dead man’s switch,
tioning or malfunctioning not activated ➠ p. 10-62.
(raise boom, lower boom or
Fuse F3/4 SS or F6/3 SS Check fuse, replace if
fast speed not functioning)
defective necessary; ➠ p. 15-7.
The right-hand control lever is Set control lever to Derricking
switched to Telescope function function
Rocker switch Shutdown Switch off rocker switch
derricking gear switched on Shutdown derricking gear
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-87. If the error
message is displayed) message is repeated, change
the connections on the
control units; ➠ p. 15-61.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 15-2.
Lower boom not functioning Lifting limit switch triggered Leave shutdown area,
(Also check all causes in the (warning light on) raise boom
“Derricking gear not func-
SLI shutdown Leave shutdown area;
tioning” section!)
(warning lamp on) ➠ p. 12-13
Fuse F4/6 SS or F7/1 SS Check fuse, replace if
defective necessary
Raising or lowering the boom Corresponding function is Acknowledge error message
do not function blocked by the crane control once; ➠ p. 12-87.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 15-62.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-79.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 15 - 21
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Raising or lowering the boom Fuse on corresponding SLI Replace if necessary;

does not function outlet defective ➠ p. 15-13.
No raising or lowering the Maximum speed set too low Increase maximum speed on
boom, or possible only at the display Enter power unit
very low speed speed; ➠ p. 12-83.

Raising or lowering the boom Malfunction on the crane Stop the movement with the
function can not be switched control Crane control emergency stop
switch; ➠ p. 15-2.

H
off

If a malfunction occurs, first check whether it applies in both directions of

movement.
In this case also check the causes listed in the Derricking gear not
functioning section!

15.4.5 Telescoping gear malfunctions

Malfunction Cause Action

Telescoping gear not Dead man’s switch system Press dead man’s switch;
functioning or malfunctioning not activated ➠ p. 10-62.
(telescope in, telescope out or Fuse F7/2 SS or F3/4 SS or Check fuses, replace if
fast speed not functioning) F6/3 SS defective necessary; ➠ p. 15-7.
Right-hand control lever set to Set control lever to Telescoping
Derricking function
The Telescoping gear shutdown Switch off rocker switch
rocker switch is switched on Shutdown telescoping gear;
➠ p. 10-36.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-87.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 15-61.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 15-2.
01.02.2000

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Telescope section and tele- Valve defective Note down the Display status –
scoping cylinder do not locking number code on the
display and inform GROVE
lock/unlock any functions
Product Support; ➠ p. 15-62.
Extension of the telescoping SLI shutdown Leave shutdown area
not functioning (warning lamp on)
(Also check all causes in the Fuse F4/6 SS or F7/1 SS Check fuse, replace if
“Telescoping gear not defective necessary; ➠ p. 15-7.
functioning” section!) Lifting limit switch triggered Leave shutdown area,
(warning lamp on) Lower hoist
Telescope retracting not Insufficient boom lubrication Lubricate boom,
functioning (Also check all ➠ Maintenance manual
causes in the “Telescoping Boom too flat Raise boom
gear not functioning”
section!)

Telescope section does not Telescope section is still Unlock telescope section;
move when the control lever locked ➠ p. 12-65.
is extended Telescoping cylinder is not Lock telescope cylinder;
locked ➠ p. 12-62.
Lock telescope section/ Defective hydraulics/electrics Note down the number code
telescoping cylinder not on the status display when
functioning locking and inform GROVE
Product Support; ➠ p. 12-79.
Telescoping out or in or fast Corresponding function is Acknowledge error message
speed not functioning blocked by the crane control once; ➠ p. 12-87.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 15-62.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-79.
Retracting or extending does Fuse on corresponding SLI Replace if necessary;
not function outlet defective ➠ p. 15-13.
No retracting or extending, or Maximum speed set too low Increase maximum speed on
possible only at very low the display Enter power unit
speed speed; ➠ p. 12-83.
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 15 - 23
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Malfunction Cause Action

Retracting or extending Malfunction on the crane Stop the movement with the
function can not be switched control Crane control emergency stop
off switch; ➠ p. 15-2.
The boom can no longer be The electric controller of the Retract the telescope section
extended, the locking/un- hydraulic system is using hydraulic emergency
locking mechanism no longer interrupted (e. g. a cable in mode; ➠ Retracting emergency
reacts to the control instru- the main boom is broken) mode, p. 15-44.
ments in the crane cab

The boom can no longer be The hydraulic supply is Extend the telescope section
extended, the telescoping interrupted with mechanical emergency
cylinder can no longer be mode; ➠ Retracting emergency

H
moved mode, p. 15-44.

If a malfunction occurs, first check whether it applies in both directions of

movement.
If the malfunction occurs in both directions of movement you must also
check the causes listed in the Telescoping gear not functioning section!

01.02.2000

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.6 Slewing gear malfunctions

Malfunction Cause Action

Slewing gear does not Mechanical superstructure Disengage lock;

function lock engaged ➠ p. 12-6.
Slewing gear permanent Release slewing gear
brake applied permanent brake, rocker
switch; ➠ p. 12-43.
Dead man’s switch not Press dead man’s switch;
activated ➠ p. 10-62.
Fuses F6/5 SS or F3/4 SS Check fuses, replace if
defective necessary; ➠ p. 15-7.
A control unit of the crane Acknowledge error message
control has failed (error once; ➠ p. 12-87.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 15-68.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 15-2.
Slewing to left or right not Corresponding function is Acknowledge error message
functioning blocked by the crane control once; ➠ p. 12-87.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 15-62.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-79.
No slewing, or possible only Maximum speed set too low Increase maximum speed on
at very low speed the display Enter power unit
speed; ➠ p. 12-83.
Slewing can not be Malfunction on the crane Stop the movement with the
switched off control Crane control emergency stop
switch; ➠ p. 15-2.
01.02.2000

Operating Instructions GMK 6300 2 084 548 en 15 - 25

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.7 Counterweight lifting gear / lock malfunctions

Malfunction Cause Action

Counterweight lifting gear/ A control unit of the crane Acknowledge error message
lock not functioning control has failed (error once; ➠ p. 12-87.
message is displayed) If the error message is
repeated, change the
connections on the control
units; ➠ p. 15-61.
Crane control emergency stop Release crane functions
switch pressed in again; ➠ p. 15-2.
Counterweight lifting cylinder Hydraulic connection on the Make hydraulic connection;
or lock not functioning 4.4 t base plate not made ➠ p. 13-51.
Corresponding function is Acknowledge error message
blocked by the crane control once; ➠ p. 12-87.
(error message is displayed) If this happens again, note
down the number codes and
inform GROVE Product
Support; ➠ p. 15-62.
Corresponding function is Switch off ignition briefly then
blocked from the crane switch on again.
control (no error message is If this happens again, note
displayed) down the status display’s
stored number codes and
inform GROVE Product
Support; ➠ p. 12-79.
Locking pins cannot be Safety tap is closed Open safety tap;
retracted/extended ➠ p. 13-59.

01.02.2000

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.8 Hydraulic system / hydraulic oil cooler malfunctions

Malfunction Cause Action

Hydraulic oil temperature abo- Hydraulic system under Stop crane operations and
ve 80 °C severe strain allow the crane engine to run
Fan in hydraulic oil cooler is until the oil has cooled down.
running.
Hydraulic oil temperature abo- Fuse F1/1 SS, F1/2 SS Check fuses and replace if
ve 80 °C or F1/6 SS blown necessary; ➠ p. 15-7.
Fan in hydraulic oil cooler not
Fan’s thermostat valve Switch fan thermostat to
running
defective emergency operation;
➠ p. 15-60.
Warning lamp for feed circuit Hydraulic oil filter dirty Replace hydraulic oil filter;
or control circuit hydraulic oil ➠ Maintenance manual
filter lights up

Warning lamp for hydraulic Hydraulic oil filter dirty Replace hydraulic oil filter;
oil return filter or return fine ➠ Maintenance manual
filter lights up
01.02.2000

Operating Instructions GMK 6300 2 084 548 en 15 - 27

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.9 Crane control malfunctions

Malfunction Cause Action

The Crane control display One or more of the following Check fuses, replace if
remains unlit even though superstructure fuses is necessary; ➠ p. 15-7.
the ignition is switched on defective:
F5 1 / 2 / 3 / 4 / 5 / 6
F7 / 5 or F8 4 / 5 / 6
On the Crane control display Length indicator or proximity Retract the main boom with
you can see the message switch defective or no the emergency program and
EMERGENCY OPERATION connection any more go for drive repairs;
(e. g. cable torn or damaged) ➠ p. 15-74.
On the Crane control display Electric connection between Make plug connections under
you can see the message the main boom and the the main boom in front of the
NOT CONNECTED turntable interrupted (plug derricking cylinder foot axle
connection separated or cable or check the cable for damage
damaged or torn) and have it repaired
In the Crane control display The current telescope or Acknowledge error (the
the two number codes appear locking status does not match display changes automatically
one below the other: that in the control system to the Enter telescope status
ECOS 00001000 saved values (e. g. after after emergency operation
STATUS: 0 0 0 0 0 0 0 1 telescoping with emergency menu) and enter the
operation). current telescope status;

H
➠ p. 15-80.
If there are further malfunctions on the crane control, the corresponding
error messages will appear on the Crane control display; ➠ p. 15-61.

01.02.2000

15 - 28 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.10 Malfunctions on the SLI

S
You must halt crane operation immediately when SLI error messages
appear!

Repairs to the SLI may only be carried out by properly qualified

personnel.

If malfunctions cannot be eliminated by means of the actions described

on the following page, you must notify the local GROVE Product Support.
If you have to contact GROVE Product Support, a precise and extensive
description of the malfunction is extremely useful.
The precise description of the malfunction, as well as the answers to the
following questions, can help to optimise troubleshooting:

1. During which crane operation did the malfunction occur?

2. What is indicated on the SLI status display?
3. What is indicated on the SLI information display?
4. What is shown in the status displays Rigging mode and Reeving?
5. What is indicated on the information display when the information
selector switch is moved to different positions?
6. Have the fuses been replaced?
01.02.2000

s
Operating Instructions GMK 6300 2 084 548 en 15 - 29
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Other malfunc-
tions on the SLI

Malfunction Cause Action

SLI does not function Power supply switched off Switch on ignition
(displays not lit, no buzzer
Fuse F7/1 SS or F4/6 SS Check fuses, replace if
signal)
defective (fuses behind the necessary; ➠ fuses, p. 15-7.
flap on the front panel of the
crane cab)
Fuse S I 13 defective Check fuses, replace if
(fuse at the rear on the SLI necessary;
plug-in module) ➠ SLI fuses, p. 15-13.

SLI error The following table shows the different error messages on the SLI, the
message table cause of the error and how you can help if necessary.

Error messages from error group 1, sensory mechanism

Error Cause Action

message

1. 01. 1 Pressure sensor 1, lower Check line; ➠ p. 15-42.

chamber does not react If line is O.K., switch off
pressure sensor 1;
➠ p. 15-39 and notify
GROVE Product Support

1. 01. 2...6 Pressure sensor 1, lower Switch off pressure sensor 1;

chamber reports error ➠ p. 15-39 and notify
GROVE Product Support

1. 01. 7 Notify GROVE Product Support

1. 01. 8 Information message; Message remains as long as

You have switched off the ignition is switched off
pressure sensor 1 because of
an error message

1. 02. 1 Pressure sensor 2, lower Check line; ➠ p. 15-42.

chamber does not react If line is O.K., switch off
pressure sensor 2;
➠ p. 15-39 and notify
GROVE Product Support
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

1. 02. 2...6 Pressure sensor 2, lower Switch off pressure sensor 2;

chamber reports error ➠ p. 15-39 and notify GROVE
Product Support

1. 02. 7 Notify GROVE Product Support

1. 02. 8 Information message; Message remains as long as

You have switched off the ignition is switched off
pressure sensor 2 because of
an error message

1. 03. 1 Pressure sensor upper Check line; ➠ p. 15-42. If line

chamber does not react is O.K., notify GROVE Product
Support

1. 03. 2...6 Notify GROVE Product Support

1. 04. 1 Angle sensor A, Check line; ➠ p. 15-42.

basic section does not react If line is O.K., switch off angle
sensor A; ➠ p. 15-39 and
notify GROVE Product Support

1. 04. 2...6 Angle sensor A, Switch off angle sensor A,

basic section reports error basic section; ➠ p. 15-39 and
notify GROVE Product Support

1. 04. 7 Notify GROVE Product Support

1. 04. 8 Information message; Message remains as long as

You have switched off angle the ignition is switched off
sensor A, basic section
because of an error message

1. 05. 1 Angle sensor B, Check line; ➠ p. 15-42.

basic section does not react If line is O.K., switch off angle
sensor B; ➠ p. 15-39 and
notify GROVE Product Support

1. 05. 2...6 Angle sensor B, Switch off angle sensor B,

basic section reports error basic section; ➠ p. 15-39 and
notify GROVE Product Support

1. 05. 7 Notify GROVE Product Support

1. 05. 8 Information message; Message remains as long as

You have switched off angle the ignition is switched off
sensor B, basic section
because of an error message
01.02.2000

Operating Instructions GMK 6300 2 084 548 en 15 - 31

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

1. 06. 1 Length indicator A for Check line; ➠ p. 15-42.

telescope section V does not If line is O.K., switch off
react length indicator A; ➠ p. 15-39
and notify GROVE Product
Support

1. 06. 2...6 Length indicator A for Switch off length indicator A

telescope section V reports an for telescope section V;
error ➠ p. 15-39 and notify
GROVE Product Support

1. 06. 7 Notify GROVE Product Support

1. 06. 8 Information message; Message remains as long as

You have switched off length the ignition is switched off
indicator A for telescope
section V because of an error
message

1. 07. 1 Length indicator B for Check line; ➠ p. 15-42.

telescope section V does not If line is O.K., switch off
react length indicator B; ➠ p. 15-39
and notify GROVE Product
Support

1. 07. 2...6 Length indicator B for Switch off length indicator B

telescope section V reports an for telescope section V;
error ➠ p. 15-39 and notify GROVE
Product Support

1. 07. 7 Notify GROVE Product Support

1. 07. 8 Information message; Message remains as long as

You have switched off length the ignition is switched off
indicator B for telescope
section V because of an error
message

1. 08. 1 Length indicator A of the Check line; ➠ p. 15-42.

telescoping cylinder does not If line is O.K., switch off
react length indicator A of the
telescoping cylinder;
➠ p. 15-39 and notify
GROVE Product Support

1. 08. 2...6 Length indicator A of the Switch off length indicator A

telescoping cylinder reports of the telescoping cylinder;
an error ➠ p. 15-39 and notify
01.02.2000

GROVE Product Support

1. 08. 7 Notify GROVE Product Support

15 - 32 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

1. 08. 8 Information message; Message remains as long as

You have switched off length the ignition is switched off
indicator A of the telescoping
cylinder because of an error
message

1. 09. 1 Length indicator B of the Check line; ➠ p. 15-42.

telescoping cylinder does not If the line is O.K., switch off
react length indicator B of the tele-
scoping cylinder; ➠ p. 15-39
and notify GROVE Product
Support

1. 09. 2...6 Length indicator B of the Switch off length indicator B

telescoping cylinder reports of the telescoping cylinder;
an error ➠ p. 15-39 and notify
GROVE Product Support

1. 09. 7 Notify GROVE Product Support

1. 09. 8 Information message; Message remains as long as

You have switched off length the ignition is switched off
indicator A of the telescoping
cylinder because of an error
message

1.10. 1 Angle sensor A (pendulum), luffing jib does not react

1.10. 2...6 Angle sensor A, luffing jib reports fault

1.10. 7 Inform GROVE Product Support

1.10. 8 Information message;

You have switched off Angle sensor A, luffing jib, because of
an error message

1.11. 1 Angle sensor B (differential angle indicator), luffing jib, does

not react

1.11. 2...6 Angle sensor B, luffing jib, reports fault

1.11. 7 Inform GROVE Product Support

1.11. 8 Information message;

You have switched off Angle sensor B at the luffing jib
because of an error message

1.12. 1 Load measurement shaft for the point, pickup A does not react
01.02.2000

1.12. 2...6 Load measuring shaft for the point, pickup A reports fault

Operating Instructions GMK 6300 2 084 548 en 15 - 33

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

1.12. 7 Inform GROVE Product Support

1.12. 8 Information message;

You have switched off the load measuring shaft for the point,
pickup A, because of an error message

1.13. 1 Load measurement shaft for the point,

pickup B does not react

1.13. 2...6 Load measuring shaft for the Switch off load measuring
point, shaft for the point, pickup B;
pickup B reports an error ➠ p. 15-39 and inform
GROVE Product Support.

1.13. 7 Inform GROVE Product Support

1.13. 8 Information message;

You have switched off the load measuring shaft for the point,
pickup B, because of an error message

1.15.1...6 Inform GROVE Product Support

1.16.1...6 Inform GROVE Product Support

1.18.1...6 Inform GROVE Product Support

1.19. 1 Differences between the main Test length indicator, plug

boom length and telescopic connections and supply lines;
section IV length indicator are ➠ p. 15-42.
too great. The Actual load and Test telescope diagram from
Actual radius displays flash outside.
Notify GROVE Product
Support if necessary.

1.21. 1 Differences between the main Inform GROVE Product

boom length and the Support.
telescoping cylinder length
indicator are too great.
The Actual load and Cuurent
radius displays are flashing.
01.02.2000

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Error messages from error group 2, digital inlets

Error Cause Remedy
message
2. 01. 1 Telescopic section foot Check the supply line;
section, line breakage has ➠ p. 15-42.
been recognised Check gear shifting gate if
necessary.
2. 01. 4 Telescopic section foot
section, loose contact has
been recognised
2. 05. 1 Line breakage recognised
between SLI and rocker
switch Disconnect main hoist
2. 05. 4 Loose connection recognised Check supply line; ➠ p. 15-42.
in the line between
SLI and Disconnect main hoist
rocker switch
2. 06. 1 (only for additional
equipment)
Line breakage recognised
between SLI and
superstructure lock
Check supply line; ➠ p. 15-42.
2. 06. 4 (only for additional
equipment)
Loose contact recognised
between SLI and
superstructure lock
2. 07. 1 Line breakage recognised
between SLI and rocker
switch Shutoff auxiliary hoist
2. 07 4 Loose connection recognised Check supply line; ➠ p. 15-42.
in the line between SLI and
rocker switch Shutoff auxiliary
hoist
2. 11. 1 Line breakage recognised for
telescopic section foot section
Check supply line; ➠ p. 15-42.
2. 11. 4 Loose contact recognised for
telescopic section foot section
2. 12. 1 “Telescope sections locked”
(on telescoping cylinder) line
breakage recognised
Check supply line; ➠ p. 15-42.
01.02.2000

2. 12. 4 “Telescopic section locked”

(at the telescoping cylinder)
loose contact recognised,

Operating Instructions GMK 6300 2 084 548 en 15 - 35

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

2. 13. 1 “Left telescoping cylinder

locked” line breakage
recognised
Check supply line; ➠ p. 15-42.
2.13. 4 “Telescoping cylinder left
locked”
loose contact recognised
2.14. 1 “Telescoping cylinder right
locked” line breakage
recognised
Check supply line; ➠ p. 15-42.
2.14. 4 “Telescoping cylinder right
locked” loose contact
recognised
2. 16. 1 “Luffing jib rig”
line breakage recognised
2. 16. 2 “Luffing jib rigging” Check supply line; ➠ p. 15-42.
short to frame or earth
recognised
2.17. 1 Key-operated push button Remove SLI override or check
Override line breakage the line; ➠ p. 15-42.
recognised
2.17. 4 Key-operated push button Remove SLI override or check
Override short to frame or the line; ➠ p. 15-42.
earth recognised
2. 18. 1 Luffing jib operation line
breakage recognised
Check supply line; ➠ p. 15-42.
2. 18. 2 Luffing jib operation short to
frame or earth recognised

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Error messages from error group 3, kinematic system

Error Cause Action

message

3.02. 2 Communication with crane Test supply line; ➠ p. 15-42.

control interrupted

3.02. 3 Communication with crane Confirm error and invoke

control interrupted during teleautomatism again.
telescoping with teleauto-
matism

3. 06. 3 Differences occured in com- When the current telescope

parison with the crane control status is indicated on the
telescope status; if the Crane control display, take over
current telescope status was telescoping from the crane
entered on the crane control control; ➠ p. 15-41.
display after mechanical If neither SLI nor crane
emergency operation) control display show the
current telescope status,
notify GROVE Product
Support.

Error messages from error group 5, Range of cranes

Error Cause Remedy
message
5.02.03 Luffing jib angle too small Raise luffing jib
(too low)
5.02.04 Main boom angle too small Raise the main boom
(to low) for operation with the
luffing jib
5.03.04 Main boom angle too small Raise the main boom
(too low) for operation with
the boom extension
5. 04. 4 Main boom angle too small Raise main boom
5. 04. 6 Main boom angle too great Lower the main boom
(too steep)
01.02.2000

Operating Instructions GMK 6300 2 084 548 en 15 - 37

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Error messages from error group 6,

Display / safety devices / relay
Error Cause Action
message
6. 09. 1...6 Fuse no. 1...6 faulty Change respective fuse (1 to
12) on the rear of the SLI plug-
6. 10. 1...6 Fuse no. 7..12 defective
in module;
➠ SLI fuses, p. 15-13.
6. 20. 6...7 Excess temperature in Improve ventilation in the
the EKS-4 cab, open maintenance cover
at the front of ther crane cab
and wait until the error
message is acknowledged.

Error messages from error group 8, Software

Error Cause Action
message
8. 06. 4 Voltage on the SLI too low Load superstructure battery,
test supply line if necessary

Error Cause of error Countermeasure

message
9.01.2 The newly entered value for Confirm reeving and/or
the reeving or the rigging rigging mode
mode was not yet confirmed.
9.03.6 SLI is overridden Error message goes out
when the override is removed

H If further malfunctions not appearing in this table are displayed, contact

the GROVE Product Support responsible.
01.02.2000

15 - 38 2 084 548 en Operating Instructions GMK 6300

 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Switch off sensor/ The SLI works with a two-channel sensory system in which most pressure
indicator during sensors, length indicators and angle sensors are in duplicate. If there is an
malfunction error on one of these sensors or indicators with a corresponding error
message, you can switch it off and thus cancel the SLI shutdown.

H
Then you can continue to work with the other channel without delay.

If you have switched off a sensor or pickup because of a malfunction,

immediately inform the GROVE Product Support responsible and have
the cause of error rectified as quickly as possible.

Switching off sensors or indicators

• Press the membrane switch Error information until the error message of
r the sensor or indicator which should be switched off appears on the
display Information.
This error message always ends with a sensor or indicator on one of the
!0"4 numbers 1 to 6 (e. g. the error message for the pressure sensor 2, lower
chamber).

• Press the membrane switch input mode and also the membrane switch
no Switch on 2nd level. Keep both membrane switches pressed.
• Press the Acknowledge membrane switch once and let go of all mem-
p brane switches again.
The last number in the error message now changes to an 8.
!0"8 With this final number you can see that a sensor or indicator is switched off.

H After switching off a sensor/indicator, you should check that the remai-
ning sensor/indicator is functioning correctly; ➠ p. 15-40.

Releasing shutdown
The sensor or indicator remains switched off until the ignition is switched off.
If you turn the ignition back on before the error has been eliminated, a
new error message will appear for this sensor or indicator (with a final
number of 2 to 6) and there will be another SLI shutdown.
01.02.2000

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Operating Instructions GMK 6300 2 084 548 en 15 - 39
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Check that the The Error message table (➠ page 30) shows next to the error message if
remaining the sensor/indicator which was switched off is
sensor/indicator – a pressure sensor,
is working – an angle sensor,
– a length indicator or

H
an indicator of a load measurement shaft on the lattice extension.

With the tests described here you can briefly test for the presence of the
function of the remaining sensor/indicator but there is no measuring accu-
racy.

Check pressure sensor

• Hoist the hook block without a load.
The remaining pressure sensor is functioning if the status display Actual
!6 t load indicates the approximate weight of the hook block.

H The weight of the hook block is stated in the technical data; ➠ p. 16-9.

Checking an angle sensor

• Place the retracted main boom in the boom support.
The remaining angle sensor is functioning if the status display Current
=0 n° main boom angle indicates 0° when the truck crane is aligned horizontally.

Checking the length indicator of the telescoping cylinder

• Completely retract the main boom and mechanically lock the tele-
scoping cylinder in telescope section I.
• Press the Entry mode membrane switch and the Hydraulic oil pressure
nl derricking cylinder lower chamber sensor B membrane switch.
The remaining length indicator is functioning if the Information display
=0 indicates a length of approx. 0 m.

Checking the length indicator for telescope section IV

• Fully retract the main boom.
• Press the Entry mode membrane switch and the Hydraulic oil pressure
nk derricking cylinder lower chamber sensor A membrane switch.
The remaining length indicator is functioning if the Information display
=0 indicates a length of approx. 0 m.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Checking the pickup of the load measurement shaft for the point
• Enter an SLI code for the luffing jib or the boom extension.
• Put the load down and place the lattice extension on the ground.
• Remove the hoist rope from the load measuring shaft.
The remaining indicator is functioning if the status display Actual load indi-
=0 t cates about 0 t.

Accepting the The SLI and the crane control detect the telescope status independently.
telescope status The SLI compares its displayed telescope status with the value which the
from the crane control has detected. If the values differ, the SLI deactivates, the sta-
crane control tus display Current telescope status flashes and the error message 3.06.3 is
displayed.

The error message can have two causes:

– Either, the malfunction is on the length indicators, the SLI or the crane
control
– or a telescope status was manually entered on the crane control display
which does not agree with the SLI display (e. g., after an emergency
operation).

• Compare the current telescope status with the telescope status indica-
ted on the Crane control display:
– If the current telescope status is not indicated, a malfunction has occur-
red. Notify GROVE Product Support.
– If the Crane control display indicates the actual telescope status, you can
accept this telescope status into the SLI.

Accepting the telescope status

• Press the membrane switch Error information until the error message
r 3.06.3 is indicated on the status display Information.

§0&3
• Press the Entry mode membrane switch and additionaly Switch on 2nd level
no membrane switch. Hold down both membrane switches.
Press Acknowledge membrane switch and release all membrane switches
p again.
01.02.2000

The telescope status from the crane control is now accepted and indicated
on the status display Current telescope status.

s
Operating Instructions GMK 6300 2 084 548 en 15 - 41
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Checking SLI If there is an error message which indicates that a sensor or indicator
lines and connec- does not react any more or there is a line breakage or short circuit to
tions frame, the cause may be
– a loose plug connection or
– a damaged line.
The defective sensor or indicator can be found in the error tables, the
following diagrams show where to find the control boxes with the plug
connections for the sensors and indicators and the central connections.

• Check the plug connections and their electric lines outside on the main
boom or the lattice extension (additional equipment).
The plug connections for the boom extensi-
on and the luffing jib (both additional equip-
ment) are on the head section.
1 Load measuring shaft
2 Control box central connection (on the
left-hand side of the head section)
3 Control box angle sensor, point
A and B
4 Length indicator

All further connections are on the truck crane.

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

On the truck crane

1 Control box pressure sensors upper chamber and lower chamber

2 Plug connections under the main boom on the inner side of the
turntable (connection of indicators in the main boom)

3 Derricking cylinder lower chamber pressure sensor

4 Derricking cylinder upper chamber pressure sensor

5 SLI connecting box

6 SLI connection for luffing jib and boom extension (both additional
equipment)

7 Electrical connection for telescopic swing-away lattice extension and

luffing jib (both additional equipment)

8 Length indicator

9 Angle sensor basic section control box A and B

01.02.2000

10 Plug connection under the luffing jib on the turntable

(connections for additional equipment with luffing jib and telescopic
swing-away lattice extension)

Operating Instructions GMK 6300 2 084 548 en 15 - 43

Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.11 Retraction emergency operation

If the locking mechanism on the head of the telescoping cylinder does not
react to the operating instruments in the crane cab any longer, malfunc-
tions in the electrical control system of the locking mechanism, the mecha-
nical system or the hydraulic system could be the cause. For these cases,
there is
– a mechanical emergency activation system with which you can
manually lock and unlock the telescope sections. This emergency mode
is for cases where the telescoping cylinder can no longer be moved
hydraulically. In this case you need one or two auxiliary cranes.
– a hydraulic emergency mode with which you can move the locking and
unlocking mechanism on the head of the telescoping cylinder directly.
This emergency mode is for cases where the telescoping cylinder can
still be moved but you cannot control the locking mechanism from the
with the operating instruments.
In the worst case, emergency operations must be carried out by trained
specialists because the risk of injury and damage to the main boom is too
great if one proceeds incorrectly. These cases are described later in the
section. Always check the following possibility first.

Check before all First check whether the main boom may be lowered with the current
emergency extension and the current rigging mode of the truck crane (if a boom
operation extension or a luffing jib is rigged, the main boom must be fully retracted
for this purpose.) Proceed as follows:
• Enter the rigging code for the current rigging mode of the truck crane
on the SLI according to the Lifting capacity table.

H
• Lower the main boom.

If it is possible to lower but there is not sufficient space, you can check
whether the truck crane can be driven in the current rigging mode;
➠ Driving with the crane rigged, p. 12-93.
If the SLI allows lowering to the horizontal position,
danger from the raised truck crane is impossible and you can:
– check whether it is possible for you to carry out hydraulic emergency
operation in the horizontal position; ➠ When can hydraulic emergency
operation be carried out?, p. 15-48.
– carry out mechanical emergency operation without an auxiliary crane
using a personal transport vehicle because you can reach the locking
points with the extendable ladder.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

If the SLI switches off before you can lower the main boom to the
horizontal position,
you must:
– check whether it is possible for you to carry out hydraulic emergency
operation; ➠ When can hydraulic emergency operation be carried out?,
p. 15-48.
– have two auxiliary cranes ready for mechanical emergency operation,
one of them a registered personal transport vehicle.

Procedure for There are different procedures for retracting in emergency mode. Which
retracting procedure is is the best for your particular case depends both on which
functions are still possible and on the circumstances at the site. You can
e. g.:

– unlock the telescope sections in mechanical emergency mode if the

locking mechanism on the head of the telescoping cylinder is defective
and retract with an auxiliary crane (up to the section in which the tele-
scoping cylinder is located) or
– first extend the main boom with one or two auxiliary cranes far enough
that the main boom can be lowered to the horizontal position and then
retract the rest of the telescope sections in the horizontal position or
– if the electrical controller for the head of the telescoping cylinder is
defective, retract the telescope sections using hydraulic emergency ope-
ration (with the main boom raised or horizontal, depending on circum-
stances).
Not all possible situations can be described here, only activities for mecha-
nical emergency operation and hydraulic emergency operation under
certain circumstances.
Select the best procedure for your particular case and seek advice from
the responsible GROVE Product Support specialists. This applies especial-
ly if the conditions for hydraulic emergency operation are different than
described here.
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Operating Instructions GMK 6300 2 084 548 en 15 - 45
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Mechanical emer- Mechanical emergency mode must be used if the telescoping cylinder can
gency operation no longer be moved.
For manual unlocking and locking of the telescope sections, a screw is
screwed into the telescope section on each side above the locking pin.
This screw actuates a lever mechanism which pulls the locking pins into
the telescope section and thus unlocks the telescope section.
This screw is unscrewed again for manual locking.

The main boom is designed so that emergency activation of the locking

H
devices can be achieved from the outside at all possible fixed lengths.

If the telescoping cylinder is in the foot section of the telescope section, it

will not be possible to lock and unlock this telescope section by hand.

The following prerequisites must be fulfilled before you manually release

the locking device on a telescope section:
– The telescope section which is to be unlocked is slung onto an auxiliary
crane with sufficient load bearing capacity and is therefore secured
against independent retraction
– or the main boom is lowered to the horizontal position so that the tele-
scope section cannot retract independently.

For manual unlocking a total of eight M 16 x 100 set screws and an appro-
priate screwdriver are supplied with the truck crane.

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

You can manually lock or unlock a telescope

section only if the recess (2) in the locking
pin does not engage the telescope section
above it any longer.

• Extend the telescope section approx. 2 cm

(with an auxiliary crane if necessary). The
locking pin (1) must be in the center of the
opening and the recess (2) must not en-
gage the telescope section above it any
longer.

Releasing the lock

• Screw a screw into the bore (1).
The locking pin (2) is retracted.
• Screw in the screw against the spring
weight so that the locking pin (2) is inser-
ted as far as possible and is behind the
side panel of the telescope section (3).
Now the lock has been manually released on
this side.

• Also release the lock on the other side of

the telescope section.

Locking telescope sections

• Retract the telescope until the locking pin
(2) is in the middle of the opening.
• Unscrew the screw from the bore (1).
The locking pin (2), under spring weight, is
pushed out of the opening.

• Continue to retract the telescope section

until it is set onto the recesses on the
locking pin.
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Operating Instructions GMK 6300 2 084 548 en 15 - 47
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Hydraulic emer- If the electrical supply line on the head of the telescoping cylinder is cut,
gency operation the locking and unlocking functions for the telescoping cylinders and the
telescope section can no longer be controlled from the crane cab. The
truck crane is equipped with a hydraulic emergency mode for this case.
When can hydraulic emergency operation be carried out?
You may only carry out hydraulic emergency operation if:
– the truck crane is in a state in which emergency operation can be
carried out without damaging the boom and
– you can still see the current status of the telescoping cylinder in the
crane cab.
• First check the status of the truck crane using the following diagram.
Go through the questions in the diagram consecutively and compare
the specifications with the status of your mobile crane and go to the
next question depending on the answer (yes/no).

The Crane control display shows:

– either in the third line the message - NOT CONNECTED

(and before the error message UNIT 01 : 00000010 was shown
➠ Error messages via control units, p. 15-59.)
– or in the second line the number string starting with 1 - STATUS : 1 0 0
(in this case you are asked to enter a keycode;
➠ Emergency program submenu, p. 15-74.)

Yes No

Check whether the current status of the telescoping cylinder can still
be read in the crane cab; ➠ p. 15-49.

None of the measures

in the section Malfunc-
Yes tions of the telescoping
No gear, p.15-22 lead to a
correction of the prob-
lem.
Check if the telescoping cylinder is locked with the telescope
section:
– unlocked telescope section can be telescoped
– or, if the telescope section is locked, the length data for
– the telescoping cylinder does not change during telescoping

Yes No

Consult GROVE
Product Support
Prepare necessary equipment ➠p. 15-50.
01.02.2000

and prepare truck crane for emergency operation

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

S
Risk of damage to the main boom!
If you reach a field where you are referred to GROVE Product Support,
you may not carry out hydraulic emergency operation because the main
boom could be damaged. In this case hydraulic emergency operation can
only be carried out with the help or consultation of trained and properly
qualified personnel.
Consult GROVE Product Support!

Check if length data can be read

You may only carry out hydraulic emergency operation if the extended
length of the telescoping cylinder is still shown.

• Check if the current extended length of the

bottom right telescoping cylinder is shown
in the Crane control display (e. g. 9.31 m).

TELESCOPING If nothing more is displayed here, you can

have the extended length displayed on the
STATUS: 001
SLI.
EMERGENCY OPERATION
TELE: –– L.: 9.31

• Press the Entry mode membrane switch and the Hydraulic oil pressure of
no derricking cylinder lower chamber sensor B membrane switch.
• Check if the extended length of the telescoping cylinder is now shown
)3 in the Information display.

• Check if the displays are activated. To do this move the control lever for
telescoping out and check if the value for the extended length changes.
If the telescope section is locked you must press valve Y 21 33;
➠ p. 15-51.

S
Risk of damage to the main boom!
Never carry out hydraulic emergency operation if no display is available.
Otherwise you no longer have any possibility to monitor and can damage
components in the boom or put the boom in a condition in which it can
no longer be extended or retracted.
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Operating Instructions GMK 6300 2 084 548 en 15 - 49
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Connections, equipment and operating elements for emergency operation

Two hydraulic hoses (1) are delivered for
hydraulic emergency operation.
The first ends of the hoses are connected
directly with two connections (4) on the head
of the telescoping cylinder.
The other ends of the hoses are connected
alternately to the emergency supply (2).
The corresponding hydraulic circuit is clea-
red via ball valves (5).
The required function can then be controlled
with the control unit of the counterweight lift-
ing gear (3).

Preparing the truck crane for emergency operation

To connect the hoses for emergency operation, you must retract the tele-
scope section with which the telescoping cylinder is locked. If the electri-
cal supply line to the head of the telescoping ram is cut, the SLI switches
off and the locking mechanism is depressurized.

G
Risk of accidents from overridden SLI!
If you override the SLI to retract in emergency mode, crane operation is
no longer monitored. Always put down the load for emergency operation.
Emergency operation with a rigged luffing jib requires extreme care and
should be avoided. The overridden SLI does not block any function when
a permitted area is left and you must also observe the warning lamps for
luffing jib operation. If you do not notice these warning lamps due to a si-
tuation which you are not used to, the truck crane can overturn.

• Put down the load.

• Override the SLI. To do this turn the Override key-operated switch to the
right.

If the telescope section is located at a locking point at the beginning of te-

lescoping or moves over a locking point during telescoping, the telescope
section locks there.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

To unlock the telescope section the hydraulic

valve Y21 33 must be pressed.
The valve is located on the valve block (1) on
the left side of the turntable behind the crane
cab.

• Have a second person hold valve Y 21 33

pressed.
• Move the control lever to retract.
Pressure now builds up on the locking me-
chanism; the telescope section is unlocked
and retracted.

As soon as the telescope section has moved about 10 cm further, valve

Y 21 33 can be released, the locking pins extend again and move against

H
the inner panel of the above telescope section.

If the locking pins cannot be retracted, the telescope section is stuck in the
recesses of the locking pins.
In this case extend the telescope section approx. 3 cm so that the locking
pins can be retracted.

Connecting the hydraulic connections for emergency operation

• Raise the main boom until the rear
opening (3) can be reached.
• Put the two delivered hydraulic hoses (2)
in the middle of the turntable. Make sure
that the hoses do not become twisted or
knotted together.
• Guide both ends (1) to the oil cooler via
the side of the turntable.
• Guide the two other hose ends through the
rear opening (3) into the basic section.
These ends are connected to the telesco-
ping cylinder.
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Operating Instructions GMK 6300 2 084 548 en 15 - 51
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

S
Risk of damaging the hydraulic hoses!
Always guide the hydraulic hoses through the rear opening in the basic
section. If you guide the hydraulic hoses through the manhole at the top
of the basic section the hydraulic hoses will be cut during retracting.

You can reach the connections on the telescoping cylinder

– either through the rear opening in the basic section
– or, if you can extend telescope section I approx. 2 m, through the man-
hole at the top of the basic section.

G
Risk of crushing from unintentional retraction!
Secure the main boom against unintentional retraction before you reach
into or enter the manhole in order to connect the hydraulic hoses. During
retraction, the telescope sections move into the area of the manhole and
can crush you or your limbs.

The hydraulic hoses are connected directly

to the head of the telescoping cylinder.

• Insert the quick couplings in the two con-

nections (2) and (3).
• Close the two valves (1) and (4). The val-
ves are closed if the handles are perpendi-
cular to the lines.
• Mark a hose on the other end. For emer-
gency operation it is important that you
know which hose is connected with the
right connection and which hose with the
left connection.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

The connection (1) for the emergency supply

is on the left side of the turntable above the
oil cooler.

One of the two hydraulic hoses is connected

to this connection for emergency operation.
The following table shows which telescoping
cylinder connection you must connect with
the emergency supply so that you can lock
and unlock the telescope section or the tele-
scoping cylinder.

Function Make connection between

emergency supply and

Lock/unlock telescope section hose on connection 2 of the

telescoping cylinder (right)

Lock/unlock telescoping cylinder hose on connection 3 of the

telescoping cylinder (left)

• Check whether the safety cock (1) for the

counterweight locking mechanism is
closed and close it if necessary.

The safety valve must be closed so that, in

emergency operation, the locking pin cannot
retract and cause the counterweight to fall.
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Operating Instructions GMK 6300 2 084 548 en 15 - 53
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

G
Risk of accidents from falling counterweight!
Always close the safety cock before carrying out hydraulic emergency
operation.
If the safety valve is opened, the locking pins for the counterweight
retract during the releasing process in hydraulic emergency mode and
the counterweight falls.

Operating the locking/unlocking mechanism in emergency mode

The locking/unlocking process is controlled
with the counterweight lifting gear switch
unit (1).

H A hydraulic/mechanical safety circuit blocks the simultaneous unlocking

of the telescope section and the telescoping cylinder. You can only unlock
the telescoping cylinder if the telescope section is locked. The telescope
section can only be unlocked when it is locked with the telescoping
cylinder.

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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

• Attach the appropriate hose for the requi-

red locking/unlocking.
– To lock/unlock the telescoping cylinder,
the left connection (3) on the telescoping
cylinder must be connected with the emer-
gency supply.
– To lock/unlock the telescope section, the
right connection (2) on the telescoping
cylinder must be connected with the emer-
gency supply.

H You must always press the button whose symbol shows the opposite mo-
vement to carry out a movement in emergency operation. In emergency
operation you must therefore press the Unlock counterweight button to lock
and vice versa.

S
Always carry out the locking movement before you remove a hose from
the emergency supply connection so that the hose is depressurized. If the
hose is under pressure, the quick coupling can no longer be inserted and
you can not continue emergency operation.
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Operating Instructions GMK 6300 2 084 548 en 15 - 55
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

Unlocking
• Turn the Release switch unit knob to the right and hold it down.
• In addition press the Lock counterweight button and hold it down until the
locking process is finished.
To unlock the telescope section you must extend the telescope section
approx 3 cm.

Locking
• Turn the Release switch unit knob to the right and hold it down.
• In addition press the Unlock counterweight switch and hold it down until
the locking process is finished.

H The positions of the locking pins on the telescoping cylinder and the tele-
scope sections has no effect on the indicator and warning lamps in the
buttons. These lights always show the position of the hasp.

Retracting with hydraulic hoses connected

If you have retracted the telescope section in which the telescoping cylin-
der was locked when the malfunction occured and the hoses are connec-
ted for hydraulic emergency operation, you can retract the main boom
completely.

S
If the telescope sections I and II are both extended to 100 % or telescope
section I to 50

% and telescope section II to 50 % you must not unlock and retract the te-
lescoping cylinder. In this way you can prevent the end of the telescoping
cylinder coming out of the guide in telescope section II and falling into te-
lescope section I.
In this case the main boom could no longer be extended or retracted.

S
Risk of damaging the hydraulic hoses!
While you telescope the main boom, a second person must ensure that
the double hose is run through the rear hole in the basic section and back
out without blockage or kinks.
Always stay in visual contact with this person during telescoping so that
you can stop telescoping immediately in an emergency.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

H
• Retract the telescope section until it has reached its locking point at 0%.

If the telescope section locks at the locking point at 50 % during retracting,

unlock it with the corresponding buttons on the Counterweight lifting gear
switch unit.

When the telescope section has reached the locking point at 0 %, it is

locked by the spring force.

• Put the telescope section on the recesses of the locking pins. To do this
retract the telescope section slowly until the value for the extended
length of the telescoping cylinder no longer changes).
• Depressurize the connected hydraulic hose. To do this turn the Release
switch unit knob to the right and also press the Unlock counterweight
button.

• Make the necessary connection for the emergency supply for locking/
unlocking the telescoping cylinder (left connection).
• Unlock the telescoping cylinder. To do this turn the Release switch unit
knob to the right and also press the Lock counterweight button.

• See the table Extended lengths of the telescoping cylinder at the locking points
(➠ p. 15-59) for the length data for the locking point of the next exten-

H
ded telescope section.

The locking pins on the telescoping cylinder sometimes slide back out
when you are extending the telescoping cylinder.
Therefore extend the telescoping cylinder only until it is approx. 0.5 m in
front of the locking point.
• Re-insert the locking pins. To do this turn the Release switch unit knob to
the right and also press the Lock counterweight button.
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Operating Instructions GMK 6300 2 084 548 en 15 - 57
Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

• Extend the telescoping cylinder until it is at the locking point.

If the telescoping cylinder at locking point indicator lamps are still activated,
8 you can also detect the position of the telescoping cylinder in relation to
the locking point as well as details regarding length; ➠ p. 10-38.
9
• Lock the telescoping cylinder with the telescope section. To do this turn
the Release switch unit knob to the right and also press the Unlock counter-
weight button.

H If the telescoping cylinder at locking point indicator lamps are not activated,
you can check as follows if the telescoping cylinder is locked:
At the locking point at 0 % in the basic section you can see the locking
pins of telescope section I. Extend the telescoping cylinder slowly. The
telescoping cylinder is locked when the locking pins of telescope section I
also move.

• Depressurize the connected hydraulic hose. To do this turn the Release

switch unit knob to the right and also press the Unlock counterweight
button.

• Make the necessary connection to the emergency supply for locking/

unlocking the telescopic part (right connection).
• Extend the telescope section approx. 3 cm so that the telescope section
is no longer on the recesses.
• Unlock the telescope section by turning the Release switch unit knob to
the right and also pressing the “Unlock counterweight” switch.
• Retract the telescope section until it has reached the locking point
at 0 %.
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 Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

• Repeat all steps in the Section Retracting with connected hydraulic hoses until
all telescope sections are retracted or until enough telescope sections
have been retracted for the main boom to be placed.

After telescoping in hydraulic emergency mode

When you retract the main boom while the electrical connection to the
head of the telescoping cylinder is cut, you must enter the current tele-
scope status in the crane control system after the repair; ➠ Entering tele-
scope status after emergency operation menu, p. 15-80.

Extended lengths of the telescoping cylinder at the locking points

Telescope section Locking point Extended length of

at fixed length the telescoping
[%] cylinder [m]

0 0.00
T1 50 5.46
100 10.92
0 0.36
T2 50 5.89
100 11.42
0 0.76
T3 50 6.37
100 11.97
0 1.10
T4 50 6.79
100 12.47
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Malfunctions on the superstructure
15.4 Troubleshooting and malfunction correction

15.4.12 Switching the fan thermostat to emergency operation

A thermostat-controlled hydraulic valve controls the speed of the fan. The

valve can be switched with a hexagon bolt in the event of a thermostat
malfunction.

The valve is on the left side of the turntable, directly underneath the hy-
draulic oil cooler’s fan motor.

G
Accidents may occur due to turning fan wheel!
If you switch the fan to emergency operation the fan wheel immediately
begins to turn very quickly. Objects or loose clothing can be sucked in
with this.
Make sure that there are no people or objects in the vicinity of the fan
when switching to emergency operation.

To switch the valve you need a 4-mm hexagon socket spanner.

• To switch on the fan manually turn the

hexagon bolt (1) as far as possible to the
right.
To switch the fan off you must turn the he-
xagon bolt to the left as far as it will go.

The fan setting can be continuously regula-

ted with the hexagon screw.

H After installing a new thermostat you must switch off emergency operati-

H
on again and turn the hexagon screw (1) as far as possible to the left.

If your truck crane is equipped with an additional oil cooler (additional

equipment) this oil cooler will also run in emergency operation. You do
not need to make any additional adjustments.
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15.5 Crane control error messages

15.5 Crane control error messages

15.5.1 Error messages about control units

Three control units belong to the crane

control: If one control unit fails, the Crane
control display displays an error message as
in the diagram opposite:
ERROR MESSAGE SYSTEM is in the second line. In the third
SYSTEM line you will find UNIT 0, 1 or 2, for the
UNIT 1: 00000010 control units on the connections 0 to 2.
The number code in the fourth line is of
STATUS: 0 0 0 0 0 0 1 0
secondary importance.

The following table shows which crane functions are out of operation
when the control unit fails on a connection:

Error message Error and Action

on the display effect

Control unit on The truck crane can be

connection 0 defective; rigged by changing the
function of the crane connection lines on
UNIT 0: control and the main another control unit in
hoist and auxiliary hoist on-the-road mode;
blocked. Changing the connections
in the control units,
Control unit is defective p. 15-68.
at connection 1; slewing
UNIT 1: gear and high-speed
blocked.

Control unit at
connection 2 defective;
Telescoping gear,
derricking gear,
UNIT 2: counterweight lifting
cylinder and locking
pins, superstructure lock
and incline crane cab
blocked.
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15.5 Crane control error messages

15.5.2 Error messages about power units

If there is an error message about power

units it will appear in the second line of the
affected power unit (e. g. the telescoping
gear). You also get different entries and num-
MEMORY ERROR
ber codes in the two bottom lines.
SYSTEM
J3502: 01000000
STATUS: 0 0 0 0 0 0 0 1

If you have already acknowledged the error message, you can call up the
+ Display states menu and then
>the memory error submenu and view the
error message there again; ➠ Display states menu – Memory error submenu,
p. 12-81.

In the first line you will see the message

ERROR MEMORY and the number of the er-
ror (e. g. 3). The displays in the other lines
are the same as with the error message.
MEMORY ERROR 3

TELESCOPING GEAR The messages here are only an example

Y2301: 00000001 which will be dealt with at the end of the fol-
lowing sections.
STATUS: 0 0 0 0 0 1 0 0

Using the messages in the bottom two lines you can

– determine the part on which the error occurred; ➠ Determining defective
part, p. 15-63.
– determine the area of the error, depending on the detected part;
➠ Determining error area, p. 15-64.
– locate more precisely the cause of the error; ➠ Error causes and effects,

H
p. 15-65.

In the following sections you will find more information on the displayed
errors. If, in the sections, you are asked to contact GROVE Product Sup-
port, please note down the number code beforehand and have it ready.

When you have noted down the error codes you can acknowledge the
Ö error message. To do this press the ENTER key.
After you have carried out the acknowledgement process, the display
shows the indication which was displayed before the error message.
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15.5 Crane control error messages

Determining The first message in the third line of the display describes the defective
defective part part (e. g. Y2301). The following table shows all the possible messages
and their meaning.

Message Error Further troubleshooting

J3501
Error on a control lever
J3502

A3502 Error on length indicator Determine cause of

error; ➠ Error causes and
Error with the
effects, p. 15-65.
A100 communication with the
SLI

Logic error detected by

ECOS
crane control

Error on another part Determine error area;

Other message
(e. g. Y3201)
(valve, digital input, ➠ Determining error area,
pressure sensor) p. 15-64.

Example

In the display used as an example there is the

message Y2301; according to the table there is
an error on a part whereby you must first deter-
MEMORY ERROR 3 mine the area of the error before you can deter-
TELESCOPING GEAR
mine the cause of the error.

Y2301: 00000001
STATUS: 0 0 0 0 0 1 0 0
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15.5 Crane control error messages

Determining With some parts (e. g. a valve), you must first determine the error of the
error area area in order to get to the cause of the error.

The area where the error is is shown by the number code in the last line
behind STATUS (e. g. 0 0 0 0 0 1 0 0). The following table shows possible
number codes and the corresponding areas.

Number code Error in area Further troubleshooting

00000001 Control lever

00000010 Digital input

00000100 Output
Determine cause of error
00001000 Analogue input in the affected area;
➠ Error causes and effects,
CAN-Bus (always p. 15-65.
00010000 displayed together with
ECOS, A100 or A3502)

ECOS (also displayed as

10000000
a part)

Example

In the display used as an example the number

code 0 0 0 0 0 1 0 0 is in the last line.
The table assigns this number code an error in
MEMORY ERROR 3 the output area.
TELESCOPING GEAR The “output” area is in the table in the next secti-
Y2301: 00000001 on. Here you can determine the cause of the er-
STATUS: 0 0 0 0 0 1 0 0 ror in this area.
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15.5 Crane control error messages

Error causes and Once you have determined the defective part or the area where the error
effects is, the table will give you more information on the cause and the effects.
In this table the number code in the third line behind the part
(e. g. 0 0 0 0 0 0 0 1 behind Y 2301) is decisive.

Defective Number code in Cause of error Effect/

part the third line on Remedy
or area the display

00000001 Analogue
indicator in
00000010 control lever
defective Control lever
Earth contact/ emergency
00000100 programme is
Control lever line breakage
activated;
J3501 or
J3502
00001000 24 V short ➠ p. 15-72.
Earth contact/
00010000 Notify GROVE
line breakage
Product Support
00100000 24 V short
Mechanical
01000000
error

Length No data
0 0 0 0 0 0 01 Inform GROVE
indicator reception
Product Support
A3502 00000010 Hardware error
0 0 0 0 0 0 01 When there is no
Communica- No data
display on the SLI,
tion with SLI reception from
00000010 check fuse SI13;
A100 SLI
➠ p. 15-13.
After acknow-
ledgement start
Locking status the menu
00000001
unrealistic Emergency operation
ECOS access;
➠ p. 12-86.
displayed
00001000 telescope status ➠Telescoping error
messages p. 15-67
incorrect
Line breakage/
00000001 Inform GROVE
Digital input 24V short
Product Support
00000010 Earth contact
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15.5 Crane control error messages

Defective Number code in Cause of error Effect/

part the third line on Remedy
or area the display

Line breakage/
00000001
24 V short
00000010 Earth contact
00000100 Line breakage Inform GROVE
Output
Product Support
Output
00001000
overloaded
Output
00010000
underloaded
0000000 1 24 V short
Analogue Notify GROVE
input Earth contact/ Product Support
00000010
line breakage

Example

In the display used as an example the number

code 0 0 0 0 0 0 0 1 is in the third line.

In the previous section we determined that the er-

MEMORY ERROR 3
ror was in the output area.
TELESCOPING GEAR
MEMORY ER- According to the table this number code means
Y2301: 00000001 that there is a line breakage or 24 V short.
STATUS: 0 0 0 0 0 1 0 0 In this case you must inform GROVE Product
Support and have the supply line checked.

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15.5 Crane control error messages

15.5.3 Telescoping error messages

If the crane control recognises a divergence between the displayed and

the current telescope status, the following crane movements will be
switched off:
– retracting and extending,
– locking and unlocking telescoping cylinders,
– locking and unlocking telescope sections.

The error message Divergent telescope status is

displayed by the following number codes:

ECOS 00001000
ERROR MESSAGE
STATUS 1 0 0 0 0 0 0 0.
LOCKING SYSTEM
ECOS : 00001000
STATUS : 10000000

• Acknowledge the error message.

Ö
If the Display telescope status and teleautomatism
menu was selected before the error message
occurred, the crane control switches directly
to the menu to enter the telescope status.
SET TELESCOPING
> T1 < T2 – T3 – T4 –
– ● – 0 – 0 – 0 –

H If you had selected another menu before the error message, select:
– either the Display telescoping and select teleautomatism(
ä
the crane control goes directly to the menu for entering the
telescoping
),

– or directly select the Enter the telescoping after emergency operation menu
(3 x
Ä ).

• Enter the current telescoping in the crane control;

➠ Enter telescoping after emergency operation menu, p. 15-80.
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15.5 Crane control error messages

15.5.4 Changing the connections in the control units

Connections and The control units are behind the crane operator’s seat.
control units

S
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove connec-
tions from or insert them in the control units. If the ignition remains swit-
ched on, data necessary for the operation of the crane (e. g. the telescope
status) can become lost or damaged.
If this data is not available there will be malfunctions during the next
crane operation.

Crane control Telescoping gear, derricking

main hoisting gear, Slewing gear, gear, counterweight lifting cylin-

auxiliary lifting gear (additional fast traverses der and locking, cabin inclining,

equipment) superstructure locking

Control unit Control unit Control unit

The crane control has three connections which are labelled 0, 1 and 2.
Each connection is inserted into a control unit and connects this with the
different power units. If this control unit fails, the power units connected
with it can no longer be driven. You can activate the power units again in
an emergency by changing this connection to another control unit. You
can thus unrig the truck crane when there is a defect on the control unit,
as described in the following.

Unrigging If, for example, the control unit under the 0 connection fails, you can no
mobile crane longer move the power units on this connection (main hoist, auxiliary
with defective hoist) and the whole crane control is blocked. You can therefore not move
control unit any more power units.
The display shows an error message over UNIT 0.
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H At least two control units must be still intact to unrig the truck crane. If
two control units fail you will need at least one new control unit to be able
to unrig the truck crane. It is possible to put down a load without a control
unit, however.

You can re-activate the crane control and the failed power units in this
case by removing the connection from one of the two other control units
(e. g. connection 2) and inserting connection 0 on this control unit;
➠ Inserting and removing connections, p. 15-71.

Crane control Telescoping gear, derricking

main hoisting gear, Slewing gear, gear, counterweight lifting cylin-

auxiliary lifting gear (additional fast traverses der and locking, cabin inclining,

equipment) superstructure locking

Control unit Control unit

H After connection 2 has been removed, the crane control shows the rele-
vant error message UNIT 2. You can acknowledge this error message.

You can now carry out all crane movements connected with connections
0 and 1:
– putting down the load with the main and auxiliary hoist,
– slew the superstructure and
– use high speed
All power units that are connected with connection 2 are now out of ope-
ration (telescoping gear, telescoping gear, counterweight lifting cylinder
and lock, superstructure lock and incline cab).

If you need, for example, the derricking gear, you have to reconfigure the
connections.
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Malfunctions on the superstructure
15.5 Crane control error messages

To move the slewing gear, for example, remove connection 1 from the
control unit and insert it instead into connection 2 on this control unit.

Crane control Telescoping gear, derricking

main hoisting gear, Slewing gear, gear, counterweight lifting cylin-

auxiliary lifting gear (additional fast traverses der and locking, cabin inclining,

equipment) superstructure locking

Control unit Control unit

H Do not remove connection 0, this connection serves the crane control and
must always be inserted in an intact control unit. Depending on the requi-
red crane movement, always insert either connection 1 or 2 in the intact
control unit.

You can thus carry out all crane movements for unrigging the truck crane
after each other. There are only two ways in which the connections need
to be inserted for a required crane movement:
either connections 0 and 1 (for main/auxiliary hoist,
slewing gear and fast speeds)

or connections 0 and 2 (for main hoist/auxiliary hoist,

derricking gear, telescoping gear
superstructure lock,
Counterweight lifting gear and

H
locking bolts, tilt cab)

As long as a connection is removed, the crane control shows the

corresponding malfunction (UNIT 1 or UNIT 2). You can acknowledge the
malfunction for unrigging so that you can, for example, track the tele-
scoping on the display.
Replace the defective control unit before the next job!
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Inserting All connections are equipped with plugs and safety holders.
and removing
connections

• Turn the ignition off in the crane cab before you remove connections
from or insert them in the control units.

S
Risk of malfunctions due to data loss!
Always turn the ignition off in the crane cab before you remove con-
nections from or insert them in the control units. If the ignition remains
switched on, data necessary for the operation of the crane (e. g. the tele-
scope status) can become lost or damaged.
If this data is not available there will be malfunctions during the next
crane operation.

All connections are equipped with plugs and safety holders.

Removing connections
• Remove the holder (1) and then the plug
(3) from the control unit (2).

Inserting connections
• Check if the holder (1) is pulled out.
• Put the plug (3) on the control unit (2).
• Push the holder (1) in until you hear it
engage.
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15.5 Crane control error messages

15.5.5 Control lever emergency program

If a control lever is blocked because of a malfunction, the Crane control dis-

play shows one of the two following messages in the third line:
J3501: 0 0 0 0 0 0 0 1 or J3502: 0 0 0 0 0 0 0 ; ➠ Error messages via power
units, p. 15-62.

Indications on
the display
• Call up the menu Control lever emergency program on the Crane control
ü display. To do this press the membrane switch Control lever emergency
program once.
In this menu you will see the message
EMERGENCY PROGRAM in the first line.
In the second line the control lever to which
the messages in the two lower lines refer
EMERGENCY PROGRAM
(e. g. RIGHT CONTROL LEVER) is displayed.
RIGHT CONTROL LEVER
X AXLE: OFF

Y AXLE: ON

By repeatedly pressing the membrane switch Control lever emergency

ü program the message alternates between the left and the right control lever.

The message X axle indicates the extension

to the left and right.

The message Y axle indicates the extension

EMERGENCY PROGRAM forward and back.
RIGHT CONTROL LEVER
X AXLE: OFF If the emergency program for a control lever
extension is switched on, ON appears next
Y AXLE: ON
to the corresponding control lever extension.
The emergency program is switched on auto-
matically with the displays of the error
message.

In the example illustrated here, the message ON is next to the Y AXLE of

the right hand control lever. The functions which are controlled by extending
this control lever forward or back are thus blocked. You can therefore carry out
the main hoist functions lift and lower only with the emergency programme.
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Carrying out To carry out the emergency program you must extend the defective
emergency control lever and also press a membrane switch.
program
• Press the membrane switch Control lever emergency program until the
ü defective control lever is indicated on the display.
• Extend the control lever in the desired direction (e. g. the right hand
lever forward – to Lower the main hoist).
• Also press the corresponding membrane switch next to the display:
Press this membrane switch also when you have extended the control
: lever forward (in this example you would need to activate this switch).

In addition, press the membrane switch when you have extended the
< control lever back.

In addition, press the membrane switch when you have extended the
* control lever to the left.

In addition, press the membrane switch when you have extended the
+ control lever to the right.

As soon as you activate the corresponding switch for extending the

control lever, the crane movement (e. g. lower main hoist) starts.

H
• Let go of the switch or the control lever to stop the crane movement.

In the emergency program all crane movements are restricted to 10 % of

the maximum speed.
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Malfunctions on the superstructure
15.5 Crane control error messages

15.5.6 Emergency operation submenu

Emergency operation serves the purpose of allowing you to retract the

main boom for on-road driving, so that the machine can be driven to a lo-
cation where repair can take place.
Emergency operation is not designed for crane operation and therefore
can be used only for a limited time.
Emergency operation is started only when the respective error message
has been confirmed followed by entry of the correct key code in the Access
emergency operation submenu.

The submenu can be recognised by the

message EMERGENCY OPERATION in the
third line.

TELESCOPING The remaining running time is displayed on

STATUS: 0 0 1 the left in the fourth line (e. g. 180 secs.).
When the time has run out, the display swit-
EMERGENCY OPERATION
ches again to the Access emergency operation
T: 180 s L:8.40 submenu and you can re-start emergency
operation.

The three-digit number code (e. g. 001) after

the message STATUS in the second line indi-
cates which error the crane control recogni-
zed.
TELESCOPING
STATUS: 0 0 1

EMERGENCY OPERATION
T: 180 s L:8.40

Deciphering the number code:

0 0 1: – Length indicator faulty
0 1 0: – Proximity switch faulty or signals received through
locking status are unrealistic
1 0 0: – Error recognised in a valve for the locking mechanism,

When multiple errors occur simultaneously, all errors are displayed simul-

H
taneously with a 1 at the respective position.

If a 1 is displayed at the first position of the number code (e. g. 1 0 0),

the locking and unlocking mechanism can no longer be operated. In this
case, consult the responsible GROVE Product Support. If this error occurs,
the main boom can only be retracted with the mechanical emergency
01.02.2000

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15.5 Crane control error messages

G
Risk of damage to the main boom!
Never telescope the main boom if both the length indicator and the proxi-
mity switch have failed, i.e. with the number code 1 0 1 or 1 1 1. Other-
wise you will no longer have any possibility to monitor and can damage
components in the boom or put the boom in a condition in which it can
no longer be extended.

S
Risk of damage to the main boom!
Depending on which error has occurred, you can only track the telescop-
ing with certain warning and indicator lights. Use as a guide only the
lights which are stated for the respective error in the following sections.
If you observe the incorrect indicator and warning lights, boom compo-
nents could be damaged or you could put the main boom in a condition
in which telescoping is no longer possible.

When you are in the Emergency operation menu, all functions for tele-
scoping in the main boom are still released as long there are no other
errors (hydraulic or mechanical).

If the error is due to a proximity switch (number code 0 1 0);

➠ Retracting with an error on the proximity switch, p. 15-78.

If the error is due to a length indicator (number code 0 0 1), retract the
main boom as described in the following section:

Retracting with If the error is on the length indicator, you can no longer read the extended
an error on the length of the telescoping cylinder on the Crane control display.
length indicator The following status display elements are still available:

Check the position of the locking pins of the telescoping cylinder and tele-
ihjj scope section with the red warning/green indicator lamps Telescoping cylin-
der unlocked and locked and Telescope section unlocked and locked.
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15.5 Crane control error messages

Check the extended length of the telescope

1 2 3 4 sectionson the SLI display Current telescope
=60 !00 =00 =00 status of telescope section I to IV.

H
C0645

To have the current extended length of the telescoping cylinder displayed

by the SLI in the Information display, proceed as follows:

Press the Entry mode membrane switch and the Hydraulic oil pressure of
no derricking cylinder lower chamber sensor B membrane switch.

The display Information now indicates the current extended length in

/2 meter of the telescoping cylinder.
The table on page 15-79 shows at which length the telescoping cylinder is
at the locking points of the individual telescope sections.
Before telescoping:
– If both indicator lamps Telescoping cylinder at locking point light up, then
89 the telescoping cylinder is at the locking point; ➠ p. 10-38;
– the telescoping cylinder must be locked with the telescope section, the
h indicator lamp Telescoping cylinder locked must light up;
– the telescope section must be unlocked, the red warning lamp Telescope
j section unlocked must light up;
– the rocker switch Select locking/unlocking must be pushed in the upper
. position Unlock telescope section.

Retracting the telescope section

S
Risk of damage to the main boom!
As you are telescoping the telescope section, you must not activate the
rocker switch Select locking/unlocking. If you switch the rocker switch to the
central position the locking pins on the telescope section are slid out im-
mediately and they can damage or tear the electrical or hydraulic compo-
nents in the main boom.

• Only telescope the telescope section slowly.

• Telescope in the telescope section as far as possible.
• Extend the locking pins on the telescope section by putting the rocker
switch Select locking/unlocking in the central position.
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15.5 Crane control error messages

The locking pins on the telescope section are slid out, the green indicator
jj lamp Telescope section locked lights up and the red warning lamp Telescope
section unlocked goes out.

• Unlock the telescoping cylinder. To do this press the Select locking/unlock-

. ing rocker switch down.

Extending the telescoping cylinder without the telescope section

S
Risk of damage to the main boom!
As you are extending or retracting the telescoping cylinder, you must ne-
ver operate the rocker switch Select locking/unlocking. If you switch the rok-
ker switch to the central position, the locking pins on the telescoping cy-
linder are slid out immediately and they can damage or tear the electrical
or hydraulic components in the main boom.

• Extend the telescoping cylinder slowly.

• Extend the telescoping cylinder to the locking point of the nearest foot
89 section. The locking point has been reached if both Telescoping cylinder at
locking point indicator lamps are lit.

• The Information display shows the respective extended length of the

%89 telescoping cylinder (e. g. 5.89 m for the locking point of telescope sec-
tion II at 50 %, values ➠ p. 15-79).

S
Risk of damaging the telescoping gear!
To check the position of the telescoping cylinder in relation to the locking
point, always observe both display elements (indicator lamp and display
Information).
In this way, you avoid going beyond the locking point and damaging the
telescoping gear in case a display element fails (e. g. if the position light
is faulty or if a proximity switch fails).

• When you have reached the locking point, lock the telescoping cylinder.
. To do this move the rocker switch Select locking/unlocking to the central
position.
When the telescoping cylinder is locked, the green indicator lamp Tele-
h scoping cylinder locked lights up.
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Operating Instructions GMK 6300 2 084 548 en 15 - 77
Malfunctions on the superstructure
15.5 Crane control error messages

H If you have retracted the main boom with a defective length indicator, the
current telescope status does not correspond with the last telescope sta-
tus stored from the crane control. You must input the current telescoping
status on the Crane control display after repairs and before the next crane
operation; ➠Enter telescope status after emergency operation menu, p. 15-80.

Retracting with If the error is on a proximity switch of the locking pins, one or more of the
an error on the following warning and indicator lamps no longer display the actual values:
proximity switch
– Warning lamp Telescoping cylinder unlocked,
i – Warning lamp Telescope section unlocked,
j – Indicator lamp Telescoping cylinder locked,
h – Indicator lamp Telescope section locked.
j When locking the telescoping cylinder, observe the following:
• Always move the telescoping cylinder to
the correct length for the locking point be-
fore you lock it with the telescope section.
The length is indicated on the Crane control
TELESCOPING
display (e. g. 5.89 m for the locking point of
– 0 – 0 – 0 – 0 – telescope section II at 50 %, values;
EMERGENCY OPERATION ➠ p. 15-79)
T: 180 s L:5.89 m

• After locking, check that both locking pins are extended:

Carefully try to extend or retract the telescoping cylinder. If both locking
pins are extended, the indicated length L must not change.
Otherwise, you can retract the main boom exactly as with an error on a

H
length indicator (➠ p. 15-75).

Some warning and indicator lamps may show correct displays of the
locking status. While locking and unlocking, you can check if individual

H
lamps still display correctly.

When there is an error on a proximity switch, the hydraulic/mechanical

safety circuit continues to prevent the simultaneous unlocking of the tele-
scope section and the telescoping cylinder, but this is no longer electroni-
cally monitored.
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Table for approa- The following table shows the extended length of the telescoping cylinder
ching the locking at the locking positions of the various telescope sections.
points

Telescope section Locking point Extended length of the

at fixed length telescoping
[%] cylinder [m]

0 0,00
T1 50 5,46
100 10,92
0 0,36
T2 50 5,89
100 11,42
0 0,76
T3 50 6,37
100 11,97
0 1,10
T4 50 6,79
100 12,47
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15.5.7 Entering telescope status after emergency operation menu

When you have retracted the main boom with the emergency operation,
or when the power supply on the crane control is interrupted during the
storage process, the indicated telescope status no longer corresponds
with the actual status of the telescope sections.
In this case you must enter the actual telescope status in the crane control.
The menu is started:
– If you press the Enter telescope status after emergency operation membrane
Ä switch three times (within about 3 seconds) or
– If the Divergent telescope status error message was confirmed and the
Ö Display telescope status and teleautomatism menu is selected.

In the first line there is the message SET

TELESCOPE STATUS.
In the second line there are telescope sec-
tions T1 to T5 and in the line underneath the
SET TELESCOPING numerical value 0 is displayed for every tele-
> T1 < T2 – T3 – T4 – scope section.
– 100 – 0 – 0 – 0 – In addition, the entry request (●) flashes on
the numerical value for T1.

You can enter the actual telescope status for every telescope section with
the membrane switches View and entry display, located to the right, next to
the display.

You can only enter the value on which the entry request flashes.

• Press one of these two membrane switches as many times as necessary

+ until the entry request flashes on the numerical value which you would
like to enter.
*
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 Malfunctions on the superstructure
15.5 Crane control error messages

• Enter the actual telescope status for the telescope section with these
: two membrane switches. The following values are available:
For T1 : 0 50 100 >n<
< For T2 : 0
For T3 : 0
50 100 >n<
50 100 >n<
For T4 : 0 50 100 >n<
n here represents the displayed numerical value of the last saved current

H
intermediate length (e. g. 37 %)

If a telescope section is at an intermediate length, select the indicated

value n between the two angular brackets.

• Enter the actual telescope status for all telescope sections.

• If you have entered an incorrect telescope status, you can restart the
ö menu by pressing the Enter telescope status after emergency operation mem-
brane switch three times quickly.
Ö • If you have entered the actual telescope status correctly, press the Enter
key once.
The message KEYCODE is in the last line
and the input prompt (—) flashes.

To confirm the entered telescope status, you

SET TELESCOPING
must enter in this line the same key code
> T1 < T2 – T3 – T4 – which you need to start the emergency pro-
– 100 – 0 – 0 – 0 – gram;

KEYCODE:
➠ Access emergency operation menu, p. 12-86.

The crane control now saves the entered telescope status and switches to
the Display telescope status and teleautomatism menu.

If the crane control recognises an error in the entered telescope status,

the display shows the error message Divergent telescope status; ➠ p. 15-67.

Ö H The crane control accepts the newly set telescope status only when you
store the new values with the ENTER key and enter the appropriate key
code after making your selection.
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Malfunctions on the superstructure
15.5 Crane control error messages

S
Risk of damage during telescoping!
Before working with the crane, check that the telescope status now indica-
ted corresponds with the actual telescope status. If you accidentally enter
an incorrect telescope status, then you must enter the actual value again.
In this way you prevent the crane control unit from using an incorrect
value for calculations which could lead to damage and malfunctions
during telescoping.

The Enter telescope status after emergency operation menu remains switched
>@üä on until you select another menu with the respective membrane switch,

ö exit the menu with the membrane switch

occurs. ö or until an error message

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 ____________________________________________________________________________________ 16
16 Technical information for superstructure . . . . . . . . . . . 16 - 1
16.1 Technical description of the superstructure . . . . . . . . . . . . . 16 - 1
16.1.1 Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1
16.1.2 Crane operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 1
16.1.3 Crane engine and hydraulic system . . . . . . . . . . . . . . . . . . . . . 16 - 2
16.1.4 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 3
16.1.5 Main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 3
16.1.6 Telescoping gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 3
16.1.7 Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 4
16.1.8 Slewing gear units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 4
16.1.9 Derricking cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 5
16.1.10 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 5
16.1.11 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 5
16.1.12 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 6
16.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - 7
16.2.1 Measurements and weights of the truck crane . . . . . . . . . . . . . . . 16 - 8
16.2.2 Dimensions and weights of removable parts . . . . . . . . . . . . . . . . 16 - 9
16.2.3 Technical data for superstructure . . . . . . . . . . . . . . . . . . . . . . 16 - 13
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 Technical information for superstructure
16.1 Technical description of the superstructure

16 Technical information for superstructure

16.1 Technical description of the superstructure

16.1.1 Turntable

The following components are installed on the turntable:

– the crane engine with fuel tank,

– the pumps, the oil tank and the oil cooler of the crane’s hydraulic
– system,
– the main boom,
– the hoists,
– the slewing gears,
– the derricking cylinder,
– the tiltable crane operator’s cab,
– the mountings for the counterweight with the hasps.

16.1.2 Crane operator’s cab

All operating and control instruments required for crane operation are in-
stalled in the crane operator’s cab on the front left-hand side of the turn-
table. The crane operator’s cab can be tilted approx. 20° to the rear.

The aluminium cab is surrounded by safety glass. The sliding door has
a sliding window. The windscreen can be opened to ventilate the cab.

The cab is heated via a heat exchanger using the engine coolant. The coo-
lant can also be heated with an additional water heating system to pre-
heat the engine and the cab.
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Technical information for superstructure
16.1 Technical description of the superstructure

16.1.3 Crane engine and hydraulic system

The hydraulic system consists of four separate circuits for the power units
and adjustment units as well as a control and a feed circuit. The crane en-
gine, a water-cooled Mercedes Benz diesel engine, drives a total of seven
hydraulic pumps to supply the circuits from the hydraulic tank.
The crane engine drives a pump distribution gearbox directly. Four axial
piston variable displacement pumps are flanged onto the pump distribu-
tion gearbox on two auxiliary drives.

– One auxiliary drive drives two variable displacement pumps which

supply the two hydraulic circuits for the main hoist and the auxiliary
hoist (additional equipment).
– One of the two variable displacement pumps on the other auxiliary
drive supplies the hydraulic circuit for the slewing gear units. The se-
cond variable displacement pump supplies the telescoping gear, the
derricking gear, the locking pins and the hoist for the counterweight as
well as the hydraulic cylinder for the superstructure lock and to incline
the crane cab.
The three other hydraulic pumps of the whole hydraulic system are gear
pumps. These three pumps are driven directly by the crane engine via an
auxiliary drive:

– Two of the gear pumps supply the feed circuit. Via the feed circuit, the
oil is filtered into the three separate circuits for slewing gear and hoists
and the oil volume in these circuits is kept constant.
– The third gear pump supplies the control circuit for the hydraulic and
control valves and drives the fan motor of the radiator in the hydraulic
circuit.
The oil tank of the crane’s hydraulic system (hydraulic tank) is on the left
side of the turntable behind the crane driver’s cab and the storage com-
partment.
The hydraulic oil is cooled by one (with additional equipment, two) hy-
draulically driven, thermostat-controlled oil cooler.

To clean the hydraulic oil, four oil filters are built into the hydraulic circuit.
There is a return filter and a return fine filter on the hydraulic tank. The
control circuit and the feed circuit each have an additional oil filter behind
the gear pumps.
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 Technical information for superstructure
16.1 Technical description of the superstructure

16.1.4 Control system

All crane movements can be controlled on an infinitely variable basis with

the electrical-hydraulic pilot operated cross control levers in the control
consoles on the armrests of the crane operator’s seat. The control levers
have an automatic initial position.

A fully electronic crane control system controls and monitors all crane
functions, the hydraulic parts and some of the electrical parts. The crane
control system has 3 control units and is connected to the safe load indi-
cator via a CAN BUS.

On a display on the front instrument panel, information on the individual

power units and the crane engine can be called up, the telescoping proce-
dure can be followed and various values can be entered. In addition, the
crane control system displays error messages in this display.

16.1.5 Main boom

The main boom consists of the basic section and four telescope sections.
The main boom can be lengthened with an inclinable boom extension, a
luffing jib or a telescopic swing-away lattice extension (all additional
equipment and all in trelliswork).
Boom extensions can be rigged to various lengths.
The main boom can also be lengthened with an auxiliary single-sheave
boom top (additional equipment).

16.1.6 Telescoping gear

The telescoping gear consists of the non-telescoping section, four tele-

scope sections and a single-level telescoping cylinder with a locking me-
chanism. Each telescope section is equipped with locking pins which are
extended by spring force. All telescope sections can be locked at the fixed
lengths.
The telescoping cylinder is also equipped with locking pins. These locking
pins make the connection between the telescoping cylinder and the tele-
scope section to be telescoped.
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Technical information for superstructure
16.1 Technical description of the superstructure

All telescope sections must be telescoped separately. To telescope, the

telescope cylinder locks itself together with the appropriate telescope sec-
tion. Subsequently, the telescoping cylinder unlocks the telescope section
with its mechanism and extends it or retracts it to the desired length. With
0 %, 50 % and 100 % telescope statuses, the telescoping cylinder can lock
the telescope section there again with the mechanism, release its lock
with the telescope section and move to the next telescope section.

Locking or unlocking can be selected and is automatically carried out by

the crane control system. Fully automatic telescoping of the telescope sec-
tions to 0 %, 50 % and 100 % is also possible. The desired end state of the
telescoping gear is entered in the crane control here.

The telescoping gear is equipped with a mechanical and hydraulic emer-

gency operation with which the telescoping gear can be retracted during
a malfunction.

16.1.7 Hoists

The main hoist is located in the rear turntable area. The crane may also be
equipped with an auxiliary hoist (additional equipment) that is installed
behind the main hoist.
The hoists are driven by axial piston variable displacement motors via pla-
netary gear. The hoists are fitted with hydraulically ventilatable pressure-
spring multiple-disk brakes.
Both hoists are equipped with electrical lowering limit switches. When
reeling off, five turns of hoist rope must remain wound on. Lifting limit
switches on the main boom and the lattice extension limit the upward
stroke.

16.1.8 Slewing gear units

The turntable is equipped with 3 slewing gear units. The slewing gear
units are located on the right side of the turntable and affect the external
toothing of the ball bearing slewing through the meshing of a pinion.
Each of the slewing drives works with a hydraulic axial-piston fixed dis-
placement motor via planetary gear.

All three slewing gear units are equipped with a multiple-disk brake as the
parking brake, and the service brake works hydrostatically via the control
lever.
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 Technical information for superstructure
16.1 Technical description of the superstructure

In addition to the slewing gear brake, the superstructure can be mechani-

cally locked in the 0° and 180° positions with a pin on the superstructure
lock (for on-road driving or moving on the construction site with a rigged
crane and the working position 0° to the rear).

A slewing gear freewheel which can be switched with a foot-operated

switch allows free movement of the slewing gear units.

16.1.9 Derricking cylinder

The angle of the main boom is adjusted by means of a hydraulic pressure

cylinder. The cylinder is connected to the turntable and the basic section
of the main boom.

16.1.10 Electrical system

The superstructure’s 24 V electrical system is fed by the alternator in the

crane engine and by two batteries in the battery box located in front of
the crane engine. The batteries are in a battery box in the storage com-
partment in front of the crane engine.

The electrical system includes the crane system with lighting and control
instruments as well as electro-hydraulic and pneumatic switches and all
safety equipment.

The electrical connection between the superstructure and the carrier for
on-road driving runs through a slip ring assembly.

16.1.11 Counterweight

The counterweight sections can be assembled into four (with additional

equipment, into six) counterweight versions; ➠ Counterweight version,
p.16-10.

The entire counterweight is removed from the superstructure for on-road

driving and transported on a separate vehicle. Dimensions and weights of
the individual counterweight sections for transport;
➠ Dimensions and weights – counterweight sections, p. 16-9.
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Operating Instructions GMK 6300 2 084 548 en 16 - 5
Technical information for superstructure
16.1 Technical description of the superstructure

For rigging the counterweight, the individual counterweight sections are

stacked on the crane carrier with the truck crane. The base plate contains
the hydraulically driven counterweight lifting gear. A hydraulically control-
led locking pin is located on the turntable.

16.1.12 Safety equipment

The truck crane GMK 6300 is equipped with the following safety devices:

– Electronic safe load indicator (SLI) (overload shutdown device)

– Limiting of the highest and lowest boom position by means of safe load
indicator (SLI) and mechanical stop
– Dead man’s switches in the control levers and seat switches
– Lifting limit switch
– Lowering limit switch
– Maximum load restriction (pressure relief valves)
– Pipe break safety valves, safety lowering shut-off valve in telescoping
gear, outriggers and derricking cylinder
– Emergency stop switch for the electronic crane control system

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 Technical information for superstructure
16.2 Technical data

16.2 Technical data

GROVE truck crane GMK 6300

Max. load bearing capacity: 265 t (DIN/ ISO/ EN)

275 t (85 %)

Max. Load moment: 837 tm1) (DIN/ ISO/ EN)

918 tm2) (85 %)

permitted temperature range: –25 °C up to +40 °C

1)
9 m x 93 t
2)
9 m x 102 t
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Technical information for superstructure
16.2 Technical data

16.2.1 Measurements and weights of the truck crane

Dimensions for Length: 18.05 m (without auxiliary hoist)

driving on public
Width: 3.00 m
roads
Height at on-the- 3.95 m –130 / +170 mm suspension range
road level: with 14.00 R 25 tyres

4.00 m –130 / +170 mmsuspension range

with 16.00 R 25 tyres

Angle of negotiable
banks at front: about 16° at on-the-road level
Overall weight: 72.0 t
Axle load 12.0 t each in on-the-road mode
Permissible driving mode during on-road driving; ➠ Section Driving mode,
p. 6-5.
Dimensions and weights of the parts which must be transported on a
separate vehicle during on-road driving; ➠ Dimensions and weights of remo-
vable parts, p. 16-9.

all measurements in mm

375 15460
4730
2600
+170
-130
3950

16°

14°

400
2400 1700 3200 1650 2400 1650 1500 870
2370 15370 310
18050

*) max. 3 000 with 14.00 R25 and 16.00 R25 tyres

01.02.2000

2548 **) max. 3 100 with 20.50 R25 tyres

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 Technical information for superstructure
16.2 Technical data

16.2.2 Dimensions and weights of removable parts

This section contains the transport dimensions and weights of those

parts of the superstructure which can be transported on separate vehicles
during on-road driving.
On-the-road mode according to requirements; ➠ p. 6-5 .

Counterweight-
sections
Name Length x width x Weight
height (m) (kg) 1)

8-t base plate complete with 2.49 x 2.98 x 1.38 8 150

hoist unit
Lower 14-t counterweight section 2) 2.49 x 2.98 x 0.310 14 300
Middle 14-t counterweight section 2) 2.49 x 2.98 x 0.285 14 150
Upper 14-t counterweight section 2) 2.49 x 2.98 x 0.295 14 000
Upper 14-t counterweight section 2)
with folding carriers for auxiliary 2.49 x 2.98 x 0.415 14 050
hoist (additional equipment)
15-t counterweight blocks, each 2.27 x 0.965 x 1.90 14 800
block
10-t counterweight blocks, each 1.86 x 0.870 x 1.90 10 150
block
1) Deviations caused by manufacture of up to ± 2.5 %
are possible.
2) The designations lower, middle and upper plate refer to the positions in
the illustrations in the Counterweight versions section; ➠ p. 16-10.

Hook blocks and

hook tackle
Name Length x width x Weight
height (m) (kg)

Double hook, 9 sheaves, 2.30 x 0.95 x 0.85 3 000

load bearing capacity 200 t
Double hook, 7 sheaves, 2.00 x 0.80 x 0.70 3 000
load bearing capacity 160 t
Double hook, 5 sheaves, 1.85 x 0.70 x 0.60 1 700
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load bearing capacity 125 t

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Operating Instructions GMK 6300 2 084 548 en 16 - 9
Technical information for superstructure
16.2 Technical data

Name Length x width x Weight (kg)

height (m)

Single hook, 3 sheaves, 1.95 x 0.65 x 0.40 1 125

load bearing capacity 80 t
Double hook, 3 sheaves, 1.75 x 0.65 x 0.40 1 125
load bearing capacity 80 t
Single hook, 1 sheave, 1.50 x 0.65 x 0.35 620
load bearing capacity 35 t
Hook tackle, 0.91 x 0.35 x 0.35 300
load bearing capacity 12 t

Auxiliary hoist Only with additional equipment

Name Length x width x Weight (kg)

height (m)

Auxiliary hoist complete with rope 1.41 x 1.16 x 0.90 1 800

and connections

Counterweight The counterweight versions are shown in the following diagrams on the
versions next pages.

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 Technical information for superstructure
16.2 Technical data

8.0 t

8.0-t base plate

22.0 t

14.0-t counterweight section

8.0-t base plate

36.0 t

14.0-t counterweight section

14,0-t counterweight section
8.0-t base plate

50.0 t
14.0-t counterweight section
14.0-t counterweight section
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14.0-t counterweight section

8.0-t base plate

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Technical information for superstructure
16.2 Technical data

80.0 t
(additional equipment)

14-t counterweight section

14.0-t counterweight section
14.0-t counterweight section
8.0-t base plate
2 x 15-t counterweight blocks

100.0 t
(additional equipment)

14-t counterweight section

14.0-t counterweight section
14.0-t counterweight section
8.0-t base plate
2 x 15-t counterweight blocks
2 x 10-t counterweight blocks

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 Technical information for superstructure
16.2 Technical data

16.2.3 Technical data for superstructure

Crane engine Make: Mercedes-Benz

Type: OM 906 LA

Performance: 190 kW (258 PS) with 1800 rpm

(EC 80/1269 rigid fan)

Fuel tank: capacity ≈ 330 l

Crane’s electrical Alternator: 28 V / 80 A

system
Batteries: 2, each 12 V / 170 Ah

On-board voltage: 24 V

Main hoist Make: Zollern

Type: ZHP 4.26 - EC

Drum diameter: 458 mm (cable centre to cable centre)

Rope diameter: 224 mm

Rope length: 300 m

Max. wire cable: 110 kN/line (≅ 9.5 t)

Power unit group: M3

Load spectrum: L1

Factor of the load spectrum: Km = 0.125

Theoretical service life: D = 3 200 h

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Technical information for superstructure
16.2 Technical data

Auxiliary hoist Make: Zollern

(additional
equipment)
Type: ZHP 4.25 - EG

Drum diameter: 458 mm (cable centre to cable centre)

Rope diameter: 24 mm

Rope length: 420 m

Max. wire cable: 110 kN/line (≅ 9.5 t)

Power unit group: M3

Load spectrum: L1

Factor of the load spectrum: Km = 0.125

Theoretical service life: D = 3 200 h

Slewing gears Make: Siebenhaar

Type: 01 DD

Derricking gear Cylinder: Differential cylinder

Adjusting angle: –1.5° to +82° from horizontal

Main boom Main boom lengths: 15.46 m / 26.37 m / 37.43 m / 48.64 m / 60.0 m
Main boom head with 9 sheaves

Cylinder: 1 single-level telescoping cylinder for

telescope section with locking / unlocking
mechanism
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 Technical information for superstructure
16.2 Technical data

Operating speeds The operating speeds below apply to an engine speed of approx.
and times 1 800 rpm
without a load

Main hoist: Rope speed when raising and lowering

Normal speed 55 m/min
Fast speed 140 m/min

Auxiliary hoist: Rope speed when raising and lowering

Normal speed 54 m/min
Fast speed 130 m/min

Slewing gear: 0 to 1.6 turns per minute

Telescoping gear: Extend main boom

from 12.8 m to 51 m: 400 s1)

Derricking gear: ca. 60 s (–3° to 83°) (high speed

1) In automatic mode, for doing unrigged locking and telescoping

proceedures.
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Technical information for superstructure
16.2 Technical data

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 ____________________________________________________________________________________ 17
17 Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 - 1
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2 084 548 en Operating Instructions GMK 6300

 17 Alphabetical index

H How to use the alphabetical index; ➠ p.1-16.

To avoid making the index unnecessarily long and unclear, we have not
included every single element from the instrument panel.
These elements, such as rocker switches, warning and indicator lamps, as
well as status displays are described and named in detail in the overviews
of chapter 4 and 7 Description of the truck crane.
From there, you will be referred to more detailed descriptions of these
elements.
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 Alphabetical Index

A Access ladders to the superstructure . . . . . . . . . . . . . . . . . . 4-41

Activating the ignition
carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Adding oil
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Additional heating system . . . . . . . . . . . . . . . . . . . . . 4-36, 6-54
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
time, displaying, setting . . . . . . . . . . . . . . . . . . . . . . . 4-38
Additional heating system with timer . . . . . . . . . . . . . . . . . . 6-56
automatic heating start, switching off . . . . . . . . . . . . . . . . 6-58
automatic heating start, switching on and saving . . . . . . . . . 6-57
switching on/off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
time, displaying/setting . . . . . . . . . . . . . . . . . . . . . . . 6-57
Additional water heating system
see Additional heating system
Adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
on the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
Adjusting the seat
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Air-conditioning system
in the crane cab . . . . . . . . . . . . . . . . . 10-55, 12-105 to 12-108
in the driver’s cab . . . . . . . . . . . . . . . . . . . . 4-37, 6-59 to 6-62
Anemometer
installing on the main boom . . . . . . . . . . . . . . . . . . . . 13-79
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
behaviour when upshifted . . . . . . . . . . . . . . . . . . . . . . 6-21
checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
diagnosis switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
driving modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
driving ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
operation of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
procedure in the event of malfunctions . . . . . . . . . . . . . . . 7-30
starting and stopping . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Automatic gearbox diagnosis switch . . . . . . . . . . . . . . . . . . 6-19
Automatic gearbox driving modes . . . . . . . . . . . . . . . . . . . . 6-19
Auxiliary hoist
assembly/disassembly . . . . . . . . . . . . . . . . . . . 14-1 to 14-32
01.02.2000

malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-19
transport dimensions and weight . . . . . . . . . . . . . . . . . 16-10
working with the auxiliary hoist . . . . . . . . . . . . . . . . . . 12-39

Operating Instructions GMK 6300 2 084 548 en 17 - 3

 Auxiliary hoist gear
display and operating instruments . . . . . . . . . . . . . . . . 10-33
Axle drive
display and operating instruments in the driver’s cab . . . . . . . 4-27

B Battery master switch

Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
superstructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7
Brakes
auxiliary brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
checking the brakes system . . . . . . . . . . . . . . . . . . . . . . 6-7
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
display and operating instruments in the driver’s cab . . . . . . . 4-28
see also Eddy current retarder
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Breakdown
towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-10
Breakdown
procedure in road traffic . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4

C Carrier hydraulic system

check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
checking the position of the stop cocks . . . . . . . . . . . . . . . . 5-9
Charge indicator lamp
after ignition has been switched on . . . . . . . . . . . . . 5-10, 11-11
after the engine has been started . . . . . . . . . . . . . . . . . 11-14
after the vehicle engine has been started . . . . . . . . . . . . . . 5-13
warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
CHECK LIST
condition of the truck crane for on-road driving . . . . . . . . . . . 6-1
extending the outriggers . . . . . . . . . . . . . . . . . . . . . . 13-13
retracting the outriggers . . . . . . . . . . . . . . . . . . . . . . 13-15
rigging for crane operation with main boom . . . . . . . . . . . . 13-1
rigging mode when truck crane is rigged . . . . . . . . . . . . . . 12-1
starting the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-1
starting vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
unrigging for crane operation with main boom . . . . . . . . . . 13-4
Check the oil level
in the carrier hydraulic system . . . . . . . . . . . . . . . . . . . . . 5-8
in the superstructure hydraulic system . . . . . . . . . . . . . . . 11-6
Checking the coolant level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
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in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

17 - 4 2 084 548 en Operating Instructions GMK 6300

 Checking the oil level
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
checking the oil level;in the automatic gearbox . . . . . . . . . . . . . . 5-6
Checking the steering lock . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Checking the tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Checking the windscreen washing system
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
checklist
mounting/dismounting the auxiliary hoist with
auxiliary crane . . . . . . . . . . . . . . . . . . . . . . . . 14-3 to 14-8
before starting crane work in winter . . . . . . . . . . . . . . . 5-3, 11-3
rigging the counterweight . . . . . . . . . . . . . . . . . . . . . 13-42
unrigging the counterweight . . . . . . . . . . . . . . . . . . . . 13-45
CHECKLIST: Mounting/dismounting the auxiliary hoist with
counterweight lifting gear . . . . . . . . . . . . . . . . . . . 14-9 to 14-14
Checks
"boom not set down" warning lamp . . . . . . . . . . . . . . . . . 6-10
after starting the crane engine . . . . . . . . . . . . . . . . . . . 11-14
after the engine has been started . . . . . . . . . . . . . . . . . . 5-13
before driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
before starting the crane engine . . . . . . . . . . . . . . . . . . . 11-4
of the safety equipment . . . . . . . . . . . . . . . . . . . . . . 12-10
prior to starting vehicle engine . . . . . . . . . . . . . . . . . . . . 5-4
while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Choosing the site . . . . . . . . . . . . . . . . . . . . . . . . 13-7 to 13-12
clock
setting time in the crane cab . . . . . . . . . . . . . . . . . . . . . 4-38
Compressed air system
see Brakes
Constant engine speed . . . . . . . . . . . . . . . . . . . . . . . . . 12-89
constant speed
see Tempostat
Control lever emergency program . . . . . . . . . . . . . . . . . . . 15-72
counterweight
checklist: rigging the counterweight . . . . . . . . . . . . . . . . 13-42
Crane cab
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52, 12-101
inclining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-91
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-104
Crane cab windscreen wipers . . . . . . . . . . . . . . . . . . . . . 10-49
Crane control
see acknowledging error messages
display and operating instruments . . . . . . . . . . . . . . . . 10-30
display of an error message . . . . . . . . . . . . . . . . . . . . 12-87
01.02.2000

emergency stop switch . . . . . . . . . . . . . . . . . . . . . . . . 15-2

enter telescope status menu . . . . . . . . . . . . . . . . . . . . 15-80
entering power unit speeds menu . . . . . . . . . . . . . . . . . 12-83
error memory sub-menu . . . . . . . . . . . . . . . . . . . . . . 12-81

Operating Instructions GMK 6300 2 084 548 en 17 - 5

 error messages . . . . . . . . . . . . . . . . . . . . . . 15-61 to 15-82
menu Display states . . . . . . . . . . . . . . . . . . . . . . . . 12-79
menu Display telescoping status . . . . . . . . . . . . . . . . . 12-83
menus on the display . . . . . . . . . . . . . . . . . . . . . . . . 12-79
Crane control emergency stop switch . . . . . . . . . . . . . . . . . . 15-2
Crane control error messages . . . . . . . . . . . . . . . . 15-61 to 15-82
Crane engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . 11-4

display and operating instruments . . . . . . . . . . . . . . . . 10-25

inspections after starting . . . . . . . . . . . . . . . . . . . . . . 11-14
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
setting a constant engine speed . . . . . . . . . . . . . . . . . . 12-89
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
starting - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
VDO electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
crane work
critical load control . . . . . . . . . . . . . . . . . . . . . . . . . 12-90
in winter - checklist . . . . . . . . . . . . . . . . . . . . . . . . 5-3, 11-3
permissible slewing ranges . . . . . . . . . . . . . . . . . . . . 12-35
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
troubleshooting for malfunctions . . . . . . . . . . . . . . 15-3 to 15-4
Crane work with main boom
rigging - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
unrigging - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . 13-4
Critical load control . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-90
Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
driving with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

D dead man’s switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62

Derricking gear
display and operating instruments . . . . . . . . . . . . . 10-35, 10-53
lowering the main boom for maintenance . . . . . . . . . . . . 12-77
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-21
working with the derricking gear . . . . . . . . . . . . . . . . . 12-41
Differential locks
see Transverse differential locks
Door
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
01.02.2000

drive of second axle line / longitudinal differential locks

check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

17 - 6 2 084 548 en Operating Instructions GMK 6300

 Driver’s cab
adjusting the mirrors . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
adjusting the seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-51
overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
ventilating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Driving
breakdown procedure . . . . . . . . . . . . . . . . . . . . . 7-3 to 7-4
checks before driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
checks while driving . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
off-road . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 to 6-44
on downhill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
on uphill slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
with a rigged crane . . . . . . . . . . . . . . . . . . . . 12-93 to 12-98
Driving direction indicator . . . . . . . . . . . . . . . . . . . . . . . . 4-32
driving mode
equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
driving mode table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

E Earthing
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
Earthing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-34
Eddy current retarder . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Electrical system
display and operating instruments in the crane cab . . . . . . . 10-49
display and operating instruments in the driver’s cab . . . . . . . 4-32
fuses in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
fuses in the superstructure . . . . . . . . . . . . . . . . . . . . . . 15-7
plug-in modules and consoles in the crane cab . . . . . . . . . . 15-5
plug-in modules in the driver’s cab . . . . . . . . . . . . . . . . . 7-15
SLI fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
Electronic level
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
Emergency operation
solenoid valves for the outriggers . . . . . . . . . . . . . . . . . . 7-31
Emergency operation submenu on the Crane control display) . . . . 15-79
Emergency stop device
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 to 7-2
on the superstructure . . . . . . . . . . . . . . . . . . . . . 15-1 to 15-2
Enlarging the surface area of the outrigger . . . . . . . . . . . . . . . 13-9
Error messages
control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-61
power units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-62
01.02.2000

SLI, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30

Operating Instructions GMK 6300 2 084 548 en 17 - 7

 F Fast speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-78
Fire extinguisher
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
in the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Flame start system
in the crane engine . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
in the vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fuel tank
crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Fuses
in the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
in the superstructure . . . . . . . . . . . . . . . . . . . . . . . . . 15-7
of the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13

H Hazard warning system . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Heating system
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52, 12-101
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35, 6-51
Hoist rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67
checking the position . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
reeving on the main boom . . . . . . . . . . . . . . . . . . . . . 13-70
Hoists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
Hook block
on a separate vehicle . . . . . . . . . . . . . . . . . . . . . . . . 13-65
on the bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
Hydraulic system
display and control instruments . . . . . . . . . . . . . . . . . . . 4-30

I Identification
of the truck crane . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
Instrument panels
in the crane cab - overview . . . . . . . . . . . . . . . . . . . . . . 10-6
in the driver’s cab - overview . . . . . . . . . . . . . . . . . . . . . 4-8

K Keys
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
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17 - 8 2 084 548 en Operating Instructions GMK 6300

 L Ladders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Lamp test SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
Level adjustment system . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
display and operating instruments . . . . . . . . . . . . . . . . . 4-34
moving the truck crane into on-road driving position . . . . . . . 6-43
raising or lowering the entire truck crane . . . . . . . . . . . . . . 6-41
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
tilting the truck crane lengthwise or crosswise . . . . . . . . . . . 6-42
Level of on-road driving
see On-the-road level
Lifting limit switch
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 12-38
Lifting limit switch weight . . . . . . . . . . . . . . . . . . . . . . . 13-74
Load bearing capacity of the ground . . . . . . . . . . . . . . . . . . . 13-7
table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8
Locking the superstructure . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Lowering limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60

M Main boom
lower the boom for maintenance purposes . . . . . . . . . . . . 12-77
rigging work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
Main hoist
display and operating instruments . . . . . . . . . . . . . . . . 10-32
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
working with the main hoist . . . . . . . . . . . . . . . . . . . . 12-36
Main rope, possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-75
Malfunctions
automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
differential locks . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
procedure in the event of malfunctions . . . . . . . . . . . 7-29 to 7-34
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
sevel adjustment system . . . . . . . . . . . . . . . . . . . . . . . 7-28
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
suspension locking system . . . . . . . . . . . . . . . . . . . . . . 7-28
transfer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
when working with the crane . . . . . . . . . . . . . . . . . . . . 15-3
Malfunctions on
counterweight lifting gear / lock . . . . . . . . . . . . . . . . . . 15-26
crane control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-28
01.02.2000

hydraulic oil cooler for superstructure . . . . . . . . . . . . . . 15-27

Mirror heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Mounting wheel
on the spare wheel holder . . . . . . . . . . . . . . . . . . . . . . 7-12

Operating Instructions GMK 6300 2 084 548 en 17 - 9

 on the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
movements combinations
for operation with the main boom . . . . . . . . . . . . . . . . . 12-92
Multipurpose switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

O Off-road driving . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35 to 6-44

Off-the-road gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
On-the-road level
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
moving the crane into on-the-road level . . . . . . . . . . . . . . 6-43
Operating hour counter
see crane control, display status menu
Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-36
actuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
display and operating instruments . . . . . . . . . . . . . . . . 10-26
extending - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . 13-13
see also Level adjustment system
preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20
retracting - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . 13-15
variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Outrigger beams
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-23
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26
Outrigger cylinders
extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30
retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32
Outrigger pads
moving into driving position . . . . . . . . . . . . . . . . . . . . 13-29
moving into working position . . . . . . . . . . . . . . . . . . . 13-28
Outrigger pressure displays
in the crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35
Outrigger spans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17
Overview
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
crane section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
display and operating instruments . . . . . . . . . . . . . 4-1 to 4-21
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
of display and operating instruments . . . . . . . . . . . 10-1 to 10-24
vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

P Parking brake
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display and operating instruments . . . . . . . . . . . . . . . . . 4-28

releasing mechanically . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
removing the mechanical lock . . . . . . . . . . . . . . . . . . . . 7-10

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 while towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Possible reeving methods
on the main boom . . . . . . . . . . . . . . . . . . . . . . . . . 13-75
Power unit speed
see crane control, entering power unit speeds

R Refuelling
fuel for the crane engine . . . . . . . . . . . . . . . . . . . . . . . 11-9
fuel for the vehicle engine . . . . . . . . . . . . . . . . . . . . . . 6-12
Removing the tyre
from the truck crane . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Removing the wheel
from the spare wheel holder . . . . . . . . . . . . . . . . . . . . . 7-12
Rigging mode
before starting work - CHECK LIST . . . . . . . . . . . . . . . . . 12-1
setting on the SLI . . . . . . . . . . . . . . . . . . . . . . . . . . 12-16
Rigging work
main boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-63
outrigger . . . . . . . . . . . . . . . . . . . . . . . . . 13-13 to 13-36
rigging for crane operation - CHECK LIST . . . . . . . . . . . . . . 13-1
unrigging after crane work - CHECK LIST . . . . . . . . . . . . . . 13-4
Roof ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Rope end clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-67
Rotating warning light . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

S Safe distance
from banks and pits . . . . . . . . . . . . . . . . . . . . . . . . 13-10
from electrical lines . . . . . . . . . . . . . . . . . . . . . . . . . 13-10
Safe load indicator
see SLI
Safety equipment
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10
functional description . . . . . . . . . . . . . . . . . . 10-59 to 10-62
Sensor/indicator
releasing shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 15-39
switch off during malfunction . . . . . . . . . . . . . . . . . . . 15-39
Separate steering
checking the steering lock . . . . . . . . . . . . . . . . . . . . . . 6-10
general . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45 to 6-50
steering with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
switching off axle lines and locking steering . . . . . . . . . . . . 6-48
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Operating Instructions GMK 6300 2 084 548 en 17 - 11

 witching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Slewing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
display and operating instruments . . . . . . . . . . . . . . . . 10-34
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-25
slewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-43
slewing gear permanent brake . . . . . . . . . . . . . . . . . . . 12-43
tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-44
SLI
display and operating instruments . . . . . . . . . . . . . . . . 10-40
during crane work . . . . . . . . . . . . . . . . . . . . . . . . . 12-25
error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-29
functional description . . . . . . . . . . . . . . . . . . . . . . . 10-59
fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13
input of values . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-29
override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-30
setting rigging mode . . . . . . . . . . . . . . . . . . . . . . . . 12-16
switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
SLI error message table . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Spotlight for working area . . . . . . . . . . . . . . . . . . . . . . . 10-49
Steering
display and operating instruments in the driver’s cab . . . . . . . 4-30
Stop engine cable
see emergency stop device
Superstructure hydraulic system
Check the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6
checking the position of the stop cock . . . . . . . . . . . . . . . 11-7
cooling the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . 12-92
display and control instruments . . . . . . . . . . . . . . . . . . 10-48
preheating the hydraulic oil . . . . . . . . . . . . . . . . . . . . . 12-5
Superstructure lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Superstructure, access ladder . . . . . . . . . . . . . . . . . . . . . . 4-41
Suspension
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Switching off the
crane engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1
Switching the fan thermostat to emergency operation . . . . . . . . . 7-29
Symbols in the operating instructions, explanation . . . . . . . . . . . 2-1

T Technical data
superstructure . . . . . . . . . . . . . . . . . . . . . . . . 16-7 to 16-16
Technical description of the carrier . . . . . . . . . . . . . . . . 8-1 to 8-6
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Technical description of the truck crane

superstructure . . . . . . . . . . . . . . . . . . . . . . . . 16-1 to 16-6

17 - 12 2 084 548 en Operating Instructions GMK 6300

 Technical specifications . . . . . . . . . . . . . . . . . . . . . . 8-7 to 8-14
Telescoping gear
display and operating instruments . . . . . . . . . . . . . . . . 10-36
example of procedures when telescoping . . . . . . . . . . . . 12-56
function of the control lever . . . . . . . . . . . . . . . . . . . . 12-54
functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-48
main boom fixed length . . . . . . . . . . . . . . . . . . . . . . 12-49
main boom intermediate length . . . . . . . . . . . . . . . . . . 12-50
main boom telescoping length . . . . . . . . . . . . . . . . . . 12-50
malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-22
telescope status, status display on the SLI . . . . . . . . . . . . 12-50
telescoping sequence . . . . . . . . . . . . . . . . . . . . . . . 12-53
telescoping, indicated on the crane control display. . . . . . . . 12-83
Tow starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 to 7-10
compressed-air supply for engine failure . . . . . . . . . . . . . . . 7-7
gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
vehicle engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
when the diesel engine is off . . . . . . . . . . . . . . . . . . . . . 7-6
with diesel engine running . . . . . . . . . . . . . . . . . . . . . . . 7-5
Towing a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . 6-63 to 6-68
towing free
backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
Transfer case
display and operating instruments in the driver’s cab . . . . . . . 4-26
while towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Transverse differential locks
checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Transverse differential locks in all driven axle lines . . . . . . . . . . . 6-39
Trip recorder
inserting the 24-hour disc . . . . . . . . . . . . . . . . . . . . . . 6-14
setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Truck crane
checking horizontal alignment . . . . . . . . . . . . . . . . . . . 12-31
earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
freeing the crane by oneself . . . . . . . . . . . . . . . . . . . . . 6-43
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 to 1-3
in on-road driving position . . . . . . . . . . . . . . . . . . . . . . 6-43
overview of the crane section . . . . . . . . . . . . . . . . . . . . 10-1
overview of the vehicle section . . . . . . . . . . . . . . . . . . . . 4-1
raising or lowering . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
safe distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-31
securing the truck crane from rolling . . . . . . . . . . . . . . . . 6-32
tilting the crane lengthwise or crosswise . . . . . . . . . . . . . . 6-42
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towing free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Tyre change
see Wheel change

Operating Instructions GMK 6300 2 084 548 en 17 - 13

 V Vehicle engine
Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
checks before starting . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
diagnostic plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
display and operating instruments . . . . . . . . . . . . . . . . . 4-22
inspections after starting . . . . . . . . . . . . . . . . . . . . . . . 5-13
preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54, 6-56
start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10, 11-10
start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
starting - CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
starting a warm engine . . . . . . . . . . . . . . . . . . . . . . . . 5-12
starting cold vehicle engine . . . . . . . . . . . . . . . . . . . . . 5-11
turning off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Ventilation
crane cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-104
driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35, 6-53

W Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 to 7-14

Wind
influence of wind on crane work . . . . . . . . . . . . . . . . . . 12-32
permissible wind load . . . . . . . . . . . . . . . . . . . . . . . 12-34
wind speed table . . . . . . . . . . . . . . . . . . . . . . . . . . 12-32
Work break . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-99 to 12-100
for work breaks lasting more than 8 hours . . . . . . . . . . . . 12-100
short work break . . . . . . . . . . . . . . . . . . . . . . . . . . 12-99

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Operating Instructions GMK 6300 2 084 548 en 17 - 15