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Grove Crane GMK 4075 Operating Instructions Part 1 Carrier 2084718 – PDF DOWNLOAD
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Description
Grove Crane GMK 4075 Operating Instructions Part 1 Carrier 2084718 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4075 Operating Instructions Part 1 Carrier 2084718 – PDF DOWNLOAD
Language : English
Pages : 864
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 4075 Operating Instructions Part 1 Carrier 2084718 – PDF DOWNLOAD
Overview and contents of truck crane user information:
1.3.1 Carrier and superstructure operating manual:
- These instructions contain the information required to operate the truck
crane. - Chapter 2 contains Basic safety instructions. Please read and observe these
instructions, even if you are familiar with the safety manual. The Basic safety
instructions are only found in this chapter. Special safety instructions that
relate to specific hazards are described in the section containing the operation
with which the hazard is associated. - Chapter 3 contains Information for applications engineering. It is intended
primarily for the truck crane operator and those responsible for applications
engineering.
This chapter contains
– the qualifications required for 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 road and
off-road driving. - Chapter 7 contains information on Troubleshooting on the carrier of the truck
crane. - Chapter 8 contains the Technical description of the individual parts and functional
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 and 11 contain information required for Operating the crane section,
i.e. work with the truck crane: a description of all the constructional and operational
parts and information on the operation of the crane.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 4075 Operating Instructions Part 1 Carrier 2084718 – PDF DOWNLOAD
Operating instructions Part 1 Carrier.................................................................................. 1 1 Overview......................................................................................................... 7 1.1 Vehicle identification..................................................................................... 7 1.2 EC Declaration of Conformity............................................................................... 11 1.3 Overview and contents of truck crane user information...................................................... 13 1.3.1 Carrier and superstructure operating manual.......................................................... 13 1.3.2 Lattice extension operating manual (additional equipment)............................................ 14 1.3.3 Maintenance manual................................................................................... 14 1.3.4 Lifting capacity table............................................................................... 14 1.3.5 Outrigger pressure table............................................................................. 15 1.3.6 Safety manual........................................................................................ 15 1.3.7 Spare parts list..................................................................................... 15 1.3.8 Circuit diagrams..................................................................................... 15 1.4 Instructions for use of this document...................................................................... 16 1.4.1 How are the operating instructions laid out?......................................................... 16 1.4.2 How are the pages of the operating instructions formatted?........................................... 17 1.4.3 How can I find the necessary information quickly and easily?......................................... 18 Example of cross- reference usage...................................................................... 19 Explanations of how to use the index................................................................... 24 1.4.4 Definitions of stated directions..................................................................... 24 Basic rule............................................................................................. 24 Buttons and switches.................................................................................. 24 1.4.5 Conversion table for metric measurements............................................................. 25 2 Fundamental safety instructions for crane operators.............................................................. 29 2.1 Warnings and symbols....................................................................................... 29 2.2 Proper use................................................................................................. 30 2.3 Organizational measures.................................................................................... 32 2.4 Personnel qualifications................................................................................... 34 2.5 Safety instructions that apply to truck crane driving...................................................... 35 2.6 Safety instructions for truck crane work................................................................... 35 3 Information for the operating schedule........................................................................... 39 3.1 Safety instructions........................................................................................ 39 3.1.1 Proper use........................................................................................... 39 3.1.2 Organizational measures.............................................................................. 39 3.1.3 Personnel qualifications............................................................................. 40 3.2 Operating schedule......................................................................................... 41 3.2.1 Prerequisites for operations scheduling.............................................................. 41 3.2.2 Details about operations scheduling contained in the user information................................ 42 4 Description of the truck crane vehicle section................................................................... 45 4.1 Overview of the operating and display instruments.......................................................... 45 4.1.1 Overview of the vehicle.............................................................................. 45 4.1.2 Overview of the driver's cab......................................................................... 48 Top view of driver's cab............................................................................... 48 In the driver's cab, at the top........................................................................ 50 Below the front instrument panel....................................................................... 51 4.1.3 Front instrument panel............................................................................... 52 Left-hand insert....................................................................................... 52 Tachograph insert...................................................................................... 54 Speedometer insert..................................................................................... 55 Right-hand insert...................................................................................... 56 Heating and gearbox display insert..................................................................... 58 4.1.4 Side instrument panel................................................................................ 60 Insert 1............................................................................................... 60 Insert 2............................................................................................... 62 Gearbox operating instruments.......................................................................... 64 4.1.5 Switch boxes for outrigger/electronic level/outrigger pressure display (additional equipment)........ 65 4.1.6 Operating instruments on the steering column......................................................... 66 4.2 Functional description of the display and operating instruments........................................... 67 4.2.1 On the instrument panels............................................................................. 67 Diesel engine.......................................................................................... 67 Gearbox with automatic gear change..................................................................... 69 Axle drive............................................................................................. 72 Brakes................................................................................................. 73 Steering............................................................................................... 74 Suspension............................................................................................. 75 Hydraulic system....................................................................................... 76 Electrics.............................................................................................. 76 Leveladjustment....................................................................................... 79 Tachograph............................................................................................. 80 Speedometer insert.................................................................................... 81 Heating in the driver's cab............................................................................ 82 Auxiliary heater with timer (additional equipment).................................................... 83 Other operating instruments........................................................................... 85 4.2.2 On the steering column............................................................................... 87 Ignition lock.......................................................................................... 87 Multipurpose switch, right............................................................................. 87 Multipurpose switch, left.............................................................................. 89 4.2.3 Other operating instruments in the vehicle section................................................... 90 Cab lighting........................................................................................... 90 Keys................................................................................................... 90 Doors.................................................................................................. 91 Window................................................................................................. 92 Ladders................................................................................................ 93 Access ladders......................................................................................... 94 Diesel engine/ gearbox/ electronics diagnostic system.................................................. 94 Front flap............................................................................................. 95 Fire extinguisher (additional equipment).............................................................. 95 5 Diesel engine.................................................................................................... 99 5.1 Starting/turning off the diesel engine..................................................................... 99 5.1.1 CHECKLIST: Starting the diesel engine................................................................ 99 5.1.2 CHECKLIST: In winter.................................................................................101 5.1.3 Inspections before starting the diesel engine........................................................102 Check diesel engine oil level..........................................................................102 Topping up motoroil...................................................................................103 Checking coolant level.................................................................................104 Switching on the battery master switch.................................................................105 Checking hydraulic oil level...........................................................................105 Checking the stop cocks in the hydraulic system........................................................106 5.1.4 Starting the diesel engine...........................................................................107 Switching on ignition..................................................................................107 Starting the diesel engine.............................................................................108 Setting the idling speed...............................................................................110 5.1.5 Inspections before starting the diesel engine........................................................111 Checkinstruments......................................................................................111 5.2 Switching off the diesel engine............................................................................113 5.2.1 Usually via the ignition lock........................................................................113 5.2.2 In an emergency situation, with the emergency stop switch............................................114 5.2.3 In an emergency via the air intake lock (additional equipment).......................................115 Switching on the air intake lock.......................................................................115 Manually releasing the air intake lock.................................................................116 6 Driving the truck crane..........................................................................................119 6.1 Checking the truck crane before driving....................................................................119 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving..........................................119 6.1.2 Driving mode table..................................................................................122 6.1.3 Checking the condition of the hoist rope.............................................................126 Checking the reservoir of the windscreen washing system................................................126 Warning plates for vehicle width.......................................................................126 Checking the tyres.....................................................................................127 Checking the mirror settings...........................................................................128 Adjusting the steering column..........................................................................128 Checking the electrical system.........................................................................129 Switching between driving mode/crane operation.........................................................129 Check the compressed air and brake systems.............................................................129 Checking the suspension................................................................................130 Checking on-the- road level............................................................................130 Checking the transverse differential locks.............................................................131 Checking longitudinal differential locks/drive of 2nd axle line........................................131 Checking the steering locks...........................................................................131 Checking the Boom not set down warning lamp............................................................132 6.1.4 Adjusting the driver's and the passenger's seat......................................................133 Adjust the driver's seat...............................................................................133 Adjusting the driver's seat............................................................................134 6.1.5 Refuelling...........................................................................................135 6.1.6 Switching on the boom floating position..............................................................136 6.1.7 Switching on boom pretensioning......................................................................137 6.1.8 Switching on the slewing gear freewheel..............................................................139 6.1.9 Tachograph...........................................................................................140 6.2 General operation..........................................................................................145 6.2.1 Operating the transmission with automatic gear change................................................145 To switch on...........................................................................................145 Selecting the driving direction........................................................................146 Starting...............................................................................................147 Select gearbox operating mode..........................................................................148 Driving and changing gears.............................................................................149 Changing the direction of travel.......................................................................151 Stopping...............................................................................................151 Switch gearbox to neutral position.....................................................................151 Manoeuvring mode.......................................................................................152 On the roller type dynamometer.........................................................................152 Starting at extremely low temperatures................................................................153 6.2.2 Monitoring the control instruments while driving.....................................................153 6.2.3 Driving on downhill slopes...........................................................................157 Starting on a slope....................................................................................157 Monitoring the maximum permissible engine speed........................................................158 Preselecting gears.....................................................................................158 Retarder...............................................................................................159 Eddy currentretarder (additional equipment)...........................................................160 6.2.4 Driving on uphill slopes.............................................................................161 Starting...............................................................................................161 Driving................................................................................................161 6.2.5 Tempomat.............................................................................................162 Activating the tempomat...............................................................................162 Driving with tempomat..................................................................................162 Switching off tempomat.................................................................................163 6.2.6 Temposet.............................................................................................164 Switching on temposet..................................................................................164 Driving with the temposet..............................................................................164 Switching off Temposet.................................................................................165 6.2.7 Parking the truck crane..............................................................................165 Locking the parking brake..............................................................................165 Gearbox in neutral position...........................................................................165 Turning off the vehicle engine.........................................................................165 Securing the truck crane against rolling...............................................................166 After long periods of standstill.......................................................................166 Securing the truck crane against un- authorized use....................................................166 6.3 Off-the-road driving.......................................................................................167 6.3.1 Longitudinal differential locks/drive of 2nd axle line...............................................168 Switching on drive/longitudinal differential locks.....................................................168 Switching off drive/longitudinal differential locks....................................................169 6.3.2 Deactivating transverse differential locks...........................................................170 Activating transverse differential locks...............................................................170 Deactivating transverse differential locks.............................................................170 6.3.3 Level adjustment.....................................................................................171 Activating the level adjustment system.................................................................172 Raising or lower- ing the entire truck crane...........................................................172 Tilting the truck crane lengthwise or crosswise........................................................173 Bring the truck crane into position On-the-road level..................................................173 Deactivating the level adjustment system...............................................................174 6.3.4 Freeing an immobilized truck crane...................................................................174 Freeing the truck crane by onself ...................................................................174 Towing free forward....................................................................................175 Towing free in reverse.................................................................................175 6.4 Separate steering..........................................................................................177 6.4.1 Unlocking the 3rd axle line steering, connecting 3rd and 4thaxle lines..............................178 6.4.2 Steering the 3rd and 4th axle lines..................................................................178 6.4.3 Separate 4th axle line, lock steering of 3rd axle line...............................................179 6.5 Heating system and fan for driver's cab....................................................................181 6.5.1 Driver's cab heating system..........................................................................181 Heating the driver's cab...............................................................................181 Ventilating the driver's cab...........................................................................182 Air vents..............................................................................................183 6.5.2 Roof fan (additional equipment)......................................................................183 6.5.3 Additional heating system with timer (additional equipment)..........................................184 Preheating the diesel engine...........................................................................184 Preheating the driver's cab............................................................................184 Switching the additional heating system on/off.........................................................184 Displaying and setting the current time................................................................185 Automatic heating start switch on and save.............................................................185 Automatic heating start switching off..................................................................186 6.6 Air-conditioning system (additional equipment).............................................................187 6.6.1 Switching on/off.....................................................................................187 To switch on...........................................................................................187 To switch off..........................................................................................187 6.6.2 Air conditioning.....................................................................................188 How to ensure pleasant air- conditioning...............................................................188 Dry air in the driver's cab............................................................................189 6.7 Towing a trailer (additional equipment)....................................................................191 Effects on the axleloads..................................................................................191 Coupling the trailer.......................................................................................192 Connecting the supply lines...............................................................................193 Removing supplylines......................................................................................194 Uncoupling the trailer.....................................................................................194 Test position of the parking brake when towing a trailer...................................................195 7 Malfunctions on the carrier.....................................................................................199 7.1 Emergency stop device on carrier...........................................................................199 7.1.1 Diesel engine emergency stop switch..................................................................199 7.2 Breakdown in road traffic..................................................................................201 7.3 Towing the truck crane.....................................................................................203 7.3.1 Towing in the case of engine or gearbox damage.......................................................203 Towing the truck crane out of the danger area..........................................................204 Longer distances.......................................................................................204 Compressed air supply for diesel engine failure........................................................205 Power supply...........................................................................................206 Axle drives............................................................................................206 Parking brake..........................................................................................206 Mechanically releasing the parking brake...............................................................207 Towing procedure.......................................................................................207 Removing the mechanical locking from all spring- loaded brake cylinders................................208 Tow starting...........................................................................................208 7.4 Wheel change...............................................................................................209 Removing a damaged wheel...................................................................................209 Removing the wheel from the spare wheel holder.............................................................210 Mounting a damaged wheel on the spare wheel holder.........................................................211 Mounting the spare wheel...................................................................................211 7.5 Tilt driver's cab forward..................................................................................213 Prerequisites and information on tilting...................................................................213 7.5.1 Tilting without hydraulic tilt mechanism.............................................................214 Unlocking/locking the driver's cab.....................................................................214 Driver's cab tilting...................................................................................214 Lowering the driver's cab.............................................................................216 7.5.2 Tilting with hydraulic tilt mechanism................................................................217 Tilting the driver's cab..............................................................................217 Lowering the driver's cab.............................................................................219 7.6 Emergency operation for lifting the main boom..............................................................221 7.6.1 Connecting/disconnecting the hose....................................................................222 Connecting the hose....................................................................................222 Disconnecting the hose.................................................................................222 7.6.2 Connecting hydraulic circuits........................................................................223 7.6.3 Switching continuous operation on or off.............................................................224 7.6.4 Performing emergency operation.......................................................................225 7.6.5 After emergency operation...........................................................................226 7.7 Electrical system..........................................................................................227 7.7.1 Inserts..............................................................................................227 Front insert...........................................................................................227 Side insert............................................................................................228 7.7.2 Fuses................................................................................................229 Fuses in the driver's cab..............................................................................229 Fuses in battery box...................................................................................232 Fuses on input-output pcb's............................................................................233 7.8 Troubleshooting and remedy.................................................................................235 7.8.1 Malfunctions on the diesel engine....................................................................235 7.8.2 Malfunctions of the gearbox with automatic gear change...............................................237 7.8.3 Differential lock malfunctions.......................................................................238 7.8.4 Service brake malfunctions...........................................................................239 7.8.5 Steering system malfunctions.........................................................................240 7.8.6 Tachograph malfunctions..............................................................................241 7.8.7 Outrigger malfunctions...............................................................................242 7.8.8 Suspension locking system malfunctions...............................................................242 7.8.9 Level adjustment system malfunctions.................................................................242 7.8.10 Malfunctions on the carrier electronic system.......................................................243 7.9 Procedure in the event of malfunctions.....................................................................245 7.9.1 Switching the fan thermostat to emergency operation..................................................245 7.9.2 What to do if there is a gearbox malfunction.........................................................246 Error messages on the Gearbox display..................................................................246 Calling up error codes................................................................................247 7.9.3 Emergency operation of the solenoid valves for the outriggers........................................249 Pressure build-up valve................................................................................249 Position and allocation of the solenoid valves.........................................................250 8 Technical information Carrier....................................................................................255 8.1 Technical description of the carrier.......................................................................255 8.1.1 Crane carrier........................................................................................255 8.1.2 Driver's cab.........................................................................................255 8.1.3 Drive units..........................................................................................256 8.1.4 Engine cooling system................................................................................256 8.1.5 Hydraulic system.....................................................................................256 8.1.6 Steering.............................................................................................257 8.1.7 Suspension system....................................................................................257 8.1.8 Outrigger............................................................................................258 8.1.9 Compressed air system................................................................................258 8.1.10 Service brake.......................................................................................259 8.1.11 Parking brake.......................................................................................259 8.1.12 Retarder............................................................................................259 8.1.13 Secondary consumers.................................................................................260 8.1.14 Towing the crane....................................................................................260 8.1.15 Towing a trailer....................................................................................260 8.1.16 Electrical system...................................................................................260 8.2 Technical data.............................................................................................261 8.2.1 Measurements and weights of the truck crane..........................................................262 Dimensions for driving on public roads.................................................................262 Total weight and axle load.............................................................................263 8.2.2 Dimensions and weights of removable parts............................................................263 Spare wheel (additional equipment).....................................................................263 Outrigger..............................................................................................263 8.2.3 Carrier..............................................................................................264 Vehicle engine.........................................................................................264 Power shift gear.......................................................................................264 Distributor gearbox....................................................................................264 Axle lines.............................................................................................264 Steering...............................................................................................264 Tyres..................................................................................................265 Outrigger..............................................................................................265 Vehicle's electrical system............................................................................266 Tools..................................................................................................266 Driving speeds.........................................................................................266 Climbing ability.......................................................................................266 Turning circle radii...................................................................................267 9 Alphabetical index...............................................................................................271 A..............................................................................................................273 B..............................................................................................................273 C..............................................................................................................274 D..............................................................................................................276 E..............................................................................................................278 F..............................................................................................................278 G..............................................................................................................279 H..............................................................................................................279 I..............................................................................................................280 K..............................................................................................................280 L..............................................................................................................280 M..............................................................................................................281 O..............................................................................................................281 P..............................................................................................................282 R..............................................................................................................283 S..............................................................................................................283 T..............................................................................................................285 V..............................................................................................................286 W..............................................................................................................286 Operating instructions Part 2 Superstructure...........................................................................289 10 Description of the crane section of the truckcrane.............................................................295 10.1 Overview of the operating and display instruments.........................................................295 10.1.1 Overview of the crane section.......................................................................295 10.1.2 Overview of crane cab...............................................................................298 10.1.3 Front instrument panel..............................................................................300 Left-hand insert.......................................................................................300 Centre plug-in module.................................................................................302 Right-hand insert......................................................................................304 SLI plug-in module....................................................................................306 Side plug-in module...................................................................................312 10.1.4 Control consoles....................................................................................314 Left-hand control console..............................................................................314 Right-hand control console.............................................................................315 10.1.5 Control lever configuration.........................................................................316 Version 1 (standard)...................................................................................316 Version 2 (additional equipment)......................................................................317 10.1.6 Crane control plug-in module........................................................................318 Main menu – crane control display......................................................................320 Submenu for counterweight..............................................................................322 Submenu for outrigger/ electronic level/ outrigger pressure indicator..................................324 Submenu for semi-automatic telescoping.................................................................326 Submenu for fully automatic telescoping................................................................327 Submenu for Settings/status display....................................................................328 Houselock submenu......................................................................................329 10.1.7 Behind crane driver´s seat..........................................................................331 10.1.8 Control box for emergency operation without crane control...........................................332 10.1.9 Switch boxes for outrigger/electronic level/outriggerpressure display (additional equipment).......334 Operating instruments for the outrigger................................................................335 Operating instruments for outrigger pressure indicator (additional equipment)..........................335 Operating instruments for electronic level.............................................................335 10.2 Functional description of the display and operating instruments for crane work...........................337 10.2.1 Diesel engine.......................................................................................337 On the instrument panels...............................................................................337 Crane control display..................................................................................338 10.2.2 Crane control.......................................................................................340 Function of operating instruments......................................................................340 Crane control display..................................................................................342 Display elements in main menu..........................................................................342 10.2.3 Outrigger, outrigger pressure indicator, electronic level...........................................344 Display fields on the carrier..........................................................................344 Submenu for Outrigger/electronic level.................................................................346 10.2.4 Counterweight submenu...............................................................................350 Submenu for counterweight, version 1...................................................................350 Submenu for counterweight, version 2...................................................................353 10.2.5 Houselock submenu...................................................................................357 10.2.6 Hoists..............................................................................................358 Main hoist.............................................................................................358 Auxiliary hoist (additional equipment).................................................................359 10.2.7 Slewing gear........................................................................................361 10.2.8 Derricking gear.....................................................................................363 Derricking the lattice extension.......................................................................364 10.2.9 Telescoping gear....................................................................................365 Control consoles.......................................................................................365 Control lever for telescoping..........................................................................365 Telescoping submenu....................................................................................366 10.2.10 Safe load indicator (SLI) ........................................................................375 10.2.11 Hydraulic system...................................................................................385 On the instrument panels...............................................................................385 Control consoles.......................................................................................385 In submenu Monitoring carrier..........................................................................385 In submenu Settings/displays..........................................................................385 10.2.12 Electrics, lighting, windscreen wiper/washing system...............................................387 Electrics..............................................................................................387 Lighting...............................................................................................387 Windscreen wiper/washing system.....................................................................388 10.2.13 Crane cab heating system...........................................................................389 10.2.14 Air-conditioning system (additional equipment).....................................................391 10.2.15 Other operating instruments in the crane cab.......................................................392 Keys...................................................................................................392 Crane cab door.........................................................................................392 Window.................................................................................................393 Seat adjustment........................................................................................395 Fire extinguisher (additional equipment)...............................................................395 10.2.16 Control box for emergency operation without crane control..........................................396 10.3 Functional description of the display and operating elements for driving from inside the cr..............399 10.3.1 Diesel engine.......................................................................................399 10.3.2 Gearbox.............................................................................................400 10.3.3 Axle drive..........................................................................................401 10.3.4 Brakes..............................................................................................402 10.3.5 Steering............................................................................................403 Normal steering mode...................................................................................403 Separate steering......................................................................................403 10.3.6 Other operating instruments.........................................................................404 10.4 Functional description of the safety devices..............................................................405 10.4.1 Safe load indicator (SLI)...........................................................................405 10.4.2 Lowering limit switch...............................................................................407 10.4.3 Lifting limit switch................................................................................408 Overriding lifting limit switch shutdown...............................................................408 10.4.4 Dead man's and seat contact switches................................................................410 11 Crane operation.................................................................................................413 11.1 Checking the truck crane before working with the crane....................................................413 11.1.1 CHECKLIST: Condition for working with a truck crane supported on outriggers.........................413 11.1.2 CHECKLIST: Condition for working with a free on wheels truck crane..................................417 11.1.3 Checking the condition of the hoist rope............................................................422 Checking the reservoir of the windscreen washing system..............................................422 Visual inspection of the entire crane..................................................................422 Checking the mirror settings...........................................................................423 Checking the position of the hoist ropes...............................................................424 Checking the electrical system.........................................................................424 11.1.4 Checking safety equipment...........................................................................425 Checking the safe load indicator.......................................................................425 Checking the lifting limit switch.....................................................................426 Seat contact switch and dead man's switch system......................................................426 Crane control emergency stop...........................................................................427 11.1.5 Preheating the hydraulic oil........................................................................428 When the oil temperature is between –15 C and 0 C (5 F and 32 F):..................................428 For oil temperatures below –15 C (5 F):.............................................................428 11.1.6 Switching off the boom floating position............................................................429 11.1.7 Switching off boom pre-tensioning...................................................................429 11.1.8 Switching off slewing gear freewheel................................................................431 Before slewing.........................................................................................432 11.1.9 Locking/unlocking the superstructure................................................................433 11.1.10 Switching houselock on/off.........................................................................435 Switching on the houselock............................................................................436 Switching off the houselock...........................................................................437 Display of errors for houselock........................................................................438 11.2 Starting and stopping the diesel engine from inside the crane cab.........................................439 11.2.1 When starting the engine the first time in the day..................................................439 11.2.2 Start warm diesel engine............................................................................441 Checks on carrier before starting......................................................................441 Switching on the ignition..............................................................................441 Start diesel engine..................................................................................444 11.2.3 Checks after starting the diesel engine.............................................................445 Checks on the instrument panel.........................................................................445 Checks on the Crane control display...................................................................446 11.2.4 Shutting down the diesel engine.....................................................................447 11.3 Operating the safe load indicator (SLI)...................................................................449 11.3.1 Switching on the SLI................................................................................449 To switch on...........................................................................................449 Lamp test on theSLI...................................................................................451 Dimmers for the SLI displays...........................................................................451 11.3.2 Setting rigging mode................................................................................452 Setting via the SLIcode...............................................................................452 Setting using individual components..................................................................452 General instructions...................................................................................453 Sequence during setting................................................................................453 Switching on entry mode................................................................................454 Entering values........................................................................................455 Confirming entry.......................................................................................457 Accepting values.......................................................................................457 Switching over Hoist position lights...................................................................458 11.3.3 Checks before working with the crane................................................................459 11.3.4 During crane work...................................................................................461 Continuous displays...................................................................................461 Optional displays.....................................................................................462 SLI early warning......................................................................................463 SLI shutdown...........................................................................................463 Monitor overall height................................................................................464 Error message..........................................................................................465 Error messages with additional optical displays........................................................466 SLIoverride...........................................................................................467 11.3.5 Monitoring the overall height.......................................................................468 Display current overall height.........................................................................468 Display maximum permissible overall height.............................................................469 Enter maximum permissible overall height...............................................................469 Switching off monitoring of overall height.............................................................470 Display entered height for the crane carrier...........................................................471 Overshooting the maximum permissible overall height....................................................471 Overriding shutdown of overall height..................................................................472 11.4 Crane work with main boom.................................................................................473 11.4.1 External influences during crane operation..........................................................473 Horizontal alignment...................................................................................473 Safedistances.........................................................................................473 Monitoring wind speed without an anemometer............................................................474 Monitoring wind speed with an anemometer..............................................................475 When the maximum allowed wind speed has been exceeded..................................................475 Permissible windload.................................................................................476 Earthing the load......................................................................................477 11.4.2 Permissable slewing ranges and working positions for cranework.....................................478 360 slewing range.....................................................................................478 Working position 0 to the rear........................................................................478 Free-standing truck crane..............................................................................479 11.4.3 Main hoist..........................................................................................480 Switching on the main hoist............................................................................480 Lifting and lowering..................................................................................481 Switching off the main hoist..........................................................................483 11.4.4 Auxiliary hoist (additional equipment)..............................................................484 Switching on the auxiliary hoist......................................................................484 Lifting and lowering..................................................................................485 Switching off the auxiliary hoist.....................................................................485 11.4.5 Derricking gear.....................................................................................486 Switching on the derricking gear.......................................................................486 Raising and lowering...................................................................................487 Switching off the derricking gear.....................................................................487 11.4.6 Slewing gear........................................................................................489 Switching on the slewing gear.........................................................................489 Slewing................................................................................................490 Braking slewing movement...............................................................................491 Tracking the slewing gear..............................................................................492 Maximum permissible slewing speed......................................................................492 Switching off the slewing gear........................................................................494 11.4.7 Telescoping gear....................................................................................495 Structure of the chapter...............................................................................495 Description of functioning.............................................................................496 Main boom fixed length, intermediate length, telescoping length........................................497 Telescope status.......................................................................................498 Notes on the telescoping sequence......................................................................501 Checking before the first telescoping.................................................................501 Switching on telescoping gear..........................................................................502 Function of the control lever..........................................................................502 Switching off telescoping gear.........................................................................504 Example of the procedure for telescoping...............................................................504 Check initial position.................................................................................506 Unlocking the telescoping cylinder.....................................................................511 Extend/retract telescoping cylinder....................................................................514 Locking the telescoping cylinder.......................................................................515 Unlocking the telescopic part..........................................................................519 Telescope telescopic section..........................................................................521 Locking telescope section.............................................................................523 Telescoping the telescopic section to intermediate retracting..........................................527 Lock telescopic section for on- road driving..........................................................527 Telescoping with fully automatic control...............................................................528 Lowering the main boom for maintenance................................................................533 Telescoping the main boom into ahorizontal position..................................................533 11.4.8 Fast speed..........................................................................................535 11.4.9 Special menus on the crane control display..........................................................536 Operating hours meter submenu........................................................................536 Driving gear speeds submenu..........................................................................537 Warning message submenu................................................................................540 Error menu.............................................................................................542 Changing the background colour of the display..........................................................544 11.4.10 Setting a constant engine speed....................................................................545 11.4.11 Inclining crane cab................................................................................546 11.4.12 Cooling the hydraulic oil..........................................................................547 Standard oil cooler....................................................................................547 Additional oil cooler..................................................................................547 11.4.13 Possible movement combinations.....................................................................548 11.5 Driving the truck crane from inside the crane cab.........................................................549 11.5.1 Preparing to drive..................................................................................550 In the driver's cab....................................................................................550 Prerequisites..........................................................................................550 11.5.2 Driving route.......................................................................................551 11.5.3 Operating the gear box..............................................................................551 11.5.4 Steering............................................................................................552 Adapting the steering direction to the superstructure setting..........................................552 Normal steering mode...................................................................................552 Separate steering......................................................................................553 11.5.5 Driving the rigged truck crane......................................................................555 Driving................................................................................................556 Align free on wheels truck crane horizontally..........................................................556 11.5.6 Possible gear changes...............................................................................557 Drive of the second axle line/ longitudinal differential locks.........................................557 Switching off drive/longitudinal differential locks....................................................558 Activating transverse differential locks...............................................................558 Deactivating transverse differential locks.............................................................558 11.5.7 After driving.......................................................................................559 11.6 Work break................................................................................................561 11.6.1 Short work break....................................................................................561 11.6.2 Work breaks lasting more than 8 hours...............................................................561 11.7 Crane cab heating and ventilation.........................................................................563 11.7.1 Heating the crane cab...............................................................................563 Switching heating on/off...............................................................................563 Regulate temperature..................................................................................564 Setting air distribution..............................................................................564 Setting air escape jets................................................................................565 Setting recirculated air/fresh air operation...........................................................566 Fuel tank.............................................................................................566 Storing automatic heating start........................................................................567 Setting automatic heating length.......................................................................568 Switching automatic heating start on/off...............................................................568 Setting remaining time.................................................................................569 Seting time and day....................................................................................569 11.7.2 Ventilating the crane cab...........................................................................570 11.8 Air-conditioning system (additional equipment)............................................................571 11.8.1 To switch on........................................................................................571 11.8.2 Setting the air flow................................................................................572 11.8.3 To switch off.......................................................................................572 11.8.4 Air conditioning....................................................................................573 How to ensure pleasant air-conditioning................................................................573 Dehumidifying the crane cab air........................................................................574 12 Rigging work for outriggers and main boom.......................................................................577 12.1 Checklists for rigging work for crane operation withmain boom............................................577 12.1.1 CHECKLIST: Rigging..................................................................................577 12.1.2 CHECKLIST: Unrigging................................................................................580 12.2 Choosing a suitable site..................................................................................582 12.2.1 Load bearing capacity of the ground and the outrigger...............................................582 Outrigger surface area enlarge.........................................................................584 12.2.2 Safe distance from banks and pits...................................................................585 12.2.3 Safe distance from electrical lines.................................................................586 12.2.4 Earthing the truck crane............................................................................589 Earthing the truck crane...............................................................................589 12.3 Outrigger.................................................................................................591 12.3.1 CHECKLIST: Extending the outrigger..................................................................591 12.3.2 CHECKLIST: Retracting the outrigger.................................................................593 12.3.3 Permissible outrigger spans.........................................................................594 Outrigger span 26.6 x 23.0ft..........................................................................595 Outrigger span 26.6 x 19.7ft..........................................................................595 Outrigger span 26.6 x 16.4ft..........................................................................596 Outrigger span 26.6 x 7.6ft...........................................................................596 12.3.4 Preparing the truck crane...........................................................................597 Align horizontally....................................................................................597 Locking the suspension................................................................................597 Switch on/off display field on the carrier.............................................................597 12.3.5 Securing/releasing outrigger beam for crane operations..............................................599 Securing the outrigger beams..........................................................................599 Releasing the outrigger beams.........................................................................600 12.3.6 Extending/retracting the outrigger beams............................................................602 Operation from the carrier.............................................................................602 Operation from the cranecabin.........................................................................604 Setting outrigger spans................................................................................607 12.3.7 Securing outrigger beam for on-road driving.........................................................609 12.3.8 Moving the outrigger pads into working/driving position.............................................610 Moving the outrigger pads into working position........................................................610 Moving the outrigger pads into driving position.......................................................611 12.3.9 Extending/retracting the support cylinder...........................................................612 Operation from the carrier.............................................................................612 Operation from the crane cabin.........................................................................616 12.3.10 Checking the alignment of the truck crane..........................................................619 Electronic level on the carrier......................................................................619 Electronic level on crane control display.............................................................621 12.3.11 Aligning the truck crane horizontally..............................................................623 If the boom is in the boom support...................................................................623 If the boom israised................................................................................623 Automatic aligning.....................................................................................623 12.3.12 Outrigger pressure display.........................................................................625 Outrigger pressure display on the carrier..............................................................625 Outrigger pressure display on superstructure...........................................................626 12.4 Rigging work on the main boom.............................................................................627 12.4.1 Hook block on the bumper............................................................................627 Picking up the hook block from the bumper..............................................................627 Attach the hook block to the bumper....................................................................628 12.4.2 Hook block on a separate vehicle....................................................................629 Picking up the hookblock from the separate vehicle...................................................629 Positioning the hook block on the separate vehicle and securing the hoist rope for on- road driving....630 12.4.3 Reeving and unreeving the hoist rope................................................................631 Rope end clamp.........................................................................................631 Reeve the hoist rope..................................................................................633 Lifting limit switch on the main boom..................................................................635 12.4.4 Possible reeving on the main boom for standard design with 6sheaves................................638 12.4.5 Possible reeving on the main boom for additional equipment with 8sheaves...........................641 12.4.6 Anemometer..........................................................................................644 13 Counterweight rigging work......................................................................................647 13.1 Permissible counterweight versions........................................................................647 13.2 Counterweight rigging– version 1.........................................................................649 13.2.1 Counterweight parts and identification..............................................................649 Counterweight parts...................................................................................649 Identification.........................................................................................649 13.2.2 Counterweight versions..............................................................................650 13.2.3 Slinging points on the counterweight sections.......................................................652 13.2.4 CHECKLIST: Rigging the counterweight................................................................653 13.2.5 CHECKLIST: Unrigging the counterweight..............................................................656 13.2.6 Lower 3.3 t counterweight section on the counterweight platform.....................................658 13.2.7 Assembling the counterweight version................................................................659 13.2.8 Counterweight lifting unit..........................................................................661 Checks to be carried out prior to lifting..............................................................661 Recall counterweight sub-menu.........................................................................661 Checking the current hoist unit status................................................................662 Display incorrectstatus.............................................................................663 Extending/ retracting the lifting cylinder.............................................................664 Unlock/lock counterweight.............................................................................666 13.2.9 Removing/installing the 2.0 t counterweight section ontheturntable................................668 Opening the mechanical lock..........................................................................669 Closing the mechanical lock...........................................................................670 13.2.10 Slewing with the rigged counterweight..............................................................671 13.3 Counterweight rigging– version 2.........................................................................673 13.3.1 Counterweight parts and identification..............................................................673 Counterweight parts...................................................................................673 Identification.........................................................................................673 13.3.2 Counterweight versions..............................................................................674 13.3.3 Slinging points on the counterweight sections.......................................................677 Lifting individual counterweight sections.............................................................677 Lifting stacked counterweight sections................................................................678 13.3.4 CHECKLIST: Rigging the counterweight................................................................679 13.3.5 CHECKLIST: Unrigging the counterweight..............................................................682 13.3.6 Lower 3.3tbaseplate on the counterweight platform.................................................685 13.3.7 Check the position of the locking pins..............................................................686 Checking the 1.3t counterweight section...............................................................686 Checking the 2.0 t counterweight sections..............................................................687 13.3.8 Assembling the counterweight version................................................................688 Procedures.............................................................................................688 Versions that can be installed on the turntable.......................................................689 Combinations that can be differently assembled.......................................................691 13.3.9 Counterweight lifting unit..........................................................................695 Check the position of the locking pins.................................................................695 Recall counterweight sub-menu........................................................................696 Checking the current hoist unit status...............................................................697 Display incorrect status.............................................................................698 Extending/ retracting the lifting cylinder.............................................................698 Unlock/lock counterweight............................................................................700 13.3.10 Removing/installing the counterweight sections ontheturntable....................................702 Installing counterweight sections......................................................................702 Uninstalling counterweight sections...................................................................703 13.3.11 Locking/unlocking the 2.0 t and 5.0 t counterweight sections.......................................704 Locking counterweight sections.........................................................................704 Unlocking the counterweight sections...................................................................705 13.3.12 Slewing with the rigged counterweight..............................................................706 14 Malfunctions on the superstructure..............................................................................709 14.1 Superstructure emergency stop device......................................................................709 Turning off the diesel engine..............................................................................709 Crane control emergency stop switch........................................................................710 14.2 What to do in the event of a malfunction when working with the crane.....................................711 Load cannot be lowered.....................................................................................711 14.3 Electrical system.........................................................................................713 14.3.1 Plug-in modules and consoles........................................................................713 14.3.2 Fuses...............................................................................................715 Fuses on turntable.....................................................................................715 Fuses in crane cab.....................................................................................717 Fuses on input- output bedplates.......................................................................719 14.3.3 SLI fuses...........................................................................................720 Replacing fuses........................................................................................720 14.4 Troubleshooting and remedy................................................................................723 14.4.1 Vehicle engine malfunctions during the crane operations.............................................723 14.4.2 Malfunctions when driving from crane cab............................................................723 14.4.3 Main hoist malfunctions.............................................................................724 14.4.4 Auxiliary hoist malfunctions........................................................................726 14.4.5 Derricking gear malfunctions........................................................................728 14.4.6 Telescoping gear malfunctions.......................................................................730 Error messages concerning telescoping gear.............................................................732 14.4.7 Slewing gear malfunctions...........................................................................735 14.4.8 Malfunctions at the counterweight hoist unit........................................................736 14.4.9 Hydraulic system/hydraulic oil cooler malfunctions..................................................737 14.4.10 Outrigger malfunctions.............................................................................737 14.4.11 Crane control malfunctions.........................................................................738 14.4.12 Malfunctions on the SLI............................................................................739 Other malfunctions on the SLI..........................................................................739 SLI error message table................................................................................740 Switch off sensor/ indicator during malfunction........................................................748 Check function of remaining emergency operation........................................................749 Take over telescoping from the values..................................................................750 Checking SLI lines and connections.....................................................................751 14.4.13 Emergency retract operation........................................................................753 Check prior to every emergency operation...............................................................753 Procedure for retracting...............................................................................754 Mechanical emergency operation.........................................................................755 Hydraulic emergency operation..........................................................................757 14.5 Error messages on crane control display...................................................................769 Crane control program version..............................................................................769 14.5.1 Meaning of displayed symbols........................................................................769 Symbols for Devices...................................................................................770 Symbols for Groups....................................................................................771 Symbols for types of errors...........................................................................772 Index displays allocation.............................................................................773 Control leves error table..............................................................................780 Locking system error table.............................................................................781 Error messages via Can-Bus.............................................................................784 14.5.2 Connections for the crane control control units.....................................................787 Control units connections position.....................................................................787 Layout of connections.................................................................................788 Truck crane for defective control unrigging units......................................................790 Example for unrigging with three control units.........................................................790 Replacing control units................................................................................792 14.5.3 Sub-menu emergency program telescoping..............................................................794 Starting emergency program............................................................................794 Emergency program display and operating elements.......................................................795 Retracting with an error on the length indicator.......................................................797 Retracting with an error on the proximity switch.......................................................801 Emergency program end.................................................................................803 Table for approaching the locking points...............................................................803 14.5.4 Enter telescope status after emergency operation....................................................804 14.5.5 Emergency operation in case of the crane control failure............................................807 Truck crane preparation................................................................................807 Emergency operation switch on.........................................................................808 Operating driving gears................................................................................808 Movements stopping....................................................................................810 Stopping the movent in case of an emergency............................................................810 14.6 Hydraulic emergency stop according to ZH1/461.............................................................811 14.6.1 Important instructions for hydraulic emergency operation............................................811 14.6.2 Functioning and accessories.........................................................................813 14.6.3 Establishing hose connections.......................................................................814 For the emergency operation with the transformer.......................................................814 For the emergency operation with the hand pump.........................................................816 14.6.4 Establishing required hydraulic circuits............................................................817 Taps connecting points.................................................................................817 Additional connections for the main hoist..............................................................819 Additional connections for the slewing gear............................................................820 14.6.5 Executing emergency operation.......................................................................821 Emergency operation main hoist movement................................................................822 Emergency operation driving derricking gear............................................................822 Emergency operation driving the slewing gear...........................................................824 14.6.6 After the emergency operation.......................................................................825 Establishing hydraulic circuits for crane operation .................................................825 Loosen established hose connections...................................................................825 15 Technical information for superstructure........................................................................829 15.1 Technical description of the superstructure...............................................................829 15.1.1 Turntable...........................................................................................829 15.1.2 Crane operator's cab................................................................................829 15.1.3 Crane engine and hydraulic system...................................................................830 15.1.4 Control system......................................................................................830 15.1.5 Main boom...........................................................................................831 15.1.6 Telescoping gear....................................................................................831 15.1.7 Hoists..............................................................................................832 15.1.8 Slewing gear........................................................................................832 15.1.9 Houselock...........................................................................................832 15.1.10 Derricking cylinder................................................................................833 15.1.11 Electrical system.................................................................................833 15.1.12 Counterweight......................................................................................833 15.1.13 Safety equipment...................................................................................834 15.2 Technical data............................................................................................835 15.2.1 Maximum load bearing capacity (DIN/ISO/EN)..........................................................835 15.2.2 Max. lifting capacity (85%)........................................................................835 15.2.3 Dimensions, weights and axle load...................................................................836 Dimensions when driving on public roads................................................................836 Total weight and axle load.............................................................................837 15.2.4 Dimensions and weights of removable parts...........................................................837 Hook blocks and hook tackle............................................................................837 Counterweight sections – version 1....................................................................838 Counterweight sections – version2....................................................................838 Counterweight versions – version1.....................................................................839 Counterweight versions – version2.....................................................................840 15.2.5 Technical data for superstructure...................................................................842 Main hoist.............................................................................................842 Auxiliary hoist (additional equipment)................................................................842 Slewing gear...........................................................................................842 Derricking gear........................................................................................842 Main boom..............................................................................................843 Working speed and times without load...................................................................843 16 Alphabetical index..............................................................................................847 A..............................................................................................................849 B..............................................................................................................849 C..............................................................................................................850 D..............................................................................................................852 E..............................................................................................................854 F..............................................................................................................854 G..............................................................................................................855 H..............................................................................................................855 I..............................................................................................................856 K..............................................................................................................856 L..............................................................................................................856 M..............................................................................................................857 O..............................................................................................................857 P..............................................................................................................858 R..............................................................................................................859 S..............................................................................................................859 T..............................................................................................................861 V..............................................................................................................862 W..............................................................................................................862
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