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Grove Crane GMK 4075 Part 1 Carrier Operating Instruction Manual 2084665 – PDF DOWNLOAD
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Description
Grove Crane GMK 4075 Part 1 Carrier Operating Instruction Manual 2084665 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4075 Part 1 Carrier Operating Instruction Manual 2084665 – PDF DOWNLOAD
Language : English
Pages : 852
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 4075 Part 1 Carrier Operating Instruction Manual 2084665 – 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 Part 1 Carrier Operating Instruction Manual 2084665 – 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 Unlocking/locking the driver's cab.........................................................................214 Driver's cab tilting.......................................................................................214 Lowering the driver's cab.................................................................................216 7.6 Emergency operation for lifting the main boom..............................................................217 7.6.1 Connecting/disconnecting the hose....................................................................218 Connecting the hose....................................................................................218 Disconnecting the hose.................................................................................218 7.6.2 Connecting hydraulic circuits........................................................................219 7.6.3 Switching continuous operation on or off.............................................................220 7.6.4 Performing emergency operation.......................................................................221 7.6.5 After emergency operation...........................................................................222 7.7 Electrical system..........................................................................................223 7.7.1 Inserts..............................................................................................223 Front insert...........................................................................................223 Side insert............................................................................................224 7.7.2 Fuses................................................................................................225 Fuses in the driver's cab..............................................................................225 Fuses in battery box...................................................................................228 Fuses on input-output pcb's............................................................................229 7.8 Troubleshooting and remedy.................................................................................231 7.8.1 Malfunctions on the diesel engine....................................................................231 7.8.2 Malfunctions of the gearbox with automatic gear change...............................................233 7.8.3 Differential lock malfunctions.......................................................................234 7.8.4 Service brake malfunctions...........................................................................235 7.8.5 Steering system malfunctions.........................................................................236 7.8.6 Tachograph malfunctions..............................................................................237 7.8.7 Outrigger malfunctions...............................................................................238 7.8.8 Suspension locking system malfunctions...............................................................238 7.8.9 Level adjustment system malfunctions.................................................................238 7.8.10 Malfunctions on the carrier electronic system.......................................................239 7.9 Procedure in the event of malfunctions.....................................................................241 7.9.1 Switching the fan thermostat to emergency operation..................................................241 7.9.2 What to do if there is a gearbox malfunction.........................................................242 Error messages on the Gearbox display..................................................................242 Calling up error codes................................................................................243 7.9.3 Emergency operation of the solenoid valves for the outriggers........................................245 Pressure build-up valve................................................................................245 Position and allocation of the solenoid valves.........................................................246 8 Technical information Carrier....................................................................................251 8.1 Technical description of the carrier.......................................................................251 8.1.1 Crane carrier........................................................................................251 8.1.2 Driver's cab.........................................................................................251 8.1.3 Drive units..........................................................................................252 8.1.4 Engine cooling system................................................................................252 8.1.5 Hydraulic system.....................................................................................252 8.1.6 Steering.............................................................................................253 8.1.7 Suspension system....................................................................................253 8.1.8 Outrigger............................................................................................254 8.1.9 Compressed air system................................................................................254 8.1.10 Service brake.......................................................................................255 8.1.11 Parking brake.......................................................................................255 8.1.12 Retarder............................................................................................255 8.1.13 Secondary consumers.................................................................................256 8.1.14 Towing the crane....................................................................................256 8.1.15 Towing a trailer....................................................................................256 8.1.16 Electrical system...................................................................................256 8.2 Technical data.............................................................................................257 8.2.1 Measurements and weights of the truck crane..........................................................258 Dimensions for driving on public roads.................................................................258 Total weight and axle load.............................................................................259 8.2.2 Dimensions and weights of removable parts............................................................259 Spare wheel (additional equipment).....................................................................259 Outrigger..............................................................................................259 8.2.3 Carrier..............................................................................................260 Vehicle engine.........................................................................................260 Power shift gear.......................................................................................260 Distributor gearbox....................................................................................260 Axle lines.............................................................................................260 Steering...............................................................................................260 Tyres..................................................................................................261 Outrigger..............................................................................................261 Vehicle's electrical system............................................................................262 Tools..................................................................................................262 Driving speeds.........................................................................................262 Climbing ability.......................................................................................262 Turning circle radii...................................................................................263 9 Alphabetical index...............................................................................................267 A..............................................................................................................269 B..............................................................................................................269 C..............................................................................................................270 D..............................................................................................................272 E..............................................................................................................274 F..............................................................................................................274 G..............................................................................................................275 H..............................................................................................................275 I..............................................................................................................276 K..............................................................................................................276 L..............................................................................................................276 M..............................................................................................................276 O..............................................................................................................277 P..............................................................................................................278 R..............................................................................................................279 S..............................................................................................................279 T..............................................................................................................281 V..............................................................................................................282 W..............................................................................................................282 Operating instructions Part 2 Superstructure...........................................................................285 10 Description of the crane section of the truckcrane.............................................................291 10.1 Overview of the operating and display instruments.........................................................291 10.1.1 Overview of the crane section.......................................................................291 10.1.2 Overview of crane cab...............................................................................294 10.1.3 Front instrument panel..............................................................................296 Left-hand insert.......................................................................................296 Centre plug-in module.................................................................................298 Right-hand insert......................................................................................300 SLI plug-in module....................................................................................302 Side plug-in module...................................................................................308 10.1.4 Control consoles....................................................................................310 Left-hand control console..............................................................................310 Right-hand control console.............................................................................311 10.1.5 Control lever configuration.........................................................................312 Version 1 (standard)...................................................................................312 Version 2 (additional equipment)......................................................................313 10.1.6 Crane control plug-in module........................................................................314 Main menu – crane control display......................................................................316 Submenu for counterweight..............................................................................318 Submenu for outrigger/ electronic level/ outrigger pressure indicator..................................320 Submenu for semi-automatic telescoping.................................................................322 Submenu for fully automatic telescoping................................................................323 Submenu for Settings/status display....................................................................324 10.1.7 Behind crane driver´s seat..........................................................................325 10.1.8 Control box for emergency operation without crane control...........................................326 10.1.9 Switch boxes for outrigger/electronic level/outriggerpressure display (additional equipment).......328 Operating instruments for the outrigger................................................................329 Operating instruments for outrigger pressure indicator (additional equipment)..........................329 Operating instruments for electronic level.............................................................329 10.2 Functional description of the display and operating instruments for crane work...........................331 10.2.1 Diesel engine.......................................................................................331 On the instrument panels...............................................................................331 Crane control display..................................................................................332 10.2.2 Crane control.......................................................................................334 Function of operating instruments......................................................................334 Crane control display..................................................................................336 Display elements in main menu..........................................................................336 10.2.3 Outrigger, outrigger pressure indicator, electronic level...........................................338 Display fields on the carrier..........................................................................338 Submenu for Outrigger/electronic level.................................................................340 10.2.4 Counterweight submenu...............................................................................344 Submenu for counterweight, version 1...................................................................344 Submenu for counterweight, version 2...................................................................347 10.2.5 Hoists..............................................................................................350 Main hoist.............................................................................................350 Auxiliary hoist (additional equipment).................................................................351 10.2.6 Slewing gear........................................................................................353 10.2.7 Derricking gear.....................................................................................355 Derricking the lattice extension.......................................................................356 10.2.8 Telescoping gear....................................................................................357 Control consoles.......................................................................................357 Control lever for telescoping..........................................................................357 Telescoping submenu....................................................................................358 10.2.9 Safe load indicator (SLI) .........................................................................367 10.2.10 Hydraulic system...................................................................................377 On the instrument panels...............................................................................377 Control consoles.......................................................................................377 In submenu Monitoring carrier..........................................................................377 In submenu Settings/displays..........................................................................377 10.2.11 Electrics, lighting, windscreen wiper/washing system...............................................379 Electrics..............................................................................................379 Lighting...............................................................................................379 Windscreen wiper/washing system.....................................................................380 10.2.12 Crane cab heating system...........................................................................381 10.2.13 Air-conditioning system (additional equipment).....................................................383 10.2.14 Other operating instruments in the crane cab.......................................................384 Keys...................................................................................................384 Crane cab door.........................................................................................384 Window.................................................................................................385 Seat adjustment........................................................................................387 Fire extinguisher (additional equipment)...............................................................387 10.2.15 Control box for emergency operation without crane control..........................................388 10.3 Functional description of the display and operating elements for driving from inside the cr..............391 10.3.1 Diesel engine.......................................................................................391 10.3.2 Gearbox.............................................................................................392 10.3.3 Axle drive..........................................................................................393 10.3.4 Brakes..............................................................................................394 10.3.5 Steering............................................................................................395 Normal steering mode...................................................................................395 Separate steering......................................................................................395 10.3.6 Other operating instruments.........................................................................396 10.4 Functional description of the safety devices..............................................................397 10.4.1 Safe load indicator (SLI)...........................................................................397 10.4.2 Lowering limit switch...............................................................................399 10.4.3 Lifting limit switch................................................................................400 Overriding lifting limit switch shutdown...............................................................400 10.4.4 Dead man's and seat contact switches................................................................402 11 Crane operation.................................................................................................405 11.1 Checking the truck crane before working with the crane....................................................405 11.1.1 CHECKLIST: Condition for working with a truck crane supported on outriggers.........................405 11.1.2 CHECKLIST: Condition for working with a free on wheels truck crane..................................409 11.1.3 Checking the condition of the hoist rope............................................................414 Checking the reservoir of the windscreen washing system..............................................414 Visual inspection of the entire crane..................................................................414 Checking the mirror settings...........................................................................415 Checking the position of the hoist ropes...............................................................416 Checking the electrical system.........................................................................416 11.1.4 Checking safety equipment...........................................................................417 Checking the safe load indicator.......................................................................417 Checking the lifting limit switch.....................................................................418 Seat contact switch and dead man's switch system......................................................418 Crane control emergency stop...........................................................................419 11.1.5 Preheating the hydraulic oil........................................................................420 When the oil temperature is between –15 C and 0 C (5 F and 32 F):..................................420 For oil temperatures below –15 C (5 F):.............................................................420 11.1.6 Switching off the boom floating position............................................................421 11.1.7 Switching off boom pre-tensioning...................................................................421 11.1.8 Switching off slewing gear freewheel................................................................423 Before slewing.........................................................................................424 11.1.9 Locking/unlocking the superstructure................................................................425 11.2 Starting and stopping the diesel engine from inside the crane cab.........................................427 11.2.1 When starting the engine the first time in the day..................................................427 11.2.2 Start warm diesel engine............................................................................429 Checks on carrier before starting......................................................................429 Switching on the ignition..............................................................................429 Start diesel engine..................................................................................432 11.2.3 Checks after starting the diesel engine.............................................................433 Checks on the instrument panel.........................................................................433 Checks on the Crane control display...................................................................434 11.2.4 Shutting down the diesel engine.....................................................................435 11.3 Operating the safe load indicator (SLI)...................................................................437 11.3.1 Switching on the SLI................................................................................437 To switch on...........................................................................................437 Lamp test on theSLI...................................................................................439 Dimmers for the SLI displays...........................................................................439 11.3.2 Setting rigging mode................................................................................440 Setting via the SLIcode...............................................................................440 Setting using individual components..................................................................440 General instructions...................................................................................441 Sequence during setting................................................................................441 Switching on entry mode................................................................................442 Entering values........................................................................................443 Confirming entry.......................................................................................445 Accepting values.......................................................................................445 Switching over Hoist position lights...................................................................446 11.3.3 Checks before working with the crane................................................................447 11.3.4 During crane work...................................................................................449 Continuous displays...................................................................................449 Optional displays.....................................................................................450 SLI early warning......................................................................................451 SLI shutdown...........................................................................................451 Monitor overall height................................................................................452 Error message..........................................................................................453 Error messages with additional optical displays........................................................454 SLIoverride...........................................................................................455 11.3.5 Monitoring the overall height.......................................................................456 Display current overall height.........................................................................456 Display maximum permissible overall height.............................................................457 Enter maximum permissible overall height...............................................................457 Switching off monitoring of overall height.............................................................458 Display entered height for the crane carrier...........................................................459 Overshooting the maximum permissible overall height....................................................459 Overriding shutdown of overall height..................................................................460 11.4 Crane work with main boom.................................................................................461 11.4.1 External influences during crane operation..........................................................461 Horizontal alignment...................................................................................461 Safedistances.........................................................................................461 Monitoring wind speed without an anemometer............................................................462 Monitoring wind speed with an anemometer..............................................................463 When the maximum allowed wind speed has been exceeded..................................................463 Permissible windload.................................................................................464 Earthing the load......................................................................................465 11.4.2 Permissable slewing ranges and working positions for cranework.....................................466 360 slewing range.....................................................................................466 Working position 0 to the rear........................................................................466 Free-standing truck crane..............................................................................467 11.4.3 Main hoist..........................................................................................468 Switching on the main hoist............................................................................468 Lifting and lowering..................................................................................469 Switching off the main hoist..........................................................................471 11.4.4 Auxiliary hoist (additional equipment)..............................................................472 Switching on the auxiliary hoist......................................................................472 Lifting and lowering..................................................................................473 Switching off the auxiliary hoist.....................................................................473 11.4.5 Derricking gear.....................................................................................474 Switching on the derricking gear.......................................................................474 Raising and lowering...................................................................................475 Switching off the derricking gear.....................................................................475 11.4.6 Slewing gear........................................................................................477 Switching on the slewing gear.........................................................................477 Slewing................................................................................................478 Braking slewing movement...............................................................................479 Tracking the slewing gear..............................................................................480 Maximum permissible slewing speed......................................................................480 Switching off the slewing gear........................................................................482 11.4.7 Telescoping gear....................................................................................483 Structure of the chapter...............................................................................483 Description of functioning.............................................................................484 Main boom fixed length, intermediate length, telescoping length........................................485 Telescope status.......................................................................................486 Notes on the telescoping sequence......................................................................489 Checking before the first telescoping.................................................................489 Switching on telescoping gear..........................................................................490 Function of the control lever..........................................................................490 Switching off telescoping gear.........................................................................492 Example of the procedure for telescoping...............................................................492 Check initial position.................................................................................494 Unlocking the telescoping cylinder.....................................................................499 Extend/retract telescoping cylinder....................................................................502 Locking the telescoping cylinder.......................................................................503 Unlocking the telescopic part..........................................................................507 Telescope telescopic section..........................................................................509 Locking telescope section.............................................................................511 Telescoping the telescopic section to intermediate retracting..........................................515 Lock telescopic section for on- road driving..........................................................515 Telescoping with fully automatic control...............................................................516 Lowering the main boom for maintenance................................................................521 Telescoping the main boom into ahorizontal position..................................................521 11.4.8 Fast speed..........................................................................................523 11.4.9 Special menus on the crane control display..........................................................524 Operating hours meter submenu........................................................................524 Driving gear speeds submenu..........................................................................525 Warning message submenu................................................................................528 Error menu.............................................................................................530 Changing the background colour of the display..........................................................532 11.4.10 Setting a constant engine speed....................................................................533 11.4.11 Inclining crane cab................................................................................534 11.4.12 Cooling the hydraulic oil..........................................................................535 Standard oil cooler....................................................................................535 Additional oil cooler..................................................................................535 11.4.13 Possible movement combinations.....................................................................536 11.5 Driving the truck crane from inside the crane cab.........................................................537 11.5.1 Preparing to drive..................................................................................538 In the driver's cab....................................................................................538 Prerequisites..........................................................................................538 11.5.2 Driving route.......................................................................................539 11.5.3 Operating the gear box..............................................................................539 11.5.4 Steering............................................................................................540 Adapting the steering direction to the superstructure setting..........................................540 Normal steering mode...................................................................................540 Separate steering......................................................................................541 11.5.5 Driving the rigged truck crane......................................................................543 Driving................................................................................................544 Align free on wheels truck crane horizontally..........................................................544 11.5.6 Possible gear changes...............................................................................545 Drive of the second axle line/ longitudinal differential locks.........................................545 Switching off drive/longitudinal differential locks....................................................546 Activating transverse differential locks...............................................................546 Deactivating transverse differential locks.............................................................546 11.5.7 After driving.......................................................................................547 11.6 Work break................................................................................................549 11.6.1 Short work break....................................................................................549 11.6.2 Work breaks lasting more than 8 hours...............................................................549 11.7 Crane cab heating and ventilation.........................................................................551 11.7.1 Heating the crane cab...............................................................................551 Switching heating on/off...............................................................................551 Regulate temperature..................................................................................552 Setting air distribution..............................................................................552 Setting air escape jets................................................................................553 Setting recirculated air/fresh air operation...........................................................554 Fuel tank.............................................................................................554 Storing automatic heating start........................................................................555 Setting automatic heating length.......................................................................556 Switching automatic heating start on/off...............................................................556 Setting remaining time.................................................................................557 Seting time and day....................................................................................557 11.7.2 Ventilating the crane cab...........................................................................558 11.8 Air-conditioning system (additional equipment)............................................................559 11.8.1 To switch on........................................................................................559 11.8.2 Setting the air flow................................................................................560 11.8.3 To switch off.......................................................................................560 11.8.4 Air conditioning....................................................................................561 How to ensure pleasant air-conditioning................................................................561 Dehumidifying the crane cab air........................................................................562 12 Rigging work for outriggers and main boom.......................................................................565 12.1 Checklists for rigging work for crane operation with main boom............................................565 12.1.1 CHECKLIST: Rigging..................................................................................565 12.1.2 CHECKLIST: Unrigging................................................................................568 12.2 Choosing a suitable site..................................................................................570 12.2.1 Load bearing capacity of the ground and the outrigger...............................................570 Outrigger surface area enlarge.........................................................................572 12.2.2 Safe distance from banks and pits...................................................................573 12.2.3 Safe distance from electrical lines.................................................................574 12.2.4 Earthing the truck crane............................................................................577 Earthing the truck crane...............................................................................577 12.3 Outrigger.................................................................................................579 12.3.1 CHECKLIST: Extending the outrigger..................................................................579 12.3.2 CHECKLIST: Retracting the outrigger.................................................................581 12.3.3 Permissible outrigger spans.........................................................................582 Outrigger span 26.6 x 23.0ft..........................................................................583 Outrigger span 26.6 x 19.7ft..........................................................................583 Outrigger span 26.6 x 16.4ft..........................................................................584 Outrigger span 26.6 x 7.6ft...........................................................................584 12.3.4 Preparing the truck crane...........................................................................585 Align horizontally....................................................................................585 Locking the suspension................................................................................585 Switch on/off display field on the carrier.............................................................585 12.3.5 Securing/releasing outrigger beam for crane operations..............................................587 Securing the outrigger beams..........................................................................587 Releasing the outrigger beams.........................................................................588 12.3.6 Extending/retracting the outrigger beams............................................................590 Operation from the carrier.............................................................................590 Operation from the cranecabin.........................................................................592 Setting outrigger spans................................................................................595 12.3.7 Securing outrigger beam for on-road driving.........................................................597 12.3.8 Moving the outrigger pads into working/driving position.............................................598 Moving the outrigger pads into working position........................................................598 Moving the outrigger pads into driving position.......................................................599 12.3.9 Extending/retracting the support cylinder...........................................................600 Operation from the carrier.............................................................................600 Operation from the crane cabin.........................................................................604 12.3.10 Checking the alignment of the truck crane..........................................................607 Electronic level on the carrier......................................................................607 Electronic level on crane control display.............................................................609 12.3.11 Aligning the truck crane horizontally..............................................................611 If the boom is in the boom support...................................................................611 If the boom israised................................................................................611 Automatic aligning.....................................................................................611 12.3.12 Outrigger pressure display.........................................................................613 Outrigger pressure display on the carrier..............................................................613 Outrigger pressure display on superstructure...........................................................614 12.4 Rigging work on the main boom.............................................................................615 12.4.1 Hook block on the bumper............................................................................615 Picking up the hook block from the bumper..............................................................615 Attach the hook block to the bumper....................................................................616 12.4.2 Hook block on a separate vehicle....................................................................617 Picking up the hookblock from the separate vehicle...................................................617 Positioning the hook block on the separate vehicle and securing the hoist rope for on- road driving....618 12.4.3 Reeving and unreeving the hoist rope................................................................619 Rope end clamp.........................................................................................619 Reeve the hoist rope..................................................................................621 Lifting limit switch on the main boom..................................................................623 12.4.4 Possible reeving on the main boom for standard design with 6sheaves................................626 12.4.5 Possible reeving on the main boom for additional equipment with 8sheaves...........................629 12.4.6 Anemometer..........................................................................................632 13 Counterweight rigging work......................................................................................635 13.1 Permissible counterweight versions........................................................................635 13.2 Counterweight rigging– version 1.........................................................................637 13.2.1 Counterweight parts and identification..............................................................637 Counterweight parts...................................................................................637 Identification.........................................................................................637 13.2.2 Counterweight versions..............................................................................638 13.2.3 Slinging points on the counterweight sections.......................................................640 13.2.4 CHECKLIST: Rigging the counterweight................................................................641 13.2.5 CHECKLIST: Unrigging the counterweight..............................................................644 13.2.6 Lower 3.3 t counterweight section on the counterweight platform.....................................646 13.2.7 Assembling the counterweight version................................................................647 13.2.8 Counterweight lifting unit..........................................................................649 Checks to be carried out prior to lifting..............................................................649 Recall counterweight sub-menu.........................................................................649 Checking the current hoist unit status................................................................650 Display incorrectstatus.............................................................................651 Extending/ retracting the lifting cylinder.............................................................652 Unlock/lock counterweight.............................................................................654 13.2.9 Removing/installing the 2.0 t counterweight section ontheturntable................................656 Opening the mechanical lock..........................................................................657 Closing the mechanical lock...........................................................................658 13.2.10 Slewing with the rigged counterweight..............................................................659 13.3 Counterweight rigging– version 2.........................................................................661 13.3.1 Counterweight parts and identification..............................................................661 Counterweight parts...................................................................................661 Identification.........................................................................................661 13.3.2 Counterweight versions..............................................................................662 13.3.3 Slinging points on the counterweight sections.......................................................665 Lifting individual counterweight sections.............................................................665 Lifting stacked counterweight sections................................................................666 13.3.4 CHECKLIST: Rigging the counterweight................................................................667 13.3.5 CHECKLIST: Unrigging the counterweight..............................................................670 13.3.6 Lower 3.3tbaseplate on the counterweight platform.................................................673 13.3.7 Check the position of the locking pins..............................................................674 Checking the 1.3t counterweight section...............................................................674 Checking the 2.0 t counterweight sections..............................................................675 13.3.8 Assembling the counterweight version................................................................676 Procedures.............................................................................................676 Versions that can be installed on the turntable.......................................................677 Combinations that can be differently assembled.......................................................679 13.3.9 Counterweight lifting unit..........................................................................683 Check the position of the locking pins.................................................................683 Recall counterweight sub-menu........................................................................684 Checking the current hoist unit status...............................................................685 Display incorrect status.............................................................................686 Extending/ retracting the lifting cylinder.............................................................686 Unlock/lock counterweight............................................................................688 13.3.10 Removing/installing the counterweight sections ontheturntable....................................690 Installing counterweight sections......................................................................690 Uninstalling counterweight sections...................................................................691 13.3.11 Locking/unlocking the 2.0 t and 5.0 t counterweight sections.......................................692 Locking counterweight sections.........................................................................692 Unlocking the counterweight sections...................................................................693 13.3.12 Slewing with the rigged counterweight..............................................................694 14 Malfunctions on the superstructure..............................................................................697 14.1 Superstructure emergency stop device......................................................................697 Turning off the diesel engine..............................................................................697 Crane control emergency stop switch........................................................................698 14.2 What to do in the event of a malfunction when working with the crane.....................................699 Load cannot be lowered.....................................................................................699 14.3 Electrical system.........................................................................................701 14.3.1 Plug-in modules and consoles........................................................................701 14.3.2 Fuses...............................................................................................703 Fuses on turntable.....................................................................................703 Fuses in crane cab.....................................................................................705 Fuses on input- output bedplates.......................................................................707 14.3.3 SLI fuses...........................................................................................708 Replacing fuses........................................................................................708 14.4 Troubleshooting and remedy................................................................................711 14.4.1 Vehicle engine malfunctions during the crane operations.............................................711 14.4.2 Malfunctions when driving from crane cab............................................................711 14.4.3 Main hoist malfunctions.............................................................................712 14.4.4 Auxiliary hoist malfunctions........................................................................714 14.4.5 Derricking gear malfunctions........................................................................716 14.4.6 Telescoping gear malfunctions.......................................................................718 Error messages concerning telescoping gear.............................................................720 14.4.7 Slewing gear malfunctions...........................................................................723 14.4.8 Malfunctions at the counterweight hoist unit........................................................724 14.4.9 Hydraulic system/hydraulic oil cooler malfunctions..................................................725 14.4.10 Outrigger malfunctions.............................................................................725 14.4.11 Crane control malfunctions.........................................................................726 14.4.12 Malfunctions on the SLI............................................................................727 Other malfunctions on the SLI..........................................................................727 SLI error message table................................................................................728 Switch off sensor/ indicator during malfunction........................................................736 Check function of remaining emergency operation........................................................737 Take over telescoping from the values..................................................................738 Checking SLI lines and connections.....................................................................739 14.4.13 Emergency retract operation........................................................................741 Check prior to every emergency operation...............................................................741 Procedure for retracting...............................................................................742 Mechanical emergency operation.........................................................................743 Hydraulic emergency operation..........................................................................745 14.5 Error messages on crane control display...................................................................757 Crane control program version..............................................................................757 14.5.1 Meaning of displayed symbols........................................................................757 Symbols for Devices...................................................................................758 Symbols for Groups....................................................................................759 Symbols for types of errors...........................................................................760 Index displays allocation.............................................................................761 Control leves error table..............................................................................768 Locking system error table.............................................................................769 Error messages via Can-Bus.............................................................................772 14.5.2 Connections for the crane control control units.....................................................775 Control units connections position.....................................................................775 Layout of connections.................................................................................776 Truck crane for defective control unrigging units......................................................778 Example for unrigging with three control units.........................................................778 Replacing control units................................................................................780 14.5.3 Sub-menu emergency program telescoping..............................................................782 Starting emergency program............................................................................782 Emergency program display and operating elements.......................................................783 Retracting with an error on the length indicator.......................................................785 Retracting with an error on the proximity switch.......................................................789 Emergency program end.................................................................................791 Table for approaching the locking points...............................................................791 14.5.4 Enter telescope status after emergency operation....................................................792 14.5.5 Emergency operation in case of the crane control failure............................................795 Truck crane preparation................................................................................795 Emergency operation switch on.........................................................................796 Operating driving gears................................................................................796 Movements stopping....................................................................................798 Stopping the movent in case of an emergency............................................................798 14.6 Hydraulic emergency stop according to ZH1/461.............................................................799 14.6.1 Important instructions for hydraulic emergency operation............................................799 14.6.2 Functioning and accessories.........................................................................801 14.6.3 Establishing hose connections.......................................................................802 For the emergency operation with the transformer.......................................................802 For the emergency operation with the hand pump.........................................................804 14.6.4 Establishing required hydraulic circuits............................................................805 Taps connecting points.................................................................................805 Additional connections for the main hoist..............................................................807 Additional connections for the slewing gear............................................................808 14.6.5 Executing emergency operation.......................................................................809 Emergency operation main hoist movement................................................................810 Emergency operation driving derricking gear............................................................810 Emergency operation driving the slewing gear...........................................................812 14.6.6 After the emergency operation.......................................................................813 Establishing hydraulic circuits for crane operation .................................................813 Loosen established hose connections...................................................................813 15 Technical information for superstructure........................................................................817 15.1 Technical description of the superstructure...............................................................817 15.1.1 Turntable...........................................................................................817 15.1.2 Crane operator's cab................................................................................817 15.1.3 Crane engine and hydraulic system...................................................................818 15.1.4 Control system......................................................................................818 15.1.5 Main boom...........................................................................................819 15.1.6 Telescoping gear....................................................................................819 15.1.7 Hoists..............................................................................................820 15.1.8 Slewing gear........................................................................................820 15.1.9 Derricking cylinder.................................................................................821 15.1.10 Electrical system.................................................................................821 15.1.11 Counterweight......................................................................................821 15.1.12 Safety equipment...................................................................................822 15.2 Technical data............................................................................................823 15.2.1 Maximum load bearing capacity (DIN/ISO/EN)..........................................................823 15.2.2 Max. lifting capacity (85%)........................................................................823 15.2.3 Dimensions, weights and axle load...................................................................824 Dimensions when driving on public roads................................................................824 Total weight and axle load.............................................................................825 15.2.4 Dimensions and weights of removable parts...........................................................825 Hook blocks and hook tackle............................................................................825 Counterweight sections – version 1....................................................................826 Counterweight sections – version2....................................................................826 Counterweight versions – version1.....................................................................827 Counterweight versions – version2.....................................................................828 15.2.5 Technical data for superstructure...................................................................830 Main hoist.............................................................................................830 Auxiliary hoist (additional equipment)................................................................830 Slewing gear...........................................................................................830 Derricking gear........................................................................................830 Main boom..............................................................................................831 Working speed and times without load...................................................................831 16 Alphabetical index..............................................................................................835 A..............................................................................................................837 B..............................................................................................................837 C..............................................................................................................838 D..............................................................................................................840 E..............................................................................................................842 F..............................................................................................................842 G..............................................................................................................843 H..............................................................................................................843 I..............................................................................................................844 K..............................................................................................................844 L..............................................................................................................844 M..............................................................................................................844 O..............................................................................................................845 P..............................................................................................................846 R..............................................................................................................847 S..............................................................................................................847 T..............................................................................................................849 V..............................................................................................................850 W..............................................................................................................850
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