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Grove Crane GMK 4080-1 Part 1 Driving Operating Instructions Manual 3112253 – PDF DOWNLOAD
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Description
Grove Crane GMK 4080-1 Part 1 Driving Operating Instructions Manual 3112253 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4080-1 Part 1 Driving Operating Instructions Manual 3112253 – PDF DOWNLOAD
Language : English
Pages : 946
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 4080-1 Part 1 Driving Operating Instructions Manual 3112253 – PDF DOWNLOAD
Operating instructions for driving and crane operation:
- These operating instructions contain the information required to operate
the truck crane. - The operating instructions are divided into two parts. Part 1, comprising
chapters 1 to 10, describes how the truck crane is driven. Part 2, comprising
chapters 11 to 16, describes how to operate the crane. - In chapter 2 you will find Basic safety instructions. Please read and observe
these instructions, even if you are familiar with the safety manual. The Basic
safety instructions are contained in this chapter only. 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 operations planning. It is intended primarily
for the truck crane operator and those responsible for operations planning.
This chapter contains the following:
– The qualifications required for those involved in operations planning for
the truck crane,
– Special safety instructions,
– Information that is relevant to operations planning.
- In chapter 4 to chapter 6 you will find information which is necessary for
Driving the truck crane: a description of all structural and operational components,
clearly defined checklists for rigging modes or rigging work and the
operating instructions for on-road and off-road driving. - Chapter 7 gives information on Rigging for road driving.
- In chapter 8 you will find information on Troubleshooting when driving.
- Chapter 9 contains the Technical description of the individual parts and functional
elements of the carrier as well as the Technical data.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 4080-1 Part 1 Driving Operating Instructions Manual 3112253 – PDF DOWNLOAD
1 Overview.................................................................................................. 7 1.1 Vehicle identification.............................................................................. 7 1.2 EC Conformity Declaration........................................................................... 11 1.3 Overview and contents of the truck crane user information........................................... 13 1.3.1 Operating instructions for driving and crane operation........................................ 13 1.3.2 Operating instructions for the lattice extension (additional equipment)....................... 14 1.3.3 Maintenance manual............................................................................ 14 1.3.4 Lifting capacity tables....................................................................... 15 1.3.5 Outrigger pressure tables..................................................................... 15 1.3.6 Safety manual................................................................................. 15 1.3.7 Circuit diagrams.............................................................................. 15 1.3.8 Spare parts list.............................................................................. 15 1.4 Instructions for using this documentation........................................................... 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 How to use the index .......................................................................... 24 1.4.4 Definition of positional references........................................................... 24 Basic rule...................................................................................... 24 Buttons and switches........................................................................... 24 1.4.5 Conversion table for US measurements.......................................................... 25 2 Basic safety instructions for crane operators............................................................. 29 2.1 Warnings and symbols................................................................................ 29 2.2 Intended 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 operations planning....................................................................... 39 3.1 Safety instructions................................................................................. 39 3.1.1 Intended use.................................................................................. 39 3.1.2 Organizational measures....................................................................... 39 3.1.3 Personnel qualifications...................................................................... 40 3.2 Operations planning................................................................................. 41 3.2.1 Prerequisites for operations planning......................................................... 41 3.2.2 Information for operations planning contained in the user information ....................... 42 4 Description of the truck crane vehicle section............................................................ 45 4.1 Overview of the operating and display elements...................................................... 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 Overhead in the driver's cab.................................................................... 51 Below the front instrument panel............................................................... 52 Under the covering............................................................................. 53 4.1.3 Front instrument panel........................................................................ 54 Left-hand insert................................................................................ 54 Tachograph insert............................................................................... 56 Speedometer insert............................................................................. 58 Right-hand insert............................................................................... 60 4.1.4 Side instrument panel......................................................................... 62 Heating insert.................................................................................. 64 Auxiliary heater insert....................................................................... 65 Transmission operating elements................................................................. 66 4.1.5 Operating elements on the steering column..................................................... 67 4.1.6 Connections for hand-held control............................................................. 68 4.1.7 Switch boxes for the outrigger / electronic level / outrigger pressure indicator............. 69 4.2 Functional description of the display and operating elements....................................... 71 4.2.1 On the instrument panels...................................................................... 71 Diesel engine................................................................................... 71 Transmission with automatic gear change......................................................... 73 Transfer case................................................................................... 77 Axle drive...................................................................................... 79 Brakes.......................................................................................... 80 Steering........................................................................................ 81 Separate steering............................................................................... 82 Hydraulic system................................................................................ 82 Suspension...................................................................................... 83 Electrics....................................................................................... 84 Level adjustment system........................................................................ 87 Tachograph...................................................................................... 89 Speedometer insert............................................................................. 89 Heating system................................................................................. 91 Air-conditioning system......................................................................... 93 Auxiliary heater with timer..................................................................... 93 Diagnostics plug................................................................................ 95 Other operating elements....................................................................... 95 4.2.2 On the steering column........................................................................ 97 Ignition lock................................................................................... 97 Multipurpose switch, right...................................................................... 97 Multipurpose switch, left....................................................................... 99 4.2.3 Overhead in the driver's cab..................................................................100 Roof ventilator.................................................................................100 Cab lighting....................................................................................100 4.3 Other operating elements on the carrier.............................................................101 Keys................................................................................................101 Doors...............................................................................................101 Windows.............................................................................................103 Access ladders......................................................................................104 Ladders.............................................................................................104 Front flap..........................................................................................106 Fire extinguisher...................................................................................106 Folding berth.......................................................................................107 5 Diesel engine.............................................................................................111 5.1 Starting / turning off the diesel engine............................................................111 5.1.1 CHECKLIST: Starting the diesel engine.........................................................111 5.1.2 CHECKLIST: In winter..........................................................................114 5.1.3 Checks prior to starting the vehicle engine...................................................115 Checking the shut- off valves in the hydraulic system..........................................115 Switching on the battery master switch.........................................................115 Checking the coolant level......................................................................116 Checking the hydraulic oil level................................................................117 Checking the diesel engine oil level...........................................................118 Topping up engine oil...........................................................................119 5.1.4 Refuelling....................................................................................120 5.1.5 Starting the diesel engine....................................................................121 Switching on the ignition......................................................................121 Starting the diesel engine.....................................................................123 Setting the idling speed........................................................................125 5.1.6 Checks after the diesel engine has been started...............................................127 Checking instruments...........................................................................127 5.2 Shutting down the diesel engine.....................................................................129 5.2.1 Under normal circumstance with the ignition lock..............................................129 5.2.2 In an emergency situation, with the emergency stop switch.....................................130 5.2.3 In an emergency, using the air intake inhibitor...............................................131 Switching on the air intake inhibitor...........................................................131 Releasing the air intake inhibitor manually.....................................................132 5.3 Operation if equipped with dual tank................................................................133 5.3.1 Checking the fuel level and refuelling........................................................133 Checking the fuel level........................................................................133 Refuelling......................................................................................134 5.3.2 Switching over the fuel supply................................................................135 Switching to dual tank..........................................................................135 Switching to the fuel tank......................................................................136 6 Driving the truck crane...................................................................................139 6.1 Inspections and adjustments before driving..........................................................139 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving...................................139 6.1.2 Checking the condition of the truck crane.....................................................145 Checking the reservoir of the windscreen washing system........................................145 Warning plates for vehicle width................................................................145 Checking the tyres.............................................................................146 Checking the change-over to driving mode.......................................................146 Checking the electrical system..................................................................147 Checking the transfer case......................................................................147 Checking the mirror settings...................................................................147 Checking the compressed air and brake systems..................................................148 Checking the suspension.........................................................................148 Checking the on- road level...................................................................149 Checking the transverse differential locks......................................................149 Checking the longitudinal differential locks...................................................149 Checking the steering locks...................................................................150 Boom not set down warning lamp..................................................................150 6.1.3 Adjusting the seat and the steering column....................................................151 Adjusting the driver's seat....................................................................151 Adjusting the passenger seat...................................................................152 Adjusting the steering column..................................................................153 6.1.4 Tachograph....................................................................................155 6.2 General operation...................................................................................161 6.2.1 Operating the transmission with automatic gear change.........................................161 Switching on....................................................................................161 Selecting the driving direction................................................................162 Starting........................................................................................163 Selecting the transmission operating mode......................................................164 Driving and changing gears......................................................................165 Changing the direction of travel................................................................167 Stopping........................................................................................167 Shifting the transmission to neutral position..................................................168 Gear position L.................................................................................168 Manoeuvring mode................................................................................170 On the roller type dynamometer..................................................................171 Starting at extremely low temperatures.........................................................171 6.2.2 Monitoring the control instruments while driving..............................................172 6.2.3 Driving downhill..............................................................................176 Starting on a slope............................................................................176 Monitoring the maximum permissible engine speed.................................................177 Preselecting gears..............................................................................178 Engine retarder.................................................................................178 Eddy current retarder...........................................................................179 6.2.4 Driving uphill................................................................................180 Starting........................................................................................180 Driving.........................................................................................180 6.2.5 Tempomat......................................................................................181 Activating the Tempomat.........................................................................181 Driving with the Tempomat......................................................................181 Switching off the Tempomat.....................................................................182 6.2.6 Temposet......................................................................................183 Switching on Temposet..........................................................................183 Driving with the Temposet......................................................................183 Switching Temposet off.........................................................................183 6.2.7 Parking the truck crane.......................................................................184 Applying the parking brake......................................................................184 Activating neutral position....................................................................184 Turning off the diesel engine...................................................................184 Securing the truck crane against rolling........................................................185 Extended standstill.............................................................................186 6.3 Off-road driving....................................................................................187 6.3.1 Off-road gear.................................................................................188 Engaging the off- road gear.....................................................................188 Switching off the off-road gear.................................................................189 6.3.2 Longitudinal differential locks...............................................................190 Switching on the longitudinal differential lock.................................................190 Switching off the longitudinal differential locks...............................................191 6.3.3 Transverse differential locks in all driven axle lines........................................192 Switching on thetransverse differential locks.................................................192 Switching off thetransverse differential locks................................................193 6.3.4 Level adjustment system.......................................................................194 Activating the level adjustment system..........................................................194 Bringing the truck crane into on-road level.....................................................195 Tilting the truck crane lengthwise or crosswise.................................................195 Raising or lowering the entire truck crane......................................................196 Deactivating the level adjustment system........................................................196 6.3.5 Freeing an immobilized truck crane............................................................197 Freeing the truck crane by its own power......................................................197 Towing free to the front.......................................................................198 Towing free to the rear........................................................................198 6.4 Separate steering...................................................................................199 6.4.1 Switching to separate steering................................................................200 6.4.2 Steering the third and fourth axle lines......................................................200 6.4.3 Switching to normal steering mode.............................................................201 6.5 Heating and ventilating the driver's cab............................................................203 6.5.1 Heating.......................................................................................203 Switching the heater on and off.................................................................203 Setting the temperature........................................................................203 Setting recirculated / fresh air................................................................203 Setting the air distribution..................................................................204 Ventilating the driver's cab....................................................................205 6.5.2 Roof ventilator...............................................................................206 6.5.3 Auxiliary heater with timer...................................................................207 Preheating the diesel engine...................................................................207 Preheating the driver's cab....................................................................207 Switching on the auxiliary heating system.......................................................208 Switching off the auxiliary heater..............................................................209 Setting the time and weekday....................................................................209 Saving automatic heating start.................................................................210 Setting automatic heating duration..............................................................211 Switching automatic heating start on / off......................................................211 Setting the remaining time.....................................................................212 6.6 Air-conditioning system.............................................................................213 Switching on........................................................................................213 Setting the air distribution.......................................................................214 Switching off.......................................................................................214 6.6.1 Air conditioning..............................................................................215 How to use the air conditioning effectively.....................................................215 Dry air in the driver's cab.....................................................................216 6.7 Towing a trailer....................................................................................217 Effects on the axle loads...........................................................................217 Coupling the trailer...............................................................................218 Connecting the supply lines........................................................................219 Removing supplylines..............................................................................220 Uncoupling the trailer.............................................................................220 Test position of the parking brake when towing a trailer............................................222 7 Driving modes and rigging for on-road driving.............................................................225 7.1 Driving modes.......................................................................................225 Information on the axle loads.......................................................................225 7.1.1 Information on how to use the tables.........................................................226 7.1.2 Tables for maximum axle load 12t (26500lbs)................................................227 For 14.00 R25 tyres............................................................................227 For 16.00 R25 tyres............................................................................228 For 20.50 R25 tyres............................................................................229 7.2 Rigging work for driving with a trailer.............................................................231 7.2.1 Switching on the slewing gear freewheel.......................................................232 Prerequisites...................................................................................232 7.2.2 Switching on boom floating position...........................................................234 Setting the main boom down on the trailer.......................................................234 7.2.3 Switching on boom pre-tensioning..............................................................236 7.2.4 Switching the superstructure driving lights on/off............................................238 Switching off...................................................................................238 Switching on....................................................................................238 8 Malfunctions in driving mode..............................................................................241 8.1 Emergency stop device on carrier....................................................................241 8.1.1 Diesel engine emergency stop switch...........................................................241 Emergency stop switch..........................................................................241 Resetting the emergency stop switch.............................................................242 8.2 What to do in the event of a breakdown in road traffic..............................................243 8.3 Towing the truck crane..............................................................................245 8.3.1 Towing in the event of engine or transmission damage..........................................246 Compressed-air supply...........................................................................246 Electric power supply...........................................................................246 On the transmission............................................................................247 On the transfer case............................................................................247 Axle drives.....................................................................................247 Parking brake...................................................................................247 Towing the truck crane out of the danger area...................................................248 8.3.2 Tow starting..................................................................................248 8.4 Wheels and tyres....................................................................................249 8.4.1 Wheel change..................................................................................249 Removing a damaged wheel........................................................................249 Removing the wheel from the spare wheel holder..................................................250 Mounting a damaged wheel on the spare wheel holder..............................................251 Mounting the spare wheel.......................................................................251 8.4.2 Filling the tyres yourself at tyre inflator connection........................................253 Connecting the filling hose.....................................................................253 Filling the tyres...............................................................................254 Removing the tyre inflator hose.................................................................254 8.5 Tilting and lowering the driver's cabin.............................................................255 8.5.1 Prerequisites and information on tilting......................................................255 8.5.2 With mechanical tilt mechanism................................................................256 Unlocking / Locking the driver's cab............................................................256 Tilting the driver's cab........................................................................257 Lowering the driver's cab......................................................................259 8.5.3 With hydraulic tilt mechanism.................................................................260 Operating the hand pump.........................................................................260 Tilting the driver's cab........................................................................261 Lowering the driver's cab......................................................................262 8.6 Emergency operation for lifting the main boom.......................................................263 Operating principle................................................................................263 Accessories.........................................................................................263 8.6.1 Connecting / Disconnecting the hose...........................................................264 Establishing a hose connection..................................................................264 Disconnecting thehose..........................................................................264 8.6.2 Establishing necessary hydraulic circuits....................................................265 8.6.3 Switching the continuous operation on and off.................................................266 8.6.4 Performing emergency operation................................................................267 8.6.5 After the emergency activation...............................................................268 8.7 Fuses on the carrier................................................................................269 Information on replacing fuses....................................................................269 8.7.1 Fuses in the driver's cab.....................................................................270 Fuses for additional equipment..................................................................274 8.7.2 Fuses in battery box..........................................................................275 8.7.3 Fuses on I/O circuit boards...................................................................276 8.8 Finding and eliminating malfunctions................................................................277 8.8.1 Malfunctions to the diesel engine.............................................................277 When operating with the dual tank...............................................................279 8.8.2 Differential lock malfunctions................................................................279 8.8.3 Malfunctions to the transmission with automatic gear change...................................280 8.8.4 Steering malfunctions.........................................................................281 8.8.5 Service brake malfunctions....................................................................282 8.8.6 Malfunctions to the outriggers................................................................282 8.8.7 Tachograph malfunctions.......................................................................283 8.8.8 Suspension locking system malfunctions........................................................284 8.8.9 Level adjustment system malfunctions..........................................................284 8.8.10 Malfunctions to the carrier electronic system................................................285 Reading error messages at the carrier...........................................................285 Reading error messages in the driver's cab......................................................287 8.9 Procedure in the event of malfunctions..............................................................291 8.9.1 Switching the fan thermostat to emergency operation...........................................291 8.9.2 Procedure in the event of transmission malfunctions...........................................293 Error messages on the Transmission display......................................................293 Calling up error codes..........................................................................294 9 Technical Information on Carrier..........................................................................299 9.1 Technical data......................................................................................299 9.1.1 Dimensions and weights of the truck crane.....................................................300 Dimensions for driving on public roads........................................................301 Total weight and axle loads.....................................................................301 9.1.2 Dimensions and weights of removable parts.....................................................302 Spare wheel.....................................................................................302 Outriggers......................................................................................302 9.1.3 Carrier.......................................................................................303 Diesel engine...................................................................................303 Manual transmission...........................................................................303 Transfer case...................................................................................303 Axle lines......................................................................................303 Steering........................................................................................304 Tyres...........................................................................................304 Vehicle's electrical system.....................................................................304 Tools...........................................................................................304 Towing coupling................................................................................304 Outriggers......................................................................................305 Driving speeds..................................................................................306 Climbing ability................................................................................306 Turning circle radiuses........................................................................307 10 Index....................................................................................................311 A.......................................................................................................313 B.......................................................................................................313 C.......................................................................................................314 D.......................................................................................................316 E.......................................................................................................318 F.......................................................................................................318 H.......................................................................................................319 I.......................................................................................................320 K.......................................................................................................320 L.......................................................................................................320 M.......................................................................................................321 O.......................................................................................................322 P.......................................................................................................323 R.......................................................................................................323 S.......................................................................................................324 T.......................................................................................................325 V.......................................................................................................327 W.......................................................................................................327 11 Description of the crane section of the truck crane......................................................337 11.1 Overview of the operating and display instruments..................................................337 11.1.1 Overview of the crane section................................................................337 11.1.2 Overview of crane cab........................................................................340 11.1.3 Operating elements on the front panel........................................................342 11.1.4 Operating elements on the side panel.........................................................343 Left side of the side panel....................................................................343 Top of the side panel...........................................................................344 Heating insert1...............................................................................346 Heating insert2................................................................................347 11.1.5 Control consoles.............................................................................348 Left-hand control console.......................................................................348 Right-hand control console......................................................................349 11.1.6 Control lever configuration..................................................................350 Version 1 (standard)...........................................................................350 Version 2 (additional equipment)................................................................351 11.1.7 At crane control insert......................................................................352 11.1.8 Main menu of the crane control display.......................................................354 11.1.9 Crane control display - submenus.............................................................357 Counterweight submenu..........................................................................357 Outriggers / electronic level / outrigger pressure display submenu...........................358 Semi-automatic telescoping submenu.............................................................360 Power unit speeds submenu......................................................................362 Control instruments submenu.....................................................................363 Settings / Displays submenu...................................................................364 Submenu Driving.................................................................................366 Error menu......................................................................................369 Working range limitation submenu................................................................370 11.1.10 At the SLI insert...........................................................................372 11.1.11 Hand-held control...........................................................................377 11.1.12 Switch boxes for outrigger / electronic level / outrigger pressure display..................378 Operating elements for the outriggers..........................................................379 Display elements for the outrigger pressure indicator...........................................379 Operating and display elements for the electronic level........................................379 11.2 Functional description of the display and operating elements......................................381 11.2.1 Diesel engine................................................................................381 On the side panel..............................................................................381 On the crane control display....................................................................382 11.2.2 Crane control................................................................................382 At crane control insert.........................................................................382 On the crane control display....................................................................386 11.2.3 Outrigger, electronic level, outrigger pressure indicator....................................387 On the hand-held control........................................................................387 On the display fields of the carrier............................................................390 In the Settings / Displays submenu..............................................................392 In the Outrigger / electronic level / outrigger pressure display submenu.......................393 11.2.4 Counterweight submenu........................................................................397 Counterweight submenu..........................................................................397 11.2.5 Hoists.......................................................................................401 Main hoist......................................................................................401 Auxiliary hoist.................................................................................403 11.2.6 Slewing gear.................................................................................404 House lock......................................................................................405 11.2.7 Derricking gear..............................................................................407 Derricking the lattice extension................................................................409 11.2.8 Telescoping mechanism........................................................................410 Control consoles................................................................................410 Control lever for telescoping...................................................................410 Telescoping submenu............................................................................412 11.2.9 Hydraulic system.............................................................................421 At the control consoles........................................................................421 In the Settings / Displays submenu.............................................................421 In the Control instruments submenu............................................................422 In the Error messages submenu...................................................................422 11.2.10 Safe load indicator (SLI)...................................................................423 Input elements with displays....................................................................423 Display elements................................................................................427 Information displays...........................................................................431 On the front panel..............................................................................434 11.2.11 Electricity, lighting, windscreen wiper / washing system....................................435 Electricity.....................................................................................435 Lighting........................................................................................435 Windscreen wiper / washing system...............................................................436 11.2.12 Heating.....................................................................................438 Insert1........................................................................................438 Insert2........................................................................................439 Air-conditioning system.........................................................................440 11.2.13 On the hand-held control....................................................................441 Connections on the truck crane..................................................................441 Diesel engine operating panel...................................................................442 Horn button.....................................................................................442 Outrigger / electronic level operating panel...................................................442 Pre-selection button for emergency operation....................................................443 Two-hand operating panel........................................................................444 11.2.14 Other operating elements of the crane cab...................................................446 Keys............................................................................................446 Crane cab door..................................................................................446 Windows.........................................................................................447 Cab lighting....................................................................................448 Diagnostics plug................................................................................448 Fire extinguisher...............................................................................449 11.3 Functional description of the display and operating elements for driving from inside the cra.......451 11.3.1 Diesel engine................................................................................451 11.3.2 Driving submenu..............................................................................452 11.3.3 Transmission.................................................................................453 11.3.4 Axle drive...................................................................................457 11.3.5 Brakes.......................................................................................460 11.3.6 Steering.....................................................................................461 On the crane control display...................................................................461 On the control panels..........................................................................463 11.4 Functional description of the safety devices.......................................................465 11.4.1 Safe load indicator (SLI)....................................................................465 11.4.2 Lowering limit switch........................................................................467 11.4.3 Lifting limit switch.........................................................................468 Overriding the lifting limit switch shutdown....................................................468 11.4.4 Dead man's switch and seat contact switch....................................................470 12 Crane operation..........................................................................................473 12.1 Inspections and adjustments prior to crane operation...............................................473 12.1.1 CHECKLIST: When truck crane is rigged........................................................473 12.1.2 Adjusting the front console and the crane cab seat...........................................480 Adjusting the front panel......................................................................480 Adjusting the crane cab seat....................................................................480 12.1.3 Checking the condition of the truck crane....................................................481 Checking the reservoir of the windscreen washing system.........................................481 Visual inspection of the entire crane...........................................................481 Fuel tank level................................................................................482 Checking the electrical system..................................................................482 Checking the position of the hoist ropes........................................................483 12.1.4 Checking the safety devices..................................................................484 Checking the safe load indicator................................................................484 Checking the lifting limit switch..............................................................485 Checking the seat contact switch and dead man's switch system...................................485 Crane control emergency stop....................................................................486 12.1.5 Pre-warming the hydraulic oil................................................................487 12.1.6 Switching the houselock on / off.............................................................489 Switching on the houselock.....................................................................489 Switching off the houselock....................................................................491 12.2 Starting and stopping the diesel engine from the superstructure....................................493 12.2.1 When starting the engine the first time in the day...........................................493 12.2.2 Starting the diesel engine from the crane cab................................................495 Inspections at the carrier before starting......................................................495 Switching on the ignition......................................................................495 Crane control lamp test........................................................................496 Lamp test for electrics.......................................................................498 Alignment of switching conditions...............................................................498 Checking the fuel level.........................................................................499 Starting the diesel engine.....................................................................500 12.2.3 Inspections after starting the diesel engine.................................................502 Inspections on the instrument panel.............................................................502 Inspections on the Crane control display........................................................502 12.2.4 Shutting down the diesel engine..............................................................505 In normal operation.............................................................................505 In emergencies..................................................................................506 12.3 Operating the safe load indicator (SLI)............................................................507 12.3.1 Switching on the SLI.........................................................................507 Switching on....................................................................................507 Lamp test on the SLI............................................................................509 Display brightness..............................................................................509 12.3.2 Entering the rigging mode....................................................................511 Entering the SLI code .........................................................................512 Entering a reeving.............................................................................515 Entering individual components..................................................................516 12.3.3 Checks before working with the crane.........................................................519 12.3.4 During crane work............................................................................523 Continuous displays............................................................................523 Optional displays..............................................................................525 12.3.5 SLI pre-warning and SLI shutdown.............................................................526 SLI early warning...............................................................................526 SLI shutdown................................................................................527 Error message...................................................................................529 Error messages with additional optical display..................................................530 SLI override...................................................................................531 12.3.6 Displaying and entering the time and date....................................................532 Display.........................................................................................532 Input...........................................................................................532 12.4 Crane work with the main boom......................................................................535 12.4.1 External influences while working with the crane.............................................535 Horizontal alignment...........................................................................535 Safe distances.................................................................................535 Monitoring the wind speed without an anemometer................................................536 Monitoring the wind speed with an anemometer....................................................537 If the maximum permitted wind speed has been exceeded...........................................538 Permissible wind load..........................................................................539 Earthing the load...............................................................................539 12.4.2 Permissible slewing ranges and working positions for crane work..............................540 360 slewing range..............................................................................541 Working position 0 rearwards...................................................................541 If the truck crane is free on wheels............................................................542 180 forward set- up position...................................................................542 12.4.3 Main hoist...................................................................................543 Switching on the main hoist.....................................................................543 Lifting and lowering...........................................................................544 Switching off the main hoist...................................................................547 12.4.4 Auxiliary hoist..............................................................................548 Switching on the auxiliary hoist...............................................................548 Lifting and lowering...........................................................................549 Switching off the auxiliary hoist..............................................................549 12.4.5 Derricking gear..............................................................................550 Switching on the derricking gear................................................................550 Raising and lowering............................................................................551 Switching off the derricking gear..............................................................552 Lowering the main boom to horizontal position..................................................553 12.4.6 Slewing gear.................................................................................555 Switching on the slewing gear..................................................................555 Prerequisites...................................................................................556 Slewing.........................................................................................556 Reading the slewing angle.......................................................................558 Slewing to 0 or 180 ...........................................................................559 Braking the slewing movement....................................................................560 Tracking the slewing gear.......................................................................561 Switching off the slewing gear.................................................................562 12.4.7 Telescoping mechanism........................................................................563 Structure of the chapter........................................................................563 Description of functioning......................................................................564 Main boom fixed length, intermediate length, telescoping length................................565 Telescoping.....................................................................................567 Notes on the telescoping sequence.............................................................569 Check before telescoping for the first time.....................................................569 Switching on telescoping mechanism.............................................................570 Control lever function.........................................................................570 Switching off the telescoping mechanism.........................................................572 Example of the procedure for telescoping........................................................573 Checking the initial position...................................................................574 Unlocking the telescoping cylinder..............................................................579 Extending / retracting the telescoping cylinder.................................................582 Locking the telescoping cylinder................................................................583 Unlocking the telescopic section................................................................587 Telescoping the telescopic section.............................................................589 Locking the telescopic section..................................................................591 Telescoping telescopic section to an intermediate length........................................595 Locking the telescopic section for on-road driving.............................................595 Telescoping in fully automatic mode.............................................................596 Telescoping the main boom into ahorizontal position............................................602 12.4.8 Possible movement combinations...............................................................603 12.4.9 High-speed mode..............................................................................604 Switching on the high speed function............................................................604 Derricking gear / telescoping mechanism.........................................................604 Hoists..........................................................................................605 12.4.10 Cooling the hydraulic oil...................................................................606 Standard oil cooler............................................................................606 Additional oil cooler..........................................................................606 12.5 Adjustments and displays whilst operating the crane................................................607 12.5.1 Adjusting the brightness of the display......................................................607 12.5.2 Setting characteristic curves for the control lever.........................................608 12.5.3 Adjusting power unit speeds..................................................................610 12.5.4 Setting a constant engine speed..............................................................612 Increasing the constant engine speed............................................................613 Decreasing the constant engine speed............................................................613 Exceeding the constant engine speed.............................................................613 12.5.5 Tilting the crane cab........................................................................614 12.5.6 Adjusting the windscreen wiper stroke interval...............................................615 12.5.7 Using the directional spotlight for the working area.........................................616 Switching on / off..............................................................................616 Adjusting the direction........................................................................616 12.5.8 Display the operating hours..................................................................617 12.5.9 Warning message submenu......................................................................619 12.5.10 Error menu..................................................................................621 12.6 Working range limiter..............................................................................623 12.6.1 Opening the Working range limitation submenu.................................................624 12.6.2 Reading current settings.....................................................................625 Display monitoring switched on / off............................................................625 Reading the limit values entered...............................................................625 12.6.3 Entering a limit value for a maximum overall height..........................................627 12.6.4 Entering a limit value for a maximum working radius..........................................628 12.6.5 Entering limit values for maximum slewing angles.............................................629 Displays in the Working range limitation submenu................................................629 Presentation of slewing angles..................................................................630 Entering the slewing angle.....................................................................631 12.6.6 Entering point data for objects..............................................................632 Presentation of defined objects................................................................632 Selecting and deleting point data.............................................................633 Entering point data............................................................................634 12.6.7 Entering limit values manually...............................................................636 Limit values for overall height, working radius or slewing angle................................636 Manual point data entry.........................................................................637 12.6.8 Switching monitoring on and off..............................................................639 Switching monitoring on.........................................................................639 Switching monitoring off........................................................................640 12.6.9 Shutdown caused by working range limiter.....................................................641 Crane movements which are switched off..........................................................641 Bypassing shutdown.............................................................................642 Error messages on shutting down.................................................................642 12.7 Driving the truck crane from the crane cab.........................................................643 12.7.1 Route........................................................................................644 12.7.2 Preparing to drive...........................................................................645 In the driver's cab.............................................................................645 Preconditions for driving without a load........................................................645 Preconditions for driving with a load...........................................................646 12.7.3 Opening / closing the driving mode submenu...................................................647 Opening the submenu automatically...............................................................647 Opening the submenu manually....................................................................648 Closing the Driving mode submenu................................................................649 12.7.4 Steering.....................................................................................650 Switching on the steering function..............................................................650 Adapting the steering direction to the superstructure setting...................................650 Normal steering.................................................................................651 Separate steering...............................................................................651 12.7.5 Operating the transmission from the crane cab................................................654 Driving direction...............................................................................654 Selecting the gear position.....................................................................655 12.7.6 Driving the rigged truck crane...............................................................656 Driving.........................................................................................657 Checks while driving............................................................................658 Levelling the truck crane free on wheels........................................................658 12.7.7 Possible connections.........................................................................659 Longitudinal differential locks.................................................................660 Transverse differential locks...................................................................661 12.7.8 After driving................................................................................662 12.8 Work break.........................................................................................663 12.8.1 During short work breaks.....................................................................663 12.8.2 Work breaks lasting longer than 8 hours......................................................664 Securing the truck crane against unauthorised use...............................................664 12.9 Heating and ventilating the crane cab..............................................................665 12.9.1 Heating......................................................................................665 Switching on the heating........................................................................666 Switching off the heating.......................................................................666 Adjusting the air volume........................................................................667 Regulating the temperature......................................................................667 Setting recirculated air / fresh air............................................................667 Setting the air distribution...................................................................668 Setting the time and weekday....................................................................669 Saving automatic heating start.................................................................670 Setting the automatic heating duration.........................................................671 Switching automatic heating start on / off......................................................672 Setting the remaining time......................................................................673 12.9.2 Air-conditioning system......................................................................674 Switching on....................................................................................674 Setting the air distribution...................................................................675 Switching off...................................................................................675 How to use the air conditioning effectively.....................................................675 Drying the air in the crane cab.................................................................676 13 Rigging work.............................................................................................679 13.1 Checklists for rigging work for crane operation with main boom.....................................679 13.1.1 CHECKLIST: Rigging...........................................................................679 13.1.2 CHECKLIST: Unrigging.........................................................................683 13.2 Choosing a suitable site...........................................................................687 13.2.1 Load bearing capacity of the ground and the outriggers.......................................687 Enlarging the outrigger surface area...........................................................689 13.2.2 Safe distance from banks and pits............................................................690 13.2.3 Earthing of the truck crane..................................................................691 Earthing the truck crane........................................................................691 13.2.4 Safe distance from electrical lines..........................................................692 13.3 Rigging work after driving with a trailer..........................................................695 13.3.1 Switching off the boom floating position.....................................................696 13.3.2 Switching off boom pre-tensioning............................................................697 13.3.3 Switching off slewing gear freewheel.........................................................698 Prerequisites...................................................................................698 Before slewing..................................................................................700 13.4 Rigging add-on parts in position for crane operation / driving.....................................701 13.4.1 Folding mirrors in and out and adjusting them................................................702 Main hoist mirrors..............................................................................702 Mirror for monitoring the outriggers...........................................................703 13.5 Connecting / removing the hand-held control........................................................705 13.5.1 Connecting the hand-held control.............................................................705 13.5.2 Starting and turning off the diesel engine with connected hand- held control................706 With the hand- held control....................................................................707 From the driver's cab...........................................................................708 From the crane cab.............................................................................709 13.5.3 Disconnecting the hand-held control..........................................................710 13.6 Outriggers.........................................................................................711 13.6.1 CHECKLIST: Extending the outriggers..........................................................711 13.6.2 CHECKLIST: Retracting the outriggers.........................................................713 13.6.3 Permissible outrigger spans..................................................................715 Outrigger span of 8.10x7.00 m (26.6x23.0 ft)................................................716 Outrigger span of 8.10x6.00 m (26.6x19.7 ft)................................................716 Outrigger span of 8.10x5.00 m (26.6x16.4 ft)................................................717 Outrigger span of 8.10x2.32 m (26.6x7.6 ft).................................................718 Free on wheels..................................................................................719 13.6.4 Preparing the truck crane....................................................................720 Aligning the truck crane horizontally..........................................................720 Locking the suspension.........................................................................720 Switching on / off the display fields on the carrier...........................................720 13.6.5 Extending / Retracting the outrigger beams...................................................721 With the hand- held control.....................................................................721 From the switch boxes...........................................................................724 From the crane cab..............................................................................726 Setting outrigger spans.........................................................................729 13.6.6 Securing the outrigger beams for on-road driving.............................................733 13.6.7 Moving the outrigger pads into working / driving position....................................734 13.6.8 Extending / Retracting the outrigger cylinders...............................................735 With the hand- held control.....................................................................736 From the switch boxes...........................................................................739 From the crane cab..............................................................................743 13.6.9 Checking the alignment of the truck crane....................................................747 On the hand-held control........................................................................747 At the switch boxes.............................................................................749 On the crane control display....................................................................751 13.6.10 Aligning the truck crane on outriggers horizontally.........................................755 If the boom is on the boom support............................................................755 If the boom is raised.........................................................................755 Automatic alignment............................................................................755 13.6.11 Aligning the free-on-wheels truck crane horizontally........................................758 When rigging....................................................................................758 During crane work...............................................................................759 13.6.12 Outrigger pressure indicator................................................................761 Outrigger pressure indicator in the crane cab...................................................761 Outrigger pressure indicator on the carrier.....................................................762 13.7 Rigging / unrigging the counterweight..............................................................763 13.7.1 Counterweight parts and identification.......................................................763 Counterweight parts............................................................................763 Identification..................................................................................764 13.7.2 Counterweight combinations...................................................................765 13.7.3 Slinging points at the counterweight sections................................................769 13.7.4 CHECKLIST: Rigging the counterweight.........................................................770 13.7.5 CHECKLIST: Unrigging the counterweight.......................................................772 13.7.6 Assembling counterweight combinations........................................................775 Versions that can be installed on the turntable................................................776 Setting down the 2.5t base plate...............................................................778 Versions that can be assembled differently....................................................779 13.7.7 Counterweight hoist unit.....................................................................787 Selecting the Counterweight submenu............................................................787 Checking the current hoist unit status........................................................788 Display of incorrect statuses.................................................................789 Extending / Retracting the lifting cylinders....................................................790 Locking / unlocking counterweights.............................................................792 13.7.8 Removing / installing the counterweight sections on the turntable............................794 Removing........................................................................................794 Installing......................................................................................795 13.7.9 Slewing with the rigged counterweight........................................................796 13.8 Rigging work on the main boom......................................................................799 13.8.1 Hook block on the bumper.....................................................................799 Picking up the hook block from the bumper.......................................................799 Attaching the hook block to the bumper..........................................................800 13.8.2 Hook block on a separate vehicle.............................................................801 Picking up the hook block......................................................................802 Setting down the hook block....................................................................802 13.8.3 Reeving and unreeving the hoist rope.........................................................804 Rope end clamp..................................................................................804 Positioning the hoist rope.....................................................................806 13.8.4 Possible reeving methods with 6 main boom head sheaves.......................................810 13.8.5 Possible reeving methods with 7 main boom head sheaves.......................................813 Maximum reeving.................................................................................816 13.8.6 Installing / Removing the lifting limit switch...............................................817 Installing the lifting limit switch.............................................................817 Removing the lifting limit switch...............................................................821 13.8.7 Locking the lifting limit switch / Releasing the lock........................................823 Locking.........................................................................................823 Releasing the lock.............................................................................824 13.8.8 Anemometer and air traffic control light.....................................................825 Mounting........................................................................................825 Removing........................................................................................826 14 Malfunctions during crane operation......................................................................829 14.1 Emergency-stop devices for crane operation.........................................................829 14.1.1 Carrying out emergency-stop operations.......................................................829 14.1.2 Resetting the emergency-stop switch..........................................................831 14.2 Procedure in the event of a malfunction during craneoperation....................................833 If it is possible to lower the load.................................................................833 If it is not possible to lower the load.............................................................833 14.3 Fuses on the superstructure........................................................................835 Information on replacing fuses....................................................................835 14.3.1 Fuses on the turntable.......................................................................836 F1 fuse group..................................................................................836 Fuses on I/O circuit boards.....................................................................837 Fuses on the circuit board......................................................................837 14.3.2 Fuses in the crane cab.......................................................................838 14.3.3 SLI fuses....................................................................................840 14.4 Finding and eliminating malfunctions atthepowerunits............................................843 14.4.1 Malfunctions in the diesel engine during crane operation.....................................843 14.4.2 Malfunctions when operating with the hand-held control.......................................844 14.4.3 Malfunctions in the outriggers...............................................................844 14.4.4 Malfunctions in the main hoist...............................................................846 14.4.5 Malfunctions on the auxiliary hoist..........................................................848 14.4.6 Derricking gear malfunctions.................................................................850 14.4.7 Malfunctions in the slewing gear.............................................................852 14.4.8 Malfunctions in the counterweight hoist unit.................................................854 14.4.9 Malfunctions in the hydraulic system / hydraulic oil cooler..................................855 14.4.10 Malfunctions on the turntable lock..........................................................855 14.4.11 Malfunctions in the telescoping mechanism...................................................856 Telescoping mechanism error messages............................................................859 14.4.12 Malfunctions when driving from the crane cab................................................860 14.5 Finding and eliminating malfunctions at the SLI....................................................861 14.5.1 General malfunctions.........................................................................861 14.5.2 Error messages on the SLI insert.............................................................862 Table of error codes............................................................................863 Switch off sensor/ tachogenerator...............................................................866 14.6 Finding and eliminating malfunctions at thecranecontrol..........................................867 Program version of the crane control................................................................867 14.6.1 General malfunctions.........................................................................867 14.6.2 Error messages on the crane control display..................................................868 14.7 Emergency operations and programs..................................................................871 14.7.1 Emergency retraction operation...............................................................872 Check prior to each emergency operation.........................................................872 Retraction procedure...........................................................................873 Mechanical emergency operation..................................................................874 14.7.2 Emergency telescoping program submenu........................................................877 Starting the emergency program.................................................................877 Display and operating elements of the emergency program.........................................878 Retracting in the event of an error at the length indicator.....................................881 When an error occurs on the proximity switch...................................................884 Terminating the emergency program..............................................................885 Tables for approaching the locking points.......................................................886 14.7.3 Entering telescoping values after emergency operation........................................888 14.7.4 Emergency operation in the event of a failure of the operating elements in the crane cab.....891 Connecting the hand-held control................................................................891 Starting the diesel engine with the hand-held control...........................................892 Pre-selecting a power unit.....................................................................892 Operating the power unit........................................................................893 Stopping movements.............................................................................895 Stopping the operation in cases of emergency....................................................895 14.8 Hydraulic emergency operation according to BGR159 (ZH1/461).......................................897 14.8.1 Important instructions for hydraulic emergency operation.....................................897 14.8.2 Operating principle and accessories..........................................................899 For emergency operation........................................................................899 For the emergency supply........................................................................900 14.8.3 Connecting / disconnecting hoses.............................................................901 For emergency operation with the transformer...................................................901 For emergency operation with the hand pump.....................................................903 14.8.4 Establishing the hydraulic circuits required.................................................904 Switching positions of the hand valves..........................................................904 Additional switching operations for the main hoist..............................................906 Additional switching operations for the slewing gear............................................907 14.8.5 Operating in emergency mode..................................................................908 With the hand pump..............................................................................909 With transformer................................................................................909 Emergency main hoist operation..................................................................909 Emergency derricking gear operation.............................................................910 Emergency slewing gear operation................................................................911 14.8.6 After emergency operation....................................................................912 Establishing hydraulic circuits for crane operation ..........................................912 Disconnecting hoses.............................................................................912 14.8.7 Emergency supply of another crane............................................................913 Connecting / disconnecting hoses................................................................913 Switching on / off the emergency supply.........................................................914 15 Technical information for superstructure.................................................................917 15.1 Technical data.....................................................................................917 15.1.1 Maximum lifting capacity (DIN/ ISO/ EN)......................................................917 15.1.2 Maximum lifting capacity (ASME B 30.5).......................................................917 15.1.3 Dimensions, weights and axle loads...........................................................918 Dimensions for driving on public roads........................................................919 Total weight and axle loads.....................................................................919 15.1.4 Dimensions and weights of removable parts....................................................920 Hook blocks and hook tackle.....................................................................920 Counterweightparts.............................................................................920 15.1.5 Technical data for superstructure............................................................921 Main hoist......................................................................................921 Auxiliary hoist (additional equipment)..........................................................921 Slewing gear....................................................................................921 Derricking gear.................................................................................922 Main boom.......................................................................................922 Lattice extension...............................................................................922 Operating speeds and times without a load......................................................923 16 Index....................................................................................................927 A.......................................................................................................929 B.......................................................................................................929 C.......................................................................................................930 D.......................................................................................................932 E.......................................................................................................934 F.......................................................................................................934 H.......................................................................................................935 I.......................................................................................................936 K.......................................................................................................936 L.......................................................................................................936 M.......................................................................................................937 O.......................................................................................................938 P.......................................................................................................939 R.......................................................................................................939 S.......................................................................................................940 T.......................................................................................................941 V.......................................................................................................943 W.......................................................................................................943
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