Grove Crane GMK 4100 Operating Instructions Part 1 Driving 3112343 – PDF DOWNLOAD

Description

Grove Crane GMK 4100 Operating Instructions Part 1 Driving 3112343 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK 4100 Operating Instructions Part 1 Driving 3112343 – PDF DOWNLOAD

Language : English
Pages : 818
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Grove Crane GMK 4100 Operating Instructions Part 1 Driving 3112343 – PDF DOWNLOAD

Documentation supplied:

The precise number of documents supplied depends on the scope of equipment
of the truck crane. The following documents are included in delivery:
– Operating instructions
Contain information on driving and crane operation.
– Lattice extension operating instructions
Are only supplied when the truck crane is equipped with a lattice extension
or other parts for extending the main boom (e.g. auxiliary singlesheave
boom top and heavy load lattice extension).
– Operating instructions for additional equipment
These are only supplied when the truck crane is supplied with additional
equipment which is not described in the operating instructions for driving
and crane operation.
– Documents from other manufacturers
Original documentation for parts which are not manufactured by Manitowoc
Crane Group Germany GmbH in Germany, such as the engine and
central lubrication system, as well as the tachograph, auxiliary heaters,
radio and, when appropriate, other additional equipment.
– Maintenance manual
Contains information on maintenance work alone, and contains no
instructions for repair work.
– Safety manual
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical system, hydraulic system and pneumatic
system are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different rigging
modes.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove Crane GMK 4100 Operating Instructions Part 1 Driving 3112343 – PDF DOWNLOAD

1 Overview......................................................................................  7
	1.1 Identification..........................................................................  7
	1.2 EC Declaration of Conformity............................................................ 11
	1.3 Documentation supplied.................................................................. 12
	1.4 Information about the operating instructions............................................ 13
		1.4.1 What do the symbols used mean?.................................................... 13
		1.4.2 How are the operating instructions structured?.................................... 15
			Division............................................................................ 15
			Structure of the chapters........................................................... 15
			Structure of the pages.............................................................. 16
		1.4.3 How do I find the information I need?............................................. 17
			Cross-references example............................................................ 18
		1.4.4 What information is available for operations planning?............................ 20
	1.5 Conversion table for US measurements.................................................... 21
2 Basic safety instructions..................................................................... 25
	2.1 Intended use............................................................................ 25
		2.1.1 Improper use...................................................................... 26
	2.2 Organisational measures................................................................. 27
	2.3 Qualifications of the personnel......................................................... 29
	2.4 Safety instructions for driving the truck crane......................................... 30
	2.5 Safety instructions for crane operation................................................. 31
3 Operating elements for driving................................................................ 35
	3.1 Overview of the operating elements...................................................... 35
		3.1.1 On the outside of the truck crane................................................. 36
		3.1.2 Driver's cab...................................................................... 38
			Overview............................................................................ 38
			Behind the cover.................................................................... 40
		3.1.3 Instrument panel.................................................................. 41
			Left / right........................................................................ 41
			Middle.............................................................................. 42
		3.1.4 Display, driver's cab............................................................. 44
		3.1.5 Steering column / steering wheel.................................................. 45
		3.1.6 Transmission operating elements................................................... 46
		3.1.7 Tachograph........................................................................ 47
		3.1.8 ECOS control unit................................................................. 48
		3.1.9 ECOS display – main menu.......................................................... 50
		3.1.10 ECOS display – submenus.......................................................... 52
			Level adjustment system submenu..................................................... 52
			Settings submenu.................................................................... 54
			Operating hours submenu............................................................. 55
			Warning submenu..................................................................... 55
			Transmission emergency program submenu.............................................. 56
			Error submenu....................................................................... 57
		3.1.11 Heating / Air-conditioning system................................................ 58
			Standard heating system............................................................. 58
			Auxiliary heater.................................................................... 59
		3.1.12 Sockets for hand-held control.................................................... 60
		3.1.13 Outrigger control units.......................................................... 61
	3.2 Short description of the operating elements............................................. 63
		3.2.1 Definition of positional references............................................... 63
			Basic rules......................................................................... 63
			Switches and buttons................................................................ 64
		3.2.2 General information on the operating elements..................................... 64
		3.2.3 General rules for buttons and symbols on the display.............................. 65
		3.2.4 Engine............................................................................ 66
			Steering column..................................................................... 66
			Multipurpose switch................................................................. 66
			Instrument panel.................................................................... 67
		3.2.5 Electrical system................................................................. 68
		3.2.6 ECOS crane control................................................................ 68
			Control unit........................................................................ 68
		3.2.7 Transmission...................................................................... 71
			Transmission display................................................................ 71
			ECOS display........................................................................ 71
			Operating elements.................................................................. 72
			Instrument panel.................................................................... 73
		3.2.8 Transfer case..................................................................... 75
			Main menu........................................................................... 75
		3.2.9 Final drive....................................................................... 76
		3.2.10 Brakes........................................................................... 77
			Service brake....................................................................... 77
			Parking brake....................................................................... 78
			Additional brakes................................................................... 79
		3.2.11 Steering / separate steering..................................................... 80
			ECOS display........................................................................ 80
			Driver's door....................................................................... 80
		3.2.12 Suspension....................................................................... 81
		3.2.13 Lighting / windscreen wipers / horn.............................................. 82
			Steering column..................................................................... 82
			Instrument panel.................................................................... 82
			Roof................................................................................ 84
		3.2.14 Level adjustment system.......................................................... 84
		3.2.15 Tachograph / speedometer......................................................... 86
			Tachograph.......................................................................... 86
			Speedometer......................................................................... 86
		3.2.16 Diagnostics...................................................................... 87
			Displays / submenu.................................................................. 87
		3.2.17 On-board computer................................................................ 88
		3.2.18 Push-up roof..................................................................... 90
		3.2.19 Windows, doors, keys............................................................. 90
			Window winder....................................................................... 90
			Doors............................................................................... 91
			Keys................................................................................ 91
		3.2.20 Front flap....................................................................... 92
		3.2.21 Storage compartment.............................................................. 92
4 Starting / turning off the engine for driving................................................. 95
	4.1 Starting the engine from the driver's cab............................................... 95
		4.1.1 CHECKLIST: Starting the engine.................................................... 95
		4.1.2 CHECKLIST: if the temperature is low.............................................. 98
		4.1.3 Ladders and access ladders........................................................ 99
			Access ladders...................................................................... 99
			Ladders............................................................................. 99
		4.1.4 Refuelling........................................................................101
		4.1.5 Checks before starting the engine.................................................102
			On the hydraulic tank...............................................................102
			Battery master switch...............................................................102
			Checking the hand-held control......................................................103
		4.1.6 Switching on the ignition.........................................................103
		4.1.7 Lamp test / equalisation of the switching states..................................104
			Lamp test...........................................................................104
			Equalisation of the switching states................................................105
		4.1.8 Display – setting the brightness..................................................106
		4.1.9 To start the engine...............................................................107
			Without flame start system..........................................................108
			With flame start system.............................................................109
		4.1.10 Checks after starting the engine.................................................110
		4.1.11 Control elements.................................................................111
			Instrument panel....................................................................111
			ECOS display........................................................................112
			Display, driver's cab...............................................................112
		4.1.12 Setting the idling speed.........................................................113
	4.2 Turning off the engine..................................................................115
		4.2.1 On the ignition lock / with hand-held control.....................................115
			After turning off...................................................................115
		4.2.2 With emergency stop switches......................................................116
			Resetting the emergency stop switch.................................................116
	4.3 Air intake inhibitor....................................................................117
		Releasing the air intake inhibitor......................................................117
5 Driving.......................................................................................121
	5.1 Before driving..........................................................................121
		5.1.1 CHECKLIST: inspections before on-road driving.....................................121
		5.1.2 Checking the condition of the truck crane.........................................126
			Windscreen washing system...........................................................126
			Electrical system...................................................................126
			Adjusting the mirrors...............................................................127
			Warning plates for vehicle width....................................................128
			Displaying the vehicle height.......................................................128
			Supply pressure.....................................................................129
			Parking brake.......................................................................130
		5.1.3 Adjusting the seats and steering column...........................................131
			Driver's seat.......................................................................131
			Passenger's seat....................................................................132
			Adjusting the steering column.......................................................133
		5.1.4 Switching the suspension on / off.................................................134
			Opening the submenu.................................................................134
			Switching on the suspension.........................................................135
			To switch off the suspension........................................................135
		5.1.5 Adjusting the tachograph..........................................................136
			Prerequisites.......................................................................136
			In the event of malfunctions........................................................136
			Adjusting the tachograph............................................................137
			Additional displays.................................................................140
		5.1.6 Displaying the operating hours....................................................141
		5.1.7 Settings / displays with the on-board computer....................................142
			Operation...........................................................................142
			Overview............................................................................143
			Inspection information..............................................................143
			Error information...................................................................144
			Alarm clock.........................................................................144
			Language............................................................................145
			Settings............................................................................145
			Diagnostics.........................................................................146
	5.2 Operating the transmission..............................................................149
		5.2.1 Switching on......................................................................149
		5.2.2 Switching the transmission to neutral position....................................150
		5.2.3 Changing the operating mode.......................................................150
			Change-over to automatic mode.......................................................150
			Change-over to manual mode..........................................................150
		5.2.4 Display of the selected gears.....................................................151
		5.2.5 Selecting the direction of travel and starting gear...............................151
			Selecting the driving direction.....................................................151
			Selecting the starting gear.........................................................152
		5.2.6 Starting..........................................................................153
		5.2.7 Driving and changing gears........................................................154
			In automatic operating mode.........................................................154
			In manual operating mode............................................................155
		5.2.8 Changing the driving direction....................................................156
			Quick change of gear................................................................156
		5.2.9 Stopping..........................................................................157
			Stopping for a long period of time..................................................157
		5.2.10 On the roller type dynamometer...................................................157
	5.3 Driving and turning off the truck crane.................................................159
		5.3.1 Inspections while driving.........................................................159
			Immediately after you start to move.................................................159
			While driving.......................................................................160
		5.3.2 Tempomat..........................................................................161
			Switching on........................................................................161
			Switching off.......................................................................162
		5.3.3 Temposet..........................................................................163
			Switching on........................................................................163
			Switching off.......................................................................163
		5.3.4 Driving downhill..................................................................164
			Starting............................................................................164
			Inspections when driving downhill...................................................164
			Downshifting........................................................................165
			Additional brakes...................................................................166
		5.3.5 Driving uphill....................................................................167
			Starting............................................................................167
			Driving.............................................................................167
		5.3.6 Warning submenu...................................................................168
			Meaning of the symbols..............................................................168
			Exiting the submenu.................................................................169
		5.3.7 Error submenu.....................................................................170
		5.3.8 Messages on the on-board computer display.........................................170
			Warnings............................................................................171
			Warning messages....................................................................172
			Error messages......................................................................173
			Information.........................................................................175
		5.3.9 Turning off the truck crane.......................................................178
			Secure against rolling away.........................................................178
			When stationary for more than 8hours...............................................179
	5.4 Off-road driving........................................................................181
		Adjustments to the transmission.........................................................181
		Connections.............................................................................181
		Changing the vehicle level..............................................................181
		Rocking the vehicle free and towing.....................................................181
		5.4.1 Transfer case – off-road gear on / off............................................182
			Neutral position....................................................................182
		5.4.2 Longitudinal and transverse differential locks....................................183
		5.4.3 Operation of the level adjustment system..........................................185
			Opening the submenu.................................................................185
			Setting the on-road level...........................................................186
			Pre-selecting suspension struts.....................................................186
			Changing the vehicle level..........................................................187
			Viewing the current inclination.....................................................187
			Exiting the submenu.................................................................188
		5.4.4 Freeing the truck crane stuck in terrain..........................................189
			Rocking the truck crane free........................................................189
			Towing free forwards................................................................190
			Towing free in reverse gear.........................................................190
		5.4.5 Separate steering.................................................................191
			Switching to separate steering......................................................191
			Steering............................................................................192
			Switching to normal steering mode...................................................193
	5.5 Heating and air-conditioning system.....................................................195
		5.5.1 Standard heating system...........................................................195
			Switching on........................................................................195
			Heating.............................................................................195
			Air distribution....................................................................196
			Examples............................................................................197
			Switching off.......................................................................197
		5.5.2 Air-conditioning system...........................................................198
			Warnings............................................................................198
			Switching on / off..................................................................198
			Cooling.............................................................................199
			Drying..............................................................................199
		5.5.3 Auxiliary heater..................................................................200
			Switching on........................................................................200
			Temperature.........................................................................201
			Setting the day and time............................................................201
			Storing the heating start...........................................................202
			Setting the heating period..........................................................203
			Switching the heating start on and off..............................................203
			Switching off.......................................................................204
			Setting the remaining time..........................................................204
	5.6 Towing a trailer........................................................................205
		Effects on the axle loads...............................................................205
		Coupling the trailer....................................................................206
		Connecting the supply lines.............................................................207
		Removing the supply lines...............................................................208
		Uncoupling the trailer..................................................................208
		Checking the braking force..............................................................210
6 Driving modes.................................................................................213
	6.1 Driving modes...........................................................................213
		Information on the axle loads...........................................................213
		6.1.1 Information on how to use the tables..............................................214
		6.1.2 Table for a maximum axle load of 12 t (26500 lbs)................................215
			For 14.00 R25 tyres.................................................................215
			For 16.00 R25 tyres.................................................................216
			For 20.5 R25 tyres..................................................................217
		6.1.3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs)..............218
	6.2 Rigging work for driving with a trailer.................................................219
		6.2.1 Switching on the slewing gear freewheel...........................................220
		6.2.2 Switching on boom floating position...............................................221
		6.2.3 Switching on boom pre-tensioning..................................................222
		6.2.4 Switching the superstructure driving lights on / off..............................224
			Switching off.......................................................................224
			Switching on........................................................................224
7 Malfunctions in driving mode..................................................................227
	7.1 Emergency stop switch...................................................................227
	7.2 What to do when a malfunction occurs in road traffic....................................229
	7.3 Towing the truck crane..................................................................231
		7.3.1 Towing in the event of engine or transmission damage..............................232
			Compressed-air supply...............................................................232
			Electric power supply...............................................................232
			On the transmission.................................................................233
			Axle drives.........................................................................234
			Transfer case.......................................................................234
			Parking brake.......................................................................234
			Towing the truck crane out of the danger area.......................................235
		7.3.2 Starting to tow...................................................................236
	7.4 Wheels and tyres........................................................................237
		7.4.1 Wheel change......................................................................237
			Removing a damaged wheel............................................................238
			On the spare wheel holder...........................................................238
			Mounting a wheel....................................................................239
		7.4.2 Filling the tyres yourself........................................................241
			Connecting the filling hose.........................................................241
			Filling the tyres...................................................................242
			Removing the filling hose...........................................................242
	7.5 Fuses...................................................................................243
		Notes on changing fuses.................................................................243
		7.5.1 Fuses in the driver's cab.........................................................244
			F1 to F 41..........................................................................244
			A1 to A3............................................................................246
		7.5.2 Fuses in the battery box..........................................................248
	7.6 Finding and eliminating malfunctions....................................................249
		7.6.1 Malfunctions on the engine........................................................249
		7.6.2 Malfunctions on the transmission..................................................251
		7.6.3 Service brake malfunctions........................................................252
		7.6.4 Steering malfunctions.............................................................253
		7.6.5 Transfer case malfunctions........................................................253
		7.6.6 Malfunctions in the differential locks............................................254
		7.6.7 Malfunctions in the hydraulic system / hydraulic oil cooler.......................254
		7.6.8 Malfunctions on the suspension....................................................255
		7.6.9 Malfunctions on the level adjustment system.......................................255
		7.6.10 Malfunctions on the ECOS carrier.................................................256
			ECOS program version................................................................256
			General malfunctions................................................................256
			Error messages......................................................................257
			Exiting the submenu.................................................................258
			On the control units................................................................259
	7.7 Procedure in the event of malfunctions..................................................261
		7.7.1 Switching on emergency operation in coolant circuit...............................261
		7.7.2 Procedure in the event of malfunctions to the transmission and engine.............262
			Engine..............................................................................262
			Transmission........................................................................263
			Transmission emergency program submenu..............................................264
			Switching gears mechanically in emergency mode......................................267
			ID number of the transmission.......................................................271
8 Technical information on the carrier..........................................................275
	8.1 Technical data..........................................................................275
		8.1.1 Dimensions and weights of the truck crane, axle loads.............................276
			Dimensions..........................................................................277
			Weight and axle loads...............................................................277
		8.1.2 Dimensions and weights of removable parts.........................................278
			Spare wheel.........................................................................278
			Outriggers..........................................................................278
		8.1.3 Carrier...........................................................................279
			Engine..............................................................................279
			Transmission........................................................................279
			Transfer case.......................................................................279
			Axle lines..........................................................................279
			Steering............................................................................279
			Tyres...............................................................................279
			Electrical system...................................................................280
			Tools...............................................................................280
			Towing couplings....................................................................280
			Outriggers..........................................................................280
			Driving speeds......................................................................281
			Climbing ability....................................................................281
			Turning circle radiuses.............................................................281
9 Index.........................................................................................285
	A...........................................................................................287
	B...........................................................................................287
	C...........................................................................................288
	D...........................................................................................289
	E...........................................................................................291
	F...........................................................................................293
	H...........................................................................................293
	I...........................................................................................294
	K...........................................................................................295
	L...........................................................................................295
	M...........................................................................................295
	O...........................................................................................296
	P...........................................................................................297
	R...........................................................................................297
	S...........................................................................................298
	T...........................................................................................299
	V...........................................................................................301
	W...........................................................................................301
10 Operating elements for crane operation.......................................................311
	10.1 Overview of the operating elements.....................................................311
		10.1.1 On the outside of the truck crane................................................312
		10.1.2 Crane cab........................................................................314
		10.1.3 Front panel......................................................................316
		10.1.4 Side panel.......................................................................317
			Bottom..............................................................................317
			Top.................................................................................318
			Standard heating system.............................................................321
			Auxiliary water heater..............................................................322
			Auxiliary air heater................................................................323
		10.1.5 Control panels...................................................................324
			Left................................................................................324
			Right...............................................................................325
		10.1.6 Control lever assignment.........................................................326
			Version 1...........................................................................326
			Version 2...........................................................................327
		10.1.7 ECOS control unit................................................................328
		10.1.8 ECOS display – main menu.........................................................330
		10.1.9 ECOS display – submenus..........................................................332
			Counterweight submenu...............................................................332
			Slewing gear / Houselock submenu....................................................333
			Outriggers submenu..................................................................334
			Telescoping submenu.................................................................336
			Power unit speeds submenu...........................................................338
			Monitoring submenu..................................................................339
			Settings submenu....................................................................340
			Operating hours submenu.............................................................342
			Warning submenu.....................................................................343
			Error submenu.......................................................................345
			Working range limitation submenu....................................................346
			Driving submenu.....................................................................348
		10.1.10 SLI control unit................................................................350
		10.1.11 Hand-held control...............................................................354
			Outriggers control panel............................................................355
		10.1.12 Outrigger control units.........................................................356
			Outriggers..........................................................................357
			Outrigger pressure display..........................................................357
			Inclination display.................................................................357
	10.2 Short description of the operating elements............................................359
		10.2.1 Definition of positional references..............................................359
			Basic rule..........................................................................359
			Switch..............................................................................360
		10.2.2 General rules for buttons and symbols on the display.............................360
		10.2.3 Engine for crane operation.......................................................361
			Side panel..........................................................................361
			ECOS display........................................................................362
		10.2.4 Engine for driving...............................................................363
			Side panel..........................................................................363
			Outriggers submenu..................................................................363
		10.2.5 Seat contact switch and dead man's switch........................................364
		10.2.6 ECOS crane control...............................................................365
			Control unit........................................................................365
		10.2.7 Outriggers.......................................................................368
			Hand-held control...................................................................368
			In the outriggers submenu...........................................................369
			In the settings submenu.............................................................370
			On the outrigger control units......................................................371
		10.2.8 Inclination displays.............................................................373
		10.2.9 Outrigger pressure displays......................................................374
			Outriggers submenu..................................................................374
			Outrigger control units.............................................................374
		10.2.10 Anemometer display..............................................................374
		10.2.11 Counterweight submenu...........................................................375
			Counterweight submenu...............................................................375
		10.2.12 Main hoist......................................................................378
		10.2.13 Auxiliary hoist.................................................................380
		10.2.14 Slewing gear....................................................................381
			Submenu.............................................................................381
		10.2.15 Derricking gear.................................................................383
		10.2.16 Telescoping mechanism...........................................................384
			Control panels......................................................................384
			Submenu.............................................................................385
			In the settings submenu.............................................................389
		10.2.17 Hydraulic system................................................................391
		10.2.18 Houselock.......................................................................392
		10.2.19 Safe load indicator (SLI).......................................................393
			Input elements with displays........................................................393
			Display elements....................................................................395
			On the front panel..................................................................398
		10.2.20 Electrical system...............................................................399
		10.2.21 Lighting, windscreen wiper / washing system.....................................399
			Lighting............................................................................399
			Windscreen wiper/ washing system...................................................401
		10.2.22 Hand-held control...............................................................402
			Sockets for hand- held control......................................................402
			Engine control panel................................................................403
			Horn................................................................................403
			Outriggers control panel............................................................404
		10.2.23 Diagnostics.....................................................................406
		10.2.24 Windows, doors, keys............................................................407
			Windows.............................................................................407
			Crane cab door......................................................................407
			Keys................................................................................408
	10.3 Short description of the operating elements – driving from the crane cab...............409
		10.3.1 Driving submenu..................................................................409
		10.3.2 Engine for driving...............................................................410
		10.3.3 Transmission.....................................................................411
		10.3.4 Final drive......................................................................412
		10.3.5 Brakes...........................................................................413
			Side panel..........................................................................413
			ECOS display........................................................................413
		10.3.6 Steering.........................................................................414
			Normal steering.....................................................................415
			Separate steering...................................................................415
11 Starting / turning off the engine – for crane operation......................................419
	11.1 Starting the engine – from the crane cab...............................................419
		11.1.1 CHECKLIST: Starting the engine...................................................419
		11.1.2 CHECKLIST: If the temperature is low.............................................422
		11.1.3 Refuelling.......................................................................423
			For standard equipment..............................................................423
			With additional equipment...........................................................424
		11.1.4 Inspections before starting the engine...........................................425
			On the hydraulic tank...............................................................425
			Battery master switch...............................................................425
			Checking the hand-held control......................................................426
		11.1.5 Switch on the ignition...........................................................426
		11.1.6 Lamp test / equalisation of the switching states.................................427
			Lamp test...........................................................................427
			Equalisation of the switching states................................................428
		11.1.7 Set brightness of display........................................................429
		11.1.8 To start the engine..............................................................430
			Without flame start system..........................................................430
			With flame start system.............................................................431
		11.1.9 Inspections after starting the engine............................................432
		11.1.10 Monitoring submenu..............................................................433
		11.1.11 Setting the idling speed........................................................434
	11.2 Starting the engine – with the hand-held control.......................................435
		Prerequisites...........................................................................435
		To start the engine.....................................................................435
	11.3 Turning off the engine.................................................................437
		11.3.1 During normal operation, with the ignition lock / with the hand- held control....437
			After parking.......................................................................437
		11.3.2 In emergencies, with the emergency-stop switches.................................438
			Resetting the emergency stop switch.................................................438
	11.4 Air intake inhibitor...................................................................439
		Releasing the air intake inhibitor......................................................439
12 Crane operation..............................................................................443
	12.1 Before crane operation.................................................................443
		12.1.1 CHECKLIST: Inspections prior to crane operation..................................443
		12.1.2 Checking the condition of the truck crane........................................447
			Tank for windscreen washing system..................................................447
			Auxiliary heater – tank.............................................................447
			Visual inspection...................................................................448
			Checking the position of the hoist ropes............................................448
			Checking the electrical system......................................................449
		12.1.3 Adjusting the crane cab seat and front panel.....................................449
			Crane cab seat......................................................................449
			Front panel.........................................................................450
		12.1.4 Checking the safety devices......................................................451
			Safe load indicator.................................................................451
			Lifting limit switch................................................................451
			Emergency stop switch...............................................................452
			Seat contact switch.................................................................453
		12.1.5 Earthing the load................................................................454
		12.1.6 Preheating the hydraulic oil.....................................................455
		12.1.7 Switching the houselock on / off.................................................456
			Switching on the houselock..........................................................456
			Switching off the houselock.........................................................458
	12.2 Operation of the safe load indicator...................................................459
		12.2.1 Switching on the SLI.............................................................460
			Switching on........................................................................460
			Lamp test on the SLI................................................................462
			Brightness of the displays..........................................................462
		12.2.2 Entering the rigging mode........................................................463
			Entering the SLI code...............................................................464
			Entering the reeving................................................................467
			Entering individual components......................................................468
		12.2.3 Inspections prior to crane operation.............................................471
		12.2.4 Displays during crane operation..................................................473
			Continuous displays.................................................................473
			Optional displays...................................................................475
		12.2.5 SLI early warning................................................................477
		12.2.6 SLI shutdown.....................................................................478
			Shutdown due to overload............................................................478
		12.2.7 Error message....................................................................479
		12.2.8 SLI override.....................................................................480
		12.2.9 Displaying and entering the time and date........................................481
			Display.............................................................................481
			Input...............................................................................482
	12.3 Crane operation with main boom.........................................................483
		12.3.1 Checks during crane operation....................................................483
			Horizontal alignment................................................................483
			Safe distances......................................................................483
			Checking the wind speed.............................................................484
		12.3.2 Permissible slewing ranges and working positions.................................485
			360 slewing range..................................................................485
			0 to the rear working position.....................................................485
			180 to the front rigging position..................................................486
			Free-on-wheels working position.....................................................486
		12.3.3 Main hoist.......................................................................487
			Switching on the main hoist.........................................................488
			Lifting and lowering................................................................488
			Switching off the main hoist........................................................489
		12.3.4 Auxiliary hoist..................................................................490
			Switching on the auxiliary hoist....................................................490
			Lifting and lowering................................................................491
			Switching off the auxiliary hoist...................................................492
		12.3.5 Lifting limit switch and lowering limit switch...................................493
			Lifting limit switch................................................................493
			Lowering limit switch...............................................................495
		12.3.6 Derricking gear..................................................................496
			Switching on the derricking gear....................................................496
			Raising and lowering the boom.......................................................497
			Switching off the derricking gear...................................................498
			Lowering the main boom to a horizontal position.....................................498
		12.3.7 Telescoping mechanism............................................................499
			Overview............................................................................500
			Telescoping process................................................................500
			Assignment for display..............................................................502
			Fixed length, intermediate length, telescoping length...............................504
			Telescoping.........................................................................505
			Telescoping sequence................................................................505
			Inspections prior to starting operations............................................506
			Switching on the telescoping mechanism..............................................507
			Function of the control lever.......................................................507
			Switching off the telescoping mechanism.............................................509
			Manual telescoping.................................................................510
			Checking the initial position.......................................................510
			Unlocking the telescoping cylinder................................................513
			Extending / retracting the telescoping cylinder.....................................515
			Locking the telescoping cylinder....................................................516
			Unlocking the telescopic section...................................................517
			Telescoping the telescopic section..................................................519
			Locking the telescopic section......................................................520
			Locking the telescopic section for on-road driving..................................521
			Telescopic extension with teleautomation............................................522
			Telescoping the main boom in horizontal position....................................527
		12.3.8 High speed.......................................................................528
			Switch on function..................................................................528
			Derricking gear / Telescoping mechanism.............................................528
			Hoists..............................................................................529
		12.3.9 Slewing gear.....................................................................530
			Switching on the slewing gear.......................................................530
			Slewing.............................................................................530
			Slewing to 0 or 180...............................................................532
			Braking the slewing movement........................................................533
			Slewing gear freewheel..............................................................533
			Switching off the slewing gear......................................................534
		12.3.10 Possible movement combinations..................................................534
		12.3.11 Hydraulic oil cooling...........................................................535
	12.4 Settings and displays for crane operation..............................................537
		12.4.1 Inclining the crane cab..........................................................537
		12.4.2 Setting the idling speed.........................................................537
		12.4.3 Adjusting the stroke interval of the windscreen wiper............................538
		12.4.4 Limiting the power unit speeds...................................................538
		12.4.5 Setting the characteristic curve for the control levers..........................540
		12.4.6 Critical load control............................................................541
			Function............................................................................541
			Switching on and off................................................................541
		12.4.7 Operation of the directional spotlights..........................................542
		12.4.8 Displaying the operating hours...................................................543
		12.4.9 Warning submenu..................................................................544
			Meaning of the symbols..............................................................544
			Exiting the submenu.................................................................547
		12.4.10 Error submenu...................................................................548
	12.5 Working range limiter..................................................................549
		12.5.1 Opening the Working range limiter submenu........................................550
		12.5.2 Viewing current settings.........................................................550
		12.5.3 Entering limit values............................................................552
			Overall height / Working radius.....................................................552
			Slewing angle.......................................................................553
			Entering objects....................................................................555
		12.5.4 Entering limit values / objects manually.........................................558
			Limit values........................................................................558
			Objects.............................................................................559
		12.5.5 Switching monitoring functions on / off..........................................560
		12.5.6 Shutdown by working range limiter................................................561
	12.6 Work break.............................................................................563
		12.6.1 Short work breaks................................................................563
		12.6.2 Work breaks of more than 8 hours.................................................564
			To secure the truck crane...........................................................564
	12.7 Heating and air-conditioning system....................................................565
		12.7.1 Standard heating system..........................................................565
			Switching on........................................................................565
			Heating.............................................................................565
			Air distribution....................................................................566
			Switching off.......................................................................567
		12.7.2 Air-conditioning system..........................................................567
			Warnings............................................................................567
			Switching on / off..................................................................568
			Cooling.............................................................................568
			Drying the air......................................................................569
		12.7.3 Auxiliary water heater...........................................................569
			Preheating the engine...............................................................570
			Preheating the crane cab............................................................570
			Switching on........................................................................571
			Setting the day and time............................................................572
			Storing the heating start...........................................................573
			Setting the heating period..........................................................574
			Switching heating start on / off....................................................574
			Switching off.......................................................................575
			Setting the remaining time..........................................................575
		12.7.4 Auxiliary air heater.............................................................576
			Switching on........................................................................576
			Temperature.........................................................................577
			Switching off.......................................................................577
			Additional functions................................................................577
13 Rigging work.................................................................................581
	13.1 Rigging work checklists for crane operation with the main boom.........................581
		13.1.1 CHECKLIST: Rigging...............................................................581
		13.1.2 CHECKLIST: Unrigging.............................................................585
	13.2 Choosing a suitable site...............................................................589
		13.2.1 Determining the required ground bearing area.....................................589
		13.2.2 Safe distance from slopes and pits...............................................592
		13.2.3 Earthing the truck crane.........................................................593
		13.2.4 Safe distance from electrical lines..............................................594
	13.3 Rigging work after driving with a trailer..............................................597
		13.3.1 Switching off the boom floating position.........................................597
		13.3.2 Switching off the slewing gear freewheel.........................................598
			Before slewing......................................................................598
		13.3.3 Switching off boom pre-tensioning................................................599
	13.4 Connecting / disconnecting the hand-held control.......................................600
	13.5 Starting the engine for driving for rigging work.......................................601
		13.5.1 Starting / turning off the engine with the hand-held control.....................601
			Prerequisites.......................................................................601
			To start the engine.................................................................602
			Turning off the engine..............................................................602
		13.5.2 Starting / turning off the engine from the crane cab.............................603
			Prerequisites.......................................................................603
			To start the engine.................................................................603
			After starting the engine...........................................................604
			Turning off the engine..............................................................604
	13.6 Outriggers.............................................................................605
		13.6.1 CHECKLIST: Extending the outriggers..............................................605
		13.6.2 CHECKLIST: Retracting the outriggers.............................................607
		13.6.3 Permissible outrigger spans......................................................608
		13.6.4 Preparing the truck crane........................................................609
			In the driver's cab.................................................................609
			Control units (outrigger)...........................................................609
		13.6.5 Setting the spans................................................................610
			For on-road driving.................................................................611
		13.6.6 Extending / retracting outriggers................................................612
			From the control units..............................................................613
			With the hand- held control.........................................................614
			From the crane cab..................................................................616
		13.6.7 Moving the outrigger pads into working / driving position........................618
		13.6.8 Enlarging the ground bearing area................................................619
		13.6.9 Extending / retracting supporting cylinders......................................621
			From the control units..............................................................622
			With the hand- held control.........................................................623
			From the crane cab..................................................................624
		13.6.10 Levelling the truck crane on outriggers.........................................626
			Inclination displays................................................................626
			Prerequisites.......................................................................627
			Manual alignment....................................................................628
			Automatic alignment.................................................................629
		13.6.11 Levelling the free-standing truck crane.........................................631
		13.6.12 Outrigger pressure display......................................................633
	13.7 Rigging / unrigging the counterweight..................................................635
		13.7.1 Counterweight parts..............................................................635
			Version A...........................................................................635
			Version B...........................................................................636
			Version C...........................................................................636
		13.7.2 Identification...................................................................637
		13.7.3 Slinging points..................................................................638
		13.7.4 CHECKLIST: Rigging counterweight.................................................639
		13.7.5 CHECKLIST: Unrigging counterweight...............................................640
		13.7.6 Assembling counterweight versions................................................641
			On the turntable....................................................................641
			With the base plate.................................................................642
			With version A......................................................................644
			With version B......................................................................646
			With version C......................................................................648
		13.7.7 counterweight hoist unit.........................................................652
			Counterweight submenu...............................................................652
			Extending / retracting the lifting cylinders........................................653
			Automatic mode, rigging.............................................................654
			Automatic mode, unrigging...........................................................655
			Cancel automatic mode...............................................................656
		13.7.8 Removing / installing the counterweight on the turntable.........................657
			Mounting............................................................................658
			Removing............................................................................659
		13.7.9 Setting down counterweight for driving the truck crane...........................660
		13.7.10 Slewing with rigged counterweight...............................................662
	13.8 Rigging work on the main boom..........................................................665
		13.8.1 Hook block on the bumper.........................................................665
			Picking up the hook block...........................................................665
			Attaching the hook block............................................................666
		13.8.2 Hook block on a separate vehicle.................................................667
			Hook block (picking up).............................................................668
			Hook block (setting down)...........................................................668
		13.8.3 Reeving and unreeving the hoist rope.............................................670
			Fastening the rope end clamp........................................................670
			Reeving the hoist rope..............................................................672
			Hoist rope (unreeving)..............................................................675
		13.8.4 Possible reeving methods on the main boom........................................676
			With 7 head sheaves.................................................................676
			With 8 head sheaves.................................................................679
		13.8.5 Installing / removing the lifting limit switch...................................682
			Installing the lifting limit switch.................................................682
			Removing the lifting limit switch...................................................685
		13.8.6 Locking / Unlocking the lifting limit switch.....................................686
			Locking.............................................................................686
			Unlocking...........................................................................687
		13.8.7 Anemometer and air traffic control light.........................................688
			Mounting............................................................................688
			Removing............................................................................689
	13.9 Other rigging work.....................................................................691
		13.9.1 Rigging in free on wheels working position.......................................691
		13.9.2 Railings on the turntable........................................................693
		13.9.3 Mirror for crane operation.......................................................694
14 Driving the rigged truck crane...............................................................697
	14.1 Route..................................................................................698
	14.2 permissible rigging modes and axle loads...............................................698
		14.2.1 To drive without a load..........................................................698
		14.2.2 To drive with a load.............................................................699
		14.2.3 Axle loads.......................................................................699
	14.3 Before driving the rigged truck crane..................................................700
		14.3.1 Checking the tyre pressure and the wind speed....................................700
	14.4 Driving from the driver's cab..........................................................701
		14.4.1 Preparing to drive...............................................................701
			Transmission........................................................................701
			Switching on separate steering......................................................701
			Connections.........................................................................701
		14.4.2 While driving....................................................................702
	14.5 Driving from the crane cab.............................................................703
		14.5.1 Preparing to drive...............................................................704
		14.5.2 Opening / closing the Driving mode submenu.......................................704
			Automatically.......................................................................704
			Manually............................................................................706
			Closing.............................................................................706
		14.5.3 Starting / turning off the engine for driving....................................707
			To start the engine.................................................................707
			Turning off the engine..............................................................708
		14.5.4 Steering.........................................................................708
			Switching on........................................................................708
			Adapt steering direction............................................................708
			Displays when steering..............................................................709
			Normal steering.....................................................................709
			Separate steering...................................................................710
		14.5.5 Operating the transmission.......................................................711
			Driving direction...................................................................712
			Selecting the transmission mode.....................................................712
		14.5.6 Starting.........................................................................713
		14.5.7 While driving....................................................................713
		14.5.8 Warning messages.................................................................714
		14.5.9 Possible connections.............................................................715
			Longitudinal / transverse differential locks........................................716
		14.5.10 After driving...................................................................717
15 Malfunctions during crane operation..........................................................721
	15.1 Emergency stop switch..................................................................721
	15.2 What to do when a malfunction occurs during crane operation............................723
		Load can be lowered....................................................................723
		Load cannot be lowered..................................................................723
	15.3 Fuses..................................................................................725
		Notes on changing fuses.................................................................725
		15.3.1 Fuses on the turntable...........................................................726
			Fuse groups F1/F2...................................................................726
			Fuses on the circuit board..........................................................727
		15.3.2 Fuses in the crane cab...........................................................728
		15.3.3 Fuses in the battery box.........................................................730
		15.3.4 SLI fuses........................................................................731
	15.4 Finding and eliminating malfunctions...................................................733
		15.4.1 Malfunctions on the engine.......................................................733
		15.4.2 Malfunctions on the main hoist / auxiliary hoist.................................735
		15.4.3 Malfunctions on the derricking gear..............................................736
		15.4.4 Malfunctions in the telescoping mechanism........................................737
			Telescoping mechanism error messages................................................738
		15.4.5 Malfunctions on the slewing gear.................................................740
		15.4.6 Malfunctions on the counterweight hoist unit.....................................741
		15.4.7 Malfunctions in the hydraulic system / hydraulic oil cooler......................742
		15.4.8 Malfunctions when inclining the crane cab........................................742
		15.4.9 Malfunctions when operating with the hand-held control...........................742
		15.4.10 Malfunctions when driving from the crane cab....................................743
		15.4.11 Malfunctions on the outriggers..................................................744
		15.4.12 Troubleshooting on the SLI......................................................745
			General malfunctions................................................................745
			Error messages......................................................................746
			Table of error codes................................................................748
			Switching off the sensor / tachogenerator..........................................751
		15.4.13 Malfunctions ECOS – superstructure..............................................752
			ECOS program version................................................................752
			General malfunctions................................................................752
			Error messages......................................................................753
			Exiting the submenu.................................................................754
	15.5 Emergency operations and programs......................................................755
		15.5.1 Mechanical emergency operation for retracting....................................756
			Check prior to the emergency operation..............................................756
			Procedure...........................................................................756
			Mechanical emergency operation......................................................757
		15.5.2 Telescoping emergency program....................................................759
			Starting the emergency program......................................................759
			Determining the type of error.......................................................760
			If there is an error on the length indicator........................................761
			If there is an error on a proximity switch..........................................765
			Terminating the emergency program...................................................766
			Tables for approaching the locking points...........................................767
		15.5.3 Entering the current telescoping.................................................769
		15.5.4 Emergency operation with the hand-held control...................................771
			Preparations........................................................................771
			Operating a power unit..............................................................772
			Stopping movements..................................................................774
			Stopping movements in emergencies...................................................774
			Turning off the engine..............................................................774
		15.5.5 Switching on emergency operation in coolant circuit..............................775
	15.6 Hydraulic emergency operation..........................................................777
		15.6.1 Operating principle..............................................................777
		15.6.2 Connecting/disconnecting hoses...................................................778
		15.6.3 Activating/deactivating emergency operation......................................779
		15.6.4 Establishing the required hydraulic circuits.....................................780
			Switching over valves...............................................................780
			For lifting/ lowering..............................................................782
			For slewing.........................................................................783
		15.6.5 Carrying out emergency operation.................................................784
			Slewing.............................................................................784
			Derricking..........................................................................785
			Lifting/lowering....................................................................785
		15.6.6 After emergency operation........................................................786
			Switching offemergency operation..................................................786
			Switching to crane operation........................................................786
			Disconnecting the hoses.............................................................786
		15.6.7 Emergency supply of another crane................................................787
			Before emergency supply.............................................................787
			After emergency supply..............................................................787
16 Technical information for the superstructure.................................................791
	16.1 Technical data.........................................................................791
		16.1.1 Maximum lifting capacity (DIN / ISO / EN)........................................791
		16.1.2 Maximum lifting capacity (ANSI B 30.5)...........................................791
		16.1.3 Dimensions and weights of the truck crane, axle loads............................792
		16.1.4 Dimensions and weights of removable parts........................................792
			Hook blocks and hook tackle.........................................................792
			Counterweight parts.................................................................793
			Counterweight versions..............................................................793
		16.1.5 Superstructure...................................................................794
			Engine..............................................................................794
			Hoists..............................................................................794
			Slewing gear........................................................................794
			Derricking gear.....................................................................794
			Main boom...........................................................................795
			Lattice extension...................................................................795
			Operating speeds....................................................................795
17 Index........................................................................................799
	A...........................................................................................801
	B...........................................................................................801
	C...........................................................................................802
	D...........................................................................................803
	E...........................................................................................805
	F...........................................................................................807
	H...........................................................................................807
	I...........................................................................................808
	K...........................................................................................809
	L...........................................................................................809
	M...........................................................................................809
	O...........................................................................................810
	P...........................................................................................811
	R...........................................................................................811
	S...........................................................................................812
	T...........................................................................................813
	V...........................................................................................815
	W...........................................................................................815

Questions? Email us: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V