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Grove Crane GMK 4100 Part 1 Driving Operating Instruction Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 4100 Part 1 Driving Operating Instruction Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 4100 Part 1 Driving Operating Instruction Manual – PDF DOWNLOAD
Language : English
Pages : 894
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 4100 Part 1 Driving Operating Instruction Manual – 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.
How are the operating instructions structured?
Division :
The operating instructions are divided into two parts.
– Part 1 with chapters 1 to 9 contains a description of how to drive the truck
crane.
– Part 2 with chapters 10 to 17 contains a description of the crane operation.
One part on its own does not constitute a complete set of operating instructions;
both parts must be included with the truck crane.
The basic safety instructions, also for crane operation, are included in
chapter 2 only. Please read these safety instructions and observe them.
Structure of the chapters:
Chapters 3 and 10 are structured in relation to the product, and give an overview
of all operating elements on the truck crane. You will find cross-references
to the related brief descriptions, and from there, to further chapters.
Chapters 4 to 7 and 11 to 15 describe procedures, and are therefore structured
in relation to these operations. For more extensive processes, the
description is given with checklists and operation instructions.
– The checklists show the procedure in the required sequence, e.g. for rigging
work. From there, cross-references take you to the corresponding
operation descriptions.
– The operation descriptions describe the work in detail, including the
required warnings and safety instructions.
You are obliged to read these sections before using the truck crane for the
first time and if you are still unsure about how to operate the truck crane.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 4100 Part 1 Driving Operating Instruction Manual – PDF DOWNLOAD
GMK 4100 ............................................................................................... 1 Operating instructions Part 1 – Driving ............................................................ 1 Additional pages................................................................................ 3 Warning display STOP........................................................................ 3 New outriggers control units................................................................ 5 New control unit........................................................................ 6 Old control unit........................................................................ 6 Outriggers.............................................................................. 7 Outrigger pressure indicator............................................................ 7 Inclination indicators.................................................................. 7 SLI override................................................................................ 11 1 Overview...................................................................................... 27 1.1 Identification.......................................................................... 27 1.2 EC Declaration of Conformity............................................................ 31 1.3 Documentation supplied.................................................................. 32 1.4 Information about the operating instructions............................................ 33 1.4.1 What do the symbols used mean?.................................................... 33 1.4.2 How are the operating instructions structured?.................................... 35 Division............................................................................ 35 Structure of the chapters........................................................... 35 Structure of the pages.............................................................. 36 1.4.3 How do I find the information I need?............................................. 37 Cross-references example............................................................ 38 1.4.4 What information is available for operations planning?............................ 40 1.5 Conversion table for US measurements.................................................... 41 2 Basic safety instructions..................................................................... 45 2.1 Intended use............................................................................ 45 2.1.1 Improper use...................................................................... 46 2.2 Organisational measures................................................................. 47 2.3 Qualifications of the personnel......................................................... 49 2.4 Safety instructions for driving the truck crane......................................... 50 2.5 Safety instructions for crane operation................................................. 50 2.6 Information on transporting persons..................................................... 52 Equipment for lifting persons........................................................... 52 Personnel............................................................................... 52 Operation............................................................................... 53 Truck crane............................................................................. 54 3 Operating elements for driving................................................................ 57 3.1 Overview of the operating elements...................................................... 57 3.1.1 On the outside of the truck crane................................................. 58 3.1.2 Driver's cab...................................................................... 60 Overview............................................................................ 60 Behind the cover.................................................................... 62 3.1.3 Instrument panel.................................................................. 63 Left / right........................................................................ 63 Middle.............................................................................. 64 3.1.4 Display, driver's cab............................................................. 66 3.1.5 Steering column / steering wheel.................................................. 67 3.1.6 Transmission operating elements................................................... 68 3.1.7 Tachograph........................................................................ 69 3.1.8 ECOS control unit................................................................. 70 3.1.9 ECOS display – main menu.......................................................... 72 3.1.10 ECOS display – submenus.......................................................... 74 Level adjustment system submenu..................................................... 74 Settings submenu.................................................................... 76 Operating hours submenu............................................................. 77 Warning submenu..................................................................... 77 Transmission emergency program submenu.............................................. 78 Error submenu....................................................................... 79 3.1.11 Heating / Air-conditioning system................................................ 80 Standard heating system............................................................. 80 Auxiliary air heater – Version A.................................................... 81 Auxiliary air heater – Version B................................................... 82 Auxiliary water heater.............................................................. 83 3.1.12 Sockets for hand-held control.................................................... 84 3.1.13 Outrigger control units.......................................................... 85 3.2 Short description of the operating elements............................................. 87 3.2.1 Definition of positional references............................................... 87 Basic rules......................................................................... 87 Switches and buttons................................................................ 88 3.2.2 General information on the operating elements..................................... 88 3.2.3 General rules for buttons and symbols on the display.............................. 89 3.2.4 Engine............................................................................ 90 Steering column..................................................................... 90 Multipurpose switch................................................................. 90 Instrument panel.................................................................... 91 Main menu........................................................................... 92 3.2.5 Electrical system................................................................. 93 3.2.6 ECOS crane control................................................................ 93 Control unit........................................................................ 93 3.2.7 Transmission...................................................................... 96 Transmission display................................................................ 96 ECOS display........................................................................ 96 Operating elements................................................................. 97 Instrument panel.................................................................... 98 3.2.8 Transfer case..................................................................... 99 Main menu........................................................................... 99 3.2.9 Final drive.......................................................................100 3.2.10 Brakes...........................................................................101 Service brake.......................................................................101 Parking brake.......................................................................102 Additional brakes...................................................................103 3.2.11 Steering / separate steering.....................................................104 ECOS display........................................................................104 Driver's door.......................................................................104 3.2.12 Suspension.......................................................................105 3.2.13 Lighting / windscreen wipers / horn..............................................106 Steering column.....................................................................106 Instrument panel....................................................................106 Roof................................................................................108 3.2.14 Level adjustment system..........................................................108 3.2.15 Tachograph / speedometer.........................................................110 Tachograph..........................................................................110 Speedometer.........................................................................110 3.2.16 Diagnostics......................................................................111 Displays / submenu..................................................................111 3.2.17 On-board computer................................................................112 3.2.18 Push-up roof.....................................................................114 3.2.19 Windows, doors, keys.............................................................114 Window winder.......................................................................114 Doors...............................................................................115 Keys................................................................................115 3.2.20 Front flap.......................................................................116 3.2.21 Storage compartment..............................................................116 4 Starting / turning off the engine for driving.................................................119 4.1 Starting the engine from the driver's cab...............................................119 4.1.1 CHECKLIST: Starting the engine....................................................119 4.1.2 CHECKLIST: if the temperature is low..............................................122 4.1.3 Ladders and access ladders........................................................123 Access ladders......................................................................123 Ladders.............................................................................123 4.1.4 Refuelling........................................................................125 4.1.5 Checks before starting the engine.................................................126 On the hydraulic tank...............................................................126 Battery master switch...............................................................126 Checking the hand-held control......................................................127 4.1.6 Switching on the ignition.........................................................127 4.1.7 Lamp test / equalisation of the switching states..................................128 Lamp test...........................................................................128 Equalisation of the switching states................................................129 4.1.8 Display – setting the brightness..................................................130 4.1.9 To start the engine...............................................................131 Without flame start system..........................................................132 With flame start system.............................................................133 4.1.10 Checks after starting the engine.................................................134 4.1.11 Control elements.................................................................135 Instrument panel....................................................................135 ECOS display........................................................................136 Display, driver's cab...............................................................136 4.1.12 Setting the idling speed.........................................................137 4.2 Turning off the engine..................................................................139 4.2.1 On the ignition lock / with hand-held control.....................................139 After turning off...................................................................139 4.2.2 With emergency stop switches......................................................140 Resetting the emergency stop switch.................................................140 4.3 Air intake inhibitor....................................................................141 Releasing the air intake inhibitor......................................................141 5 Driving.......................................................................................145 5.1 Before driving..........................................................................145 5.1.1 CHECKLIST: inspections before on-road driving.....................................145 5.1.2 Checking the condition of the truck crane.........................................150 Windscreen washing system...........................................................150 Electrical system...................................................................150 Adjusting the mirrors...............................................................151 Warning plates for vehicle width....................................................152 Displaying the vehicle height.......................................................152 Supply pressure.....................................................................153 Parking brake.......................................................................154 5.1.3 Adjusting the seats and steering column...........................................155 Driver's seat.......................................................................155 Passenger's seat....................................................................156 Adjusting the steering column.......................................................157 5.1.4 Switching the suspension on / off.................................................158 Opening the submenu.................................................................158 Switching on the suspension.........................................................159 To switch off the suspension........................................................159 5.1.5 Adjusting the tachograph..........................................................160 Prerequisites.......................................................................160 In the event of malfunctions........................................................160 Adjusting the tachograph............................................................161 Additional displays.................................................................164 5.1.6 Displaying the operating hours....................................................165 5.1.7 Settings / displays with the on-board computer....................................166 Operation...........................................................................166 Overview............................................................................167 Inspection information..............................................................167 Error information...................................................................168 Alarm clock.........................................................................168 Language............................................................................169 Settings............................................................................169 Diagnostics.........................................................................170 5.2 Operating the transmission..............................................................173 5.2.1 Switching on......................................................................173 5.2.2 Switching the transmission to neutral position....................................174 5.2.3 Changing the operating mode.......................................................174 Change-over to automatic mode.......................................................174 Change-over to manual mode..........................................................174 5.2.4 Display of the selected gears.....................................................175 5.2.5 Selecting the direction of travel and starting gear...............................175 Selecting the driving direction.....................................................175 Selecting the starting gear.........................................................176 5.2.6 Starting..........................................................................177 5.2.7 Driving and changing gears........................................................178 In automatic operating mode.........................................................178 In manual operating mode............................................................179 5.2.8 Changing the driving direction....................................................180 Quick change of gear................................................................180 5.2.9 Stopping..........................................................................181 Stopping for a long period of time..................................................181 5.2.10 On the roller type dynamometer...................................................181 5.3 Driving and turning off the truck crane.................................................183 5.3.1 Inspections while driving.........................................................183 Immediately after you start to move.................................................183 While driving.......................................................................184 5.3.2 Tempomat..........................................................................185 Switching on........................................................................185 Switching off.......................................................................186 5.3.3 Temposet..........................................................................187 Switching on........................................................................187 Switching off.......................................................................187 5.3.4 Driving downhill..................................................................188 Starting............................................................................188 Inspections when driving downhill...................................................188 Downshifting........................................................................189 Additional brakes...................................................................190 5.3.5 Driving uphill....................................................................191 Starting............................................................................191 Driving.............................................................................191 5.3.6 Warning submenu...................................................................192 Meaning of the symbols..............................................................192 Exiting the submenu.................................................................193 5.3.7 Error submenu.....................................................................194 5.3.8 Messages on the on-board computer display.........................................194 Warnings............................................................................195 Warning messages....................................................................196 Error messages......................................................................197 Information.........................................................................199 5.3.9 Turning off the truck crane.......................................................202 Secure against rolling away.........................................................202 When stationary for more than 8hours...............................................203 5.4 Off-road driving........................................................................205 Adjustments to the transmission.........................................................205 Connections.............................................................................205 Changing the vehicle level..............................................................205 Rocking the vehicle free and towing.....................................................205 5.4.1 Transfer case – off-road gear on / off............................................206 Neutral position....................................................................206 5.4.2 Longitudinal and transverse differential locks....................................207 5.4.3 Operation of the level adjustment system..........................................209 Opening the submenu.................................................................209 Setting the on-road level...........................................................210 Pre-selecting suspension struts.....................................................210 Changing the vehicle level..........................................................211 Viewing the current inclination.....................................................211 Exiting the submenu.................................................................212 5.4.4 Freeing the truck crane stuck in terrain..........................................213 Rocking the truck crane free........................................................213 Towing free forwards................................................................214 Towing free in reverse gear.........................................................214 5.4.5 Separate steering.................................................................215 Switching to separate steering......................................................215 Steering............................................................................216 Switching to normal steering mode...................................................217 5.5 Heating and air-conditioning system.....................................................219 5.5.1 Standard heating system...........................................................219 Switching on........................................................................219 Heating.............................................................................219 Air distribution....................................................................220 Examples............................................................................221 Switching off.......................................................................221 5.5.2 Air-conditioning system...........................................................222 Warnings............................................................................222 Switching on / off..................................................................222 Cooling.............................................................................223 Drying..............................................................................223 5.5.3 Auxiliary air heater – Version A..................................................224 Switching on........................................................................224 Temperature.........................................................................225 Setting the day and time............................................................225 Storing the heating start...........................................................226 Setting the heating period..........................................................227 Switching the heating start on and off..............................................227 Switching off.......................................................................228 Setting the remaining time..........................................................228 5.5.4 Auxiliary air heater – Version B..................................................229 Switching on........................................................................229 Setting the heating level...........................................................230 Setting the day and time............................................................231 Setting the preselection time.......................................................231 Setting the heating period..........................................................233 Deleting preselection times.........................................................233 Switching off.......................................................................233 5.5.5 Auxiliary water heater............................................................234 Preheating the engine...............................................................234 Preheating the driver's cab.........................................................235 Switching on........................................................................235 Setting the day and time............................................................236 Storing the heating start...........................................................237 Setting the heating period..........................................................238 Switching heating start on / off....................................................238 Switching off.......................................................................239 Setting the remaining time..........................................................239 5.6 Towing a trailer........................................................................241 Effects on the axle loads...............................................................241 Coupling the trailer....................................................................242 Connecting the supply lines.............................................................243 Removing the supply lines...............................................................244 Uncoupling the trailer..................................................................244 Checking the braking force..............................................................246 6 Driving modes.................................................................................249 6.1 Driving modes...........................................................................249 Information on the axle loads...........................................................249 6.1.1 Information on how to use the tables..............................................250 6.1.2 Table for a maximum axle load of 12 t (26500 lbs)................................251 For 14.00 R25 tyres.................................................................251 For 16.00 R25 tyres.................................................................252 For 20.5 R25 tyres..................................................................253 6.1.3 Maximum permitted speeds with an axle load of over 12 t (26500 lbs)..............254 6.2 Rigging work for driving with a trailer.................................................255 6.2.1 Switching on the slewing gear freewheel...........................................256 6.2.2 Switching on boom floating position...............................................257 6.2.3 Switching on boom pre-tensioning..................................................258 6.2.4 Switching the superstructure driving lights on / off..............................260 Switching off.......................................................................260 Switching on........................................................................260 7 Malfunctions in driving mode..................................................................263 7.1 Emergency stop switch...................................................................263 7.2 What to do when a malfunction occurs in road traffic....................................265 7.3 Towing the truck crane..................................................................267 7.3.1 Towing in the event of engine or transmission damage..............................268 Compressed-air supply...............................................................268 Electric power supply...............................................................268 On the transmission.................................................................269 Axle drives.........................................................................270 Transfer case.......................................................................270 Parking brake.......................................................................270 Towing the truck crane out of the danger area.......................................271 7.3.2 Starting to tow...................................................................272 7.4 Wheels and tyres........................................................................273 7.4.1 Wheel change......................................................................273 Removing a damaged wheel............................................................274 On the spare wheel holder...........................................................274 Mounting a wheel....................................................................275 7.4.2 Filling the tyres yourself........................................................277 Connecting the filling hose.........................................................277 Filling the tyres...................................................................278 Removing the filling hose...........................................................278 7.5 Fuses...................................................................................279 Notes on changing fuses.................................................................279 7.5.1 Fuses in the driver's cab.........................................................280 F1 to F 41..........................................................................280 A1 to A3............................................................................282 7.5.2 Fuses in the battery box..........................................................284 7.6 Finding and eliminating malfunctions....................................................285 7.6.1 Malfunctions on the engine........................................................285 7.6.2 Malfunctions on the transmission..................................................287 7.6.3 Service brake malfunctions........................................................288 7.6.4 Steering malfunctions.............................................................289 7.6.5 Transfer case malfunctions........................................................289 7.6.6 Malfunctions in the differential locks............................................290 7.6.7 Malfunctions in the hydraulic system / hydraulic oil cooler.......................290 7.6.8 Malfunctions on the suspension....................................................291 7.6.9 Malfunctions on the level adjustment system.......................................291 7.6.10 Malfunctions on the ECOS carrier.................................................292 ECOS program version................................................................292 General malfunctions................................................................292 Error messages......................................................................293 Exiting the submenu.................................................................294 On the control units................................................................295 7.7 Procedure in the event of malfunctions..................................................297 7.7.1 Switching on emergency operation in coolant circuit...............................297 7.7.2 Procedure in the event of malfunctions to the transmission and engine.............298 Engine..............................................................................298 Transmission........................................................................299 Transmission emergency program submenu..............................................300 Emergency gear shift................................................................303 Switching gears pneumatically in emergency mode....................................304 Switching gears mechanically in emergency mode......................................306 ID number of the transmission.......................................................309 8 Technical information on the carrier..........................................................313 8.1 Technical data..........................................................................313 8.1.1 Dimensions and weights of the truck crane, axle loads.............................314 Dimensions..........................................................................315 Weight and axle loads...............................................................315 8.1.2 Dimensions and weights of removable parts.........................................316 Spare wheel.........................................................................316 Outriggers..........................................................................316 8.1.3 Carrier...........................................................................317 Engine..............................................................................317 Transmission........................................................................317 Transfer case.......................................................................317 Axle lines..........................................................................317 Steering............................................................................317 Tyres...............................................................................317 Electrical system...................................................................318 Tools...............................................................................318 Towing couplings....................................................................318 Outriggers..........................................................................318 Driving speeds......................................................................319 Climbing ability....................................................................319 Turning circle radiuses.............................................................319 9 Index.........................................................................................323 A...........................................................................................325 B...........................................................................................325 C...........................................................................................326 D...........................................................................................327 E...........................................................................................329 F...........................................................................................331 H...........................................................................................331 I...........................................................................................332 K...........................................................................................333 L...........................................................................................333 M...........................................................................................334 O...........................................................................................334 P...........................................................................................335 R...........................................................................................335 S...........................................................................................336 T...........................................................................................338 V...........................................................................................340 W...........................................................................................340 Operating instructions Part 2 – Crane operation ....................................................343 Additional pages................................................................................345 SLI override................................................................................345 New outriggers control units................................................................357 New control unit........................................................................358 Old control unit........................................................................358 Outriggers..............................................................................359 Outrigger pressure indicator............................................................359 Inclination indicators..................................................................359 Warning display STOP........................................................................363 10 Operating elements for crane operation.......................................................369 10.1 Overview of the operating elements.....................................................369 10.1.1 On the outside of the truck crane................................................370 10.1.2 Crane cab........................................................................372 10.1.3 Front panel......................................................................374 10.1.4 Side panel.......................................................................375 Bottom..............................................................................375 Top.................................................................................376 Rear panel..........................................................................378 Standard heating system.............................................................379 Auxiliary water heater..............................................................380 Auxiliary air heater................................................................381 10.1.5 Control panels...................................................................382 Left................................................................................382 Right...............................................................................383 10.1.6 Control lever assignment.........................................................384 Version 1...........................................................................384 Version 2...........................................................................385 10.1.7 ECOS control unit................................................................386 10.1.8 ECOS display – main menu.........................................................388 10.1.9 ECOS display – submenus..........................................................390 Counterweight submenu...............................................................390 Slewing gear / Houselock submenu....................................................391 Outriggers submenu..................................................................392 Telescoping submenu.................................................................394 Power unit speeds submenu...........................................................396 Monitoring submenu..................................................................397 Settings submenu....................................................................398 Operating hours submenu.............................................................400 Warning submenu.....................................................................401 Error submenu.......................................................................403 Working range limitation submenu....................................................404 Driving submenu.....................................................................406 10.1.10 SLI control unit................................................................408 10.1.11 Hand-held control...............................................................412 Outriggers control panel............................................................413 10.1.12 Outrigger control units.........................................................414 Outriggers..........................................................................415 Outrigger pressure display..........................................................415 Inclination display.................................................................415 10.2 Short description of the operating elements............................................417 10.2.1 Definition of positional references..............................................417 Basic rule..........................................................................417 Switch..............................................................................418 10.2.2 General rules for buttons and symbols on the display.............................418 10.2.3 Engine for crane operation.......................................................419 Side panel..........................................................................419 Rear panel..........................................................................420 ECOS display........................................................................420 10.2.4 Engine for driving...............................................................420 Side panel..........................................................................420 Main menu...........................................................................420 Outriggers submenu..................................................................421 10.2.5 Seat contact switch and dead man's switch........................................422 10.2.6 ECOS crane control...............................................................423 Control unit........................................................................423 10.2.7 Outriggers.......................................................................426 Hand-held control...................................................................426 In the outriggers submenu...........................................................427 In the settings submenu.............................................................428 On the outrigger control units......................................................429 10.2.8 Inclination displays.............................................................431 10.2.9 Outrigger pressure displays......................................................432 Outriggers submenu..................................................................432 Outrigger control units.............................................................432 10.2.10 Anemometer display..............................................................432 10.2.11 Counterweight submenu...........................................................433 Counterweight submenu...............................................................433 10.2.12 Main hoist......................................................................436 10.2.13 Auxiliary hoist.................................................................438 10.2.14 Slewing gear....................................................................439 Submenu.............................................................................440 10.2.15 Derricking gear.................................................................443 10.2.16 Telescoping mechanism...........................................................444 Control panels......................................................................444 Submenu.............................................................................445 In the settings submenu.............................................................449 10.2.17 Hydraulic system................................................................451 10.2.18 Houselock.......................................................................452 10.2.19 Safe load indicator (SLI).......................................................453 Input elements with displays........................................................453 Display elements....................................................................455 On the front panel..................................................................458 10.2.20 Electrical system...............................................................459 10.2.21 Lighting, windscreen wiper / washing system.....................................459 Lighting............................................................................459 Windscreen wiper/ washing system...................................................461 10.2.22 Hand-held control...............................................................462 Sockets for hand- held control......................................................462 Engine control panel................................................................463 Horn................................................................................463 Outriggers control panel............................................................464 10.2.23 Diagnostics.....................................................................466 10.2.24 Windows, doors, keys............................................................467 Windows.............................................................................467 Crane cab door......................................................................467 Keys................................................................................468 10.3 Short description of the operating elements – driving from the crane cab...............469 10.3.1 Driving submenu..................................................................469 10.3.2 Engine for driving...............................................................470 10.3.3 Transmission.....................................................................471 10.3.4 Final drive......................................................................472 10.3.5 Brakes...........................................................................473 Side panel..........................................................................473 ECOS display........................................................................473 10.3.6 Steering.........................................................................474 Normal steering.....................................................................475 Separate steering...................................................................475 11 Starting / turning off the engine – for crane operation......................................479 11.1 Starting the engine – from the crane cab...............................................479 11.1.1 CHECKLIST: Starting the engine...................................................479 11.1.2 CHECKLIST: If the temperature is low.............................................482 11.1.3 Refuelling.......................................................................483 For standard equipment..............................................................483 With additional equipment...........................................................484 11.1.4 Inspections before starting the engine...........................................485 On the hydraulic tank...............................................................485 Battery master switch...............................................................485 Checking the hand-held control......................................................486 11.1.5 Switch on the ignition...........................................................486 11.1.6 Lamp test / equalisation of the switching states.................................487 Lamp test...........................................................................487 Equalisation of the switching states................................................488 11.1.7 Set brightness of display........................................................489 11.1.8 To start the engine..............................................................490 Without flame start system..........................................................490 With flame start system.............................................................491 11.1.9 Inspections after starting the engine............................................492 11.1.10 Monitoring submenu..............................................................493 11.1.11 Setting the idling speed........................................................494 11.2 Starting the engine – with the hand-held control.......................................495 Prerequisites...........................................................................495 To start the engine.....................................................................495 11.3 Turning off the engine.................................................................497 11.3.1 During normal operation, with the ignition lock / with the hand- held control....497 After parking.......................................................................497 11.3.2 In emergencies, with the emergency-stop switches.................................498 Resetting the emergency stop switch.................................................498 11.4 Air intake inhibitor...................................................................499 Releasing the air intake inhibitor......................................................499 12 Crane operation..............................................................................503 12.1 Before crane operation.................................................................503 12.1.1 CHECKLIST: Inspections prior to crane operation..................................503 12.1.2 Checking the condition of the truck crane........................................507 Tank for windscreen washing system..................................................507 Auxiliary heater – tank.............................................................507 Visual inspection...................................................................508 Checking the position of the hoist ropes............................................508 Checking the electrical system......................................................509 12.1.3 Adjusting the crane cab seat and front panel.....................................509 Crane cab seat......................................................................509 Front panel.........................................................................510 12.1.4 Checking the safety devices......................................................511 Safe load indicator.................................................................511 Lifting limit switch................................................................511 Emergency stop switch...............................................................512 Seat contact switch.................................................................513 12.1.5 Earthing the load................................................................514 12.1.6 Preheating the hydraulic oil.....................................................515 12.1.7 Switching the houselock on / off.................................................516 Switching on the houselock..........................................................516 Switching off the houselock.........................................................518 12.2 Operation of the safe load indicator...................................................519 12.2.1 Switching on the SLI.............................................................520 Switching on........................................................................520 Lamp test on the SLI................................................................522 Brightness of the displays..........................................................522 12.2.2 Entering the rigging mode........................................................523 Entering the SLI code...............................................................524 Entering the reeving................................................................527 Entering individual components......................................................528 12.2.3 Inspections prior to crane operation.............................................531 12.2.4 Displays during crane operation..................................................533 Continuous displays.................................................................533 Optional displays...................................................................535 12.2.5 SLI early warning................................................................537 12.2.6 SLI shutdown.....................................................................538 Shutdown due to overload............................................................538 12.2.7 Error message....................................................................539 12.2.8 SLI override.....................................................................540 12.2.9 Displaying and entering the time and date........................................541 Display.............................................................................541 Input...............................................................................542 12.3 Crane operation with main boom.........................................................543 12.3.1 Checks during crane operation....................................................543 Horizontal alignment................................................................543 Safe distances......................................................................543 Checking the wind speed.............................................................544 12.3.2 Permissible slewing ranges and working positions.................................545 360 slewing range..................................................................545 0 to the rear working position.....................................................545 180 to the front rigging position..................................................546 Free-on-wheels working position.....................................................546 12.3.3 Main hoist.......................................................................547 Switching on the main hoist.........................................................548 Lifting and lowering................................................................548 Switching off the main hoist........................................................549 12.3.4 Auxiliary hoist..................................................................550 Switching on the auxiliary hoist....................................................550 Lifting and lowering................................................................551 Switching off the auxiliary hoist...................................................552 12.3.5 Lifting limit switch and lowering limit switch...................................553 Lifting limit switch................................................................553 Lowering limit switch...............................................................555 12.3.6 Derricking gear..................................................................556 Switching on the derricking gear....................................................556 Raising and lowering the boom.......................................................557 Switching off the derricking gear...................................................558 Lowering the main boom to a horizontal position.....................................558 12.3.7 Telescoping mechanism............................................................559 Overview............................................................................560 Telescoping process................................................................560 Assignment for display..............................................................562 Fixed length, intermediate length, telescoping length...............................564 Telescoping.........................................................................565 Telescoping sequence................................................................565 Inspections prior to starting operations............................................566 Switching on the telescoping mechanism..............................................567 Function of the control lever.......................................................567 Switching off the telescoping mechanism.............................................569 Manual telescoping.................................................................570 Checking the initial position.......................................................570 Unlocking the telescoping cylinder................................................573 Extending / retracting the telescoping cylinder.....................................575 Locking the telescoping cylinder....................................................576 Unlocking the telescopic section...................................................577 Telescoping the telescopic section..................................................579 Locking the telescopic section......................................................580 Locking the telescopic section for on-road driving..................................581 Telescopic extension with teleautomation............................................582 Telescoping the main boom in horizontal position....................................586 12.3.8 High speed.......................................................................587 Switch on function..................................................................587 Derricking gear / Telescoping mechanism.............................................587 Hoists..............................................................................588 12.3.9 Slewing gear.....................................................................589 Slewing gear brake..................................................................589 Switching on the slewing gear.......................................................590 Releasing the slewing gear brake....................................................590 Engaging the slewing gear brake....................................................590 Slewing.............................................................................591 Slewing to 0 or 180 ...............................................................593 Braking the slewing movement........................................................594 Slewing gear freewheel..............................................................594 Switching off the slewing gear......................................................595 12.3.10 Possible movement combinations..................................................595 12.3.11 Hydraulic oil cooling...........................................................596 12.4 Settings and displays for crane operation..............................................597 12.4.1 Inclining the crane cab..........................................................597 12.4.2 Setting the idling speed.........................................................597 12.4.3 Adjusting the stroke interval of the windscreen wiper............................598 12.4.4 Limiting the power unit speeds...................................................598 12.4.5 Setting the characteristic curve for the control levers..........................600 12.4.6 Critical load control............................................................601 Function............................................................................601 Switching on and off................................................................601 12.4.7 Operation of the directional spotlights..........................................602 12.4.8 Displaying the operating hours...................................................603 12.4.9 Warning submenu..................................................................604 Meaning of the symbols..............................................................604 Exiting the submenu.................................................................607 12.4.10 Error submenu...................................................................607 12.5 Working range limiter..................................................................609 12.5.1 Opening the Working range limiter submenu........................................610 12.5.2 Viewing current settings.........................................................610 12.5.3 Entering limit values............................................................612 Overall height / Working radius.....................................................612 Slewing angle.......................................................................613 Entering objects....................................................................615 12.5.4 Entering limit values / objects manually.........................................618 Limit values........................................................................618 Objects.............................................................................619 12.5.5 Switching monitoring functions on / off..........................................620 12.5.6 Shutdown by working range limiter................................................621 12.6 Work break.............................................................................623 12.6.1 Short work breaks................................................................623 12.6.2 Work breaks of more than 8 hours.................................................624 To secure the truck crane...........................................................624 12.7 Heating and air-conditioning system....................................................625 12.7.1 Standard heating system..........................................................625 Switching on........................................................................625 Heating.............................................................................625 Air distribution....................................................................626 Switching off.......................................................................627 12.7.2 Air-conditioning system..........................................................627 Warnings............................................................................627 Switching on/off....................................................................628 Cooling.............................................................................628 Drying the air......................................................................629 12.7.3 Auxiliary water heating system...................................................629 Preheating the engine...............................................................630 Preheating the crane cab............................................................630 Switching on........................................................................631 Setting the day and time............................................................632 Storing the heating start..........................................................633 Setting the heating period.........................................................634 Switching heating start on/off......................................................634 Switching off.......................................................................635 Setting the remaining run time......................................................635 12.7.4 Auxiliary air heater.............................................................636 Switching on........................................................................636 Temperature.........................................................................637 Switching off.......................................................................637 Other functions.....................................................................637 12.8 CraneSTAR System.......................................................................639 12.8.1 Overview.........................................................................639 12.8.2 Position of the components.......................................................639 13 Rigging work.................................................................................643 13.1 Rigging work checklists for crane operation with the main boom.........................643 13.1.1 CHECKLIST: Rigging...............................................................643 13.1.2 CHECKLIST: Unrigging.............................................................647 13.2 Choosing a suitable site...............................................................651 13.2.1 Determining the required ground bearing area.....................................651 13.2.2 Safe distance from slopes and pits...............................................654 13.2.3 Earthing the truck crane.........................................................655 13.2.4 Safe distance from electrical lines..............................................656 13.3 Rigging work after driving with a trailer..............................................659 13.3.1 Switching off the boom floating position.........................................659 13.3.2 Switching off the slewing gear freewheel.........................................660 Before slewing......................................................................660 13.3.3 Switching off boom pre-tensioning................................................661 13.4 Connecting / disconnecting the hand-held control.......................................663 13.5 Starting the engine for driving for rigging work.......................................665 13.5.1 Starting / turning off the engine with the hand-held control.....................665 Prerequisites.......................................................................665 To start the engine.................................................................666 Turning off the engine..............................................................666 13.5.2 Starting / turning off the engine from the crane cab.............................667 Prerequisites.......................................................................667 To start the engine.................................................................667 After starting the engine...........................................................668 Turning off the engine..............................................................668 13.6 Outriggers.............................................................................669 13.6.1 CHECKLIST: Extending the outriggers..............................................669 13.6.2 CHECKLIST: Retracting the outriggers.............................................671 13.6.3 Permissible outrigger spans......................................................672 13.6.4 Preparing the truck crane........................................................673 In the driver's cab.................................................................673 Control units (outrigger)...........................................................673 13.6.5 Setting the spans................................................................674 For on-road driving.................................................................675 13.6.6 Extending / retracting outriggers................................................676 From the control units..............................................................677 With the hand- held control.........................................................678 From the crane cab..................................................................680 13.6.7 Moving the outrigger pads into working / driving position........................682 13.6.8 Enlarging the ground bearing area................................................683 13.6.9 Extending / retracting supporting cylinders......................................685 From the control units..............................................................686 With the hand- held control.........................................................687 From the crane cab..................................................................688 13.6.10 Levelling the truck crane on outriggers.........................................690 Inclination displays................................................................690 Prerequisites.......................................................................691 Manual alignment....................................................................692 Automatic alignment.................................................................693 13.6.11 Levelling the free-standing truck crane.........................................695 13.6.12 Outrigger pressure display......................................................697 13.7 Rigging / unrigging the counterweight..................................................699 13.7.1 Counterweight parts..............................................................699 Version A...........................................................................699 Version B...........................................................................700 Version C...........................................................................700 13.7.2 Identification...................................................................701 13.7.3 Slinging points..................................................................702 13.7.4 CHECKLIST: Rigging counterweight.................................................703 13.7.5 CHECKLIST: Unrigging counterweight...............................................704 13.7.6 Assembling counterweight versions................................................705 On the turntable....................................................................705 With the base plate.................................................................706 With version A......................................................................708 With version B......................................................................710 With version C......................................................................712 13.7.7 counterweight hoist unit.........................................................716 Counterweight submenu...............................................................716 Extending / retracting the lifting cylinders........................................717 Automatic mode, rigging.............................................................718 Automatic mode, unrigging...........................................................719 Cancel automatic mode...............................................................720 13.7.8 Removing / installing the counterweight on the turntable.........................721 Mounting............................................................................722 Removing............................................................................723 13.7.9 Setting down counterweight for driving the truck crane...........................724 13.7.10 Slewing with rigged counterweight...............................................726 13.8 Rigging work on the main boom..........................................................729 13.8.1 Hook block on the bumper.........................................................729 Picking up the hook block...........................................................729 Attaching the hook block............................................................730 13.8.2 Hook block on a separate vehicle.................................................731 Hook block (picking up).............................................................732 Hook block (setting down)...........................................................732 13.8.3 Reeving and unreeving the hoist rope.............................................734 Fastening the rope end clamp........................................................734 Reeving the hoist rope..............................................................736 Hoist rope (unreeving)..............................................................739 13.8.4 Possible reeving methods on the main boom........................................740 With 7 head sheaves.................................................................740 With 8 head sheaves.................................................................743 13.8.5 Installing / removing the lifting limit switch...................................746 Installing the lifting limit switch.................................................746 Removing the lifting limit switch...................................................749 13.8.6 Locking / Unlocking the lifting limit switch.....................................750 Locking.............................................................................750 Unlocking...........................................................................751 13.8.7 Anemometer and air traffic control light.........................................752 Mounting............................................................................752 Removing............................................................................753 13.9 Other rigging work.....................................................................755 13.9.1 Rigging in free on wheels working position.......................................755 13.9.2 Railings on the turntable........................................................757 13.9.3 Mirror for crane operation.......................................................758 14 Driving the rigged truck crane...............................................................761 14.1 Safety instructions....................................................................761 14.2 Route..................................................................................763 14.3 Before driving the rigged truck crane..................................................763 14.3.1 Checking the tyre pressure and the wind speed....................................763 14.4 Permissible rigging modes and axle loads...............................................765 14.4.1 Axle loads.......................................................................765 14.4.2 To drive without a load..........................................................765 14.4.3 To drive with a load.............................................................766 14.5 Driving from the driver's cab..........................................................767 14.5.1 Preparing to drive...............................................................767 Transmission........................................................................767 Switching on separate steering......................................................767 Connections.........................................................................767 14.5.2 While driving....................................................................768 14.6 Driving from the crane cab.............................................................769 14.6.1 Preparing to drive...............................................................769 14.6.2 Opening / closing the Driving mode submenu.......................................770 Automatically.......................................................................770 Manually............................................................................772 Closing.............................................................................772 14.6.3 Starting / turning off the engine for driving....................................773 To start the engine.................................................................773 Turning off the engine..............................................................774 14.6.4 Steering.........................................................................774 Switching on........................................................................774 Adapt steering direction............................................................774 Displays when steering..............................................................775 Normal steering.....................................................................775 Separate steering...................................................................776 14.6.5 Operating the transmission.......................................................777 Driving direction...................................................................778 Selecting the transmission mode.....................................................778 14.6.6 Starting.........................................................................779 14.6.7 While driving....................................................................779 14.6.8 Warning messages.................................................................780 14.6.9 Possible connections.............................................................781 Longitudinal / transverse differential locks........................................782 14.6.10 After driving...................................................................783 14.7 Driving in combined operation..........................................................785 14.7.1 Switching combined operation on/off..............................................785 Prerequisites.......................................................................785 Switching on........................................................................786 Switching off.......................................................................786 14.7.2 Starting/turning off the engine..................................................787 14.7.3 Preparing to drive...............................................................788 Transmission........................................................................788 Switching on separate steering......................................................788 Connections.........................................................................788 14.7.4 While driving....................................................................789 Without load........................................................................789 With load...........................................................................790 15 Malfunctions during crane operation..........................................................793 15.1 Emergency stop switch..................................................................793 15.2 What to do when a malfunction occurs during crane operation............................795 Load can be lowered....................................................................795 Load cannot be lowered..................................................................795 15.3 Fuses..................................................................................797 Notes on changing fuses.................................................................797 15.3.1 Fuses on the turntable...........................................................798 Fuse groups F1/F2...................................................................798 Fuses on the circuit board..........................................................799 15.3.2 Fuses in the crane cab...........................................................800 15.3.3 Fuses in the battery box.........................................................802 15.3.4 SLI fuses........................................................................803 15.4 Finding and eliminating malfunctions...................................................805 15.4.1 Malfunctions on the engine.......................................................805 15.4.2 Malfunctions on the main hoist / auxiliary hoist.................................807 15.4.3 Malfunctions on the derricking gear..............................................808 15.4.4 Malfunctions in the telescoping mechanism........................................809 Telescoping mechanism error messages................................................811 15.4.5 Malfunctions on the slewing gear.................................................812 15.4.6 Malfunctions on the counterweight hoist unit.....................................813 15.4.7 Malfunctions in the hydraulic system / hydraulic oil cooler......................814 15.4.8 Malfunctions when inclining the crane cab........................................814 15.4.9 Malfunctions when operating with the hand-held control...........................814 15.4.10 Malfunctions when driving from the crane cab....................................815 15.4.11 Malfunctions on the outriggers..................................................816 15.4.12 Troubleshooting on the SLI......................................................817 General malfunctions................................................................817 Error messages......................................................................818 Table of error codes................................................................820 Switching off the sensor / tachogenerator..........................................823 15.4.13 Malfunctions ECOS – superstructure..............................................824 ECOS program version................................................................824 General malfunctions................................................................824 Error messages......................................................................825 Exiting the submenu.................................................................826 15.4.14 Troubleshooting at the CraneStar system.........................................827 15.5 Emergency operations and programs......................................................831 15.5.1 Mechanical emergency operation for retracting....................................832 Check prior to the emergency operation..............................................832 Procedure...........................................................................832 Mechanical emergency operation......................................................833 15.5.2 Telescoping emergency program....................................................835 Starting the emergency program......................................................835 Determining the type of error.......................................................836 If there is an error on the length indicator........................................837 If there is an error on a proximity switch..........................................841 Terminating the emergency program...................................................842 Tables for approaching the locking points...........................................843 15.5.3 Entering the current telescoping.................................................845 15.5.4 Emergency operation with the hand-held control...................................847 Preparations........................................................................847 Operating a power unit..............................................................848 Stopping movements..................................................................850 Stopping movements in emergencies...................................................850 Turning off the engine..............................................................850 15.5.5 Switching on emergency operation in coolant circuit..............................851 15.6 Hydraulic emergency operation..........................................................853 15.6.1 Operating principle..............................................................853 15.6.2 Connecting/disconnecting hoses...................................................854 15.6.3 Activating/deactivating emergency operation......................................855 15.6.4 Establishing the required hydraulic circuits.....................................856 Switching over valves...............................................................856 For lifting/ lowering..............................................................858 For slewing.........................................................................859 15.6.5 Carrying out emergency operation.................................................860 Slewing.............................................................................860 Derricking..........................................................................861 Lifting/lowering....................................................................861 15.6.6 After emergency operation........................................................862 Switching offemergency operation..................................................862 Switching to crane operation........................................................862 Disconnecting the hoses.............................................................862 15.6.7 Emergency supply of another crane................................................863 Before emergency supply.............................................................863 After emergency supply..............................................................863 16 Technical information for the superstructure.................................................867 16.1 Technical data.........................................................................867 16.1.1 Maximum lifting capacity (DIN / ISO / EN)........................................867 16.1.2 Maximum lifting capacity (ANSI B 30.5)...........................................867 16.1.3 Dimensions and weights of the truck crane, axle loads............................868 16.1.4 Dimensions and weights of removable parts........................................868 Hook blocks and hook tackle.........................................................868 Counterweight parts.................................................................869 Counterweight versions..............................................................869 16.1.5 Superstructure...................................................................870 Engine..............................................................................870 Hoists..............................................................................870 Slewing gear........................................................................870 Derricking gear.....................................................................870 Main boom...........................................................................871 Lattice extension...................................................................871 Operating speeds....................................................................871 17 Index........................................................................................875 A...........................................................................................877 B...........................................................................................877 C...........................................................................................878 D...........................................................................................879 E...........................................................................................881 F...........................................................................................883 H...........................................................................................883 I...........................................................................................884 K...........................................................................................885 L...........................................................................................885 M...........................................................................................886 O...........................................................................................886 P...........................................................................................887 R...........................................................................................887 S...........................................................................................888 T...........................................................................................890 V...........................................................................................892 W...........................................................................................892 Unbenannt............................................................................................... 5
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