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Grove Crane GMK 5100 Carrier & Superstructure Operating Instruction Manual SN 2084598 – PDF DOWNLOAD
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Grove Crane GMK 5100 Carrier & Superstructure Operating Instruction Manual SN 2084598 – PDF DOWNLOAD
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Description
Grove Crane GMK 5100 Carrier & Superstructure Operating Instruction Manual SN 2084598 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5100 Carrier & Superstructure Operating Instruction Manual SN 2084598 – PDF DOWNLOAD
Language : English
Pages : 672
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5100 Carrier & Superstructure Operating Instruction Manual SN 2084598 – PDF DOWNLOAD
Overview:
Vehicle identification:
The following plates and numbers have been fitted to the truck crane for
identification:
1 The superstructure name plate at the front of the crane operator’s cab containing serial
number and description of the crane model.
identification:
1 The superstructure name plate at the front of the crane operator’s cab containing serial
number and description of the crane model.
2 The CE mark on the name plate (only with truck cranes that are delivered to member countries
of the EU).
of the EU).
3 The chassis name plate on the passenger seat console containing the chassis number and
designation of the crane model.
designation of the crane model.
4 The chassis number at the front right above the first axle line, in the web plate of the
frame.
frame.
The position of the identification numbers of detachable rigging parts (for example counterweight,
lattice extension) will be described in the corresponding chapters or in their own respective
operating manuals.
Carrier and superstructure operating manual:
These operating instructions contain information required to operate the
truck crane.
In chapter 2 you will find Basic safety instructions. Please read and observe
these instructions, even if you are familiar with the safety manual. These
Basic safety instructions are in this chapter only; special safety instructions
which indicate concrete dangers are contained in the text. There the
action related to the danger is described.
Chapter 3 contains Information for applications engineering. It is intended primarily
for the truck crane operator and those responsible for applications
engineering.
This chapter contains
– The required qualifications of those involved in applications engineering
– Special safety instructions
– Information that is relevant to applications engineering
Chapters 4 to 6 contain information required for driving the truck crane: a
description of all structural and operational components, clearly defined
check lists for rigging modes and work and the operating instructions for
road and off-road driving.
In chapter 7 there is information on Troubleshooting for the carrier of the
truck crane.
Chapter 8 includes the Technical description of the individual parts and functional
elements of the carrier as well as its Technical data.
Chapter 9 contains the alphabetical index at the end of part 1 – carrier.
Chapters 10 to 12 contain information required for Operating the crane section,
i. e. work with the truck crane: a description of all components and
control elements, information about operating the crane engine as well as
the crane itself.
TABLE OF CONTENTS:
Grove Crane GMK 5100 Carrier & Superstructure Operating Instruction Manual SN 2084598 – PDF DOWNLOAD
GMK 5100 ..................................................................................................... 1 Operating Instructions Part 1 Carrier..................................................................... 1 1 Overview 1 - 1.................................................................................... 5 1.1 Vehicle identification 1 - 1................................................................ 7 1.2 EC declaration of conformity 1 - 4.......................................................... 10 1.3 Overview and contents of truck crane user information 1 - 5................................. 11 1.3.1 Carrier and superstructure operating manual 1 - 5.................................... 11 1.3.2 Lattice extension operating manual (additional equipment) 1 - 6....................... 12 1.3.3 Maintenance manual 1 - 6.............................................................. 12 1.3.4 Lifting capacity table 1 - 6.......................................................... 12 1.3.5 Outrigger load table 1 - 7............................................................ 13 1.3.6 Safety manual 1 - 7................................................................... 13 1.3.7 Spare parts list 1 - 7................................................................ 13 1.3.8 Circuit diagrams 1 - 7................................................................ 13 1.4 Instructions for use of this document 1 - 8................................................. 14 1.4.1 How are the operating instructions laid out? 1 - 8................................... 14 1.4.2 How are the pages of the operating manual formatted? 1 - 9............................ 15 1.4.3 How can I find the necessary information quickly and easily? 1 - 10................... 16 1.4.4 Definition of direction information 1 - 16............................................ 22 1.4.5 Conversion table for metric measuring units 1 - 17.................................... 23 2 Fundamental safety instructions for crane operators 2 - 1......................................... 25 2.1 Warnings and symbols 2 - 1................................................................. 27 2.2 Proper use 2 - 2............................................................................ 28 2.3 Organisational measures 2 - 4.............................................................. 30 2.4 Personnel qualifications 2 - 6.............................................................. 32 2.5 Safety instructions that apply to truck crane driving 2 - 7................................ 33 2.6 Safety instructions for truck crane work 2 - 7.............................................. 33 3 Information for applications engineering 3 - 1.................................................... 37 3.1 Safety instructions 3 - 1.................................................................. 39 3.1.1 Proper use 3 - 1...................................................................... 39 3.1.2 Organizational measures 3 - 1........................................................ 39 3.1.3 Personnel qualifications 3 - 2........................................................ 40 3.2 Applications engineering 3 - 3............................................................. 41 3.2.1 Application engineering requirements 3 - 3............................................ 41 3.2.2 Details about applications engineering contained in the user information 3 - 4........ 42 4 Description of the truck crane – vehicle section 4 - 1............................................ 43 4.1 Overview of the operating and display instruments 4 - 1.................................... 45 4.1.1 Overview of the vehicle 4 - 1......................................................... 45 4.1.2 Overview of driver™s cab 4 - 4........................................................ 48 4.1.3 Front instrument panel 4 - 8.......................................................... 52 4.1.4 Side instrument panel 4 - 16.......................................................... 60 4.1.5 Steering column 4 - 20................................................................ 64 4.2 Functional description of the display and operating instruments 4 - 21...................... 65 4.2.1 Instrument panels 4 - 21............................................................. 65 4.2.2 On the steering column 4 - 38......................................................... 82 4.2.3 Above the front windshield 4 - 41.................................................... 85 4.2.4 Other operating instruments in the vehicle section 4 - 43............................. 87 5 Vehicle engine 5 - 1.............................................................................. 93 5.1 Starting/turning off vehicle engine 5 - 1................................................... 95 5.1.1 CHECKLIST: Starting vehicle engine 5 - 1.............................................. 95 5.1.2 CHECKLIST: In winter 5 - 3........................................................... 97 5.1.3 Checks before starting up vehicle engine 5 - 4........................................ 98 5.1.4 Starting vehicle engine 5 - 9.........................................................103 5.1.5 Inspections after the engine has been started 5 - 12..................................106 5.1.6 Turning off the vehicle engine 5 - 14.................................................108 6 Driving the truck crane 6 - 1.....................................................................109 6.1 Checking the truck crane before driving 6 - 1..............................................111 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving 6 - 1.....................111 6.1.2 Checks to be carried out before driving 6 - 9.........................................119 6.2 General operation 6 - 25....................................................................135 6.2.1 Operating the transmission with automatic gear change 6 - 25..........................135 6.2.2 Monitoring the control instruments while driving 6 - 32...............................142 6.2.3 Driving on downhill slopes 6 - 36.....................................................146 6.2.4 Driving on uphill slopes 6 - 39.......................................................149 6.2.5 Tempomat 6 - 40......................................................................150 6.2.6 Temposet 6 - 42.......................................................................152 6.2.7 Turning off the truck crane 6 - 43....................................................153 6.3 Off-the-road driving 6 - 45.................................................................155 6.3.1 Longitudinal differential locks/drive of the 3rd axle line (drive of 3rd axle line ....155 only with 10 x 8 x 10 additional equipment) 6 - 46.........................................156 6.3.2 Transverse differential locks in all driven axle lines 6 - 48.........................158 6.3.3 Level adjustment system 6 - 49........................................................159 6.3.4 Freeing a stuck truck crane 6 - 52....................................................162 6.4 Separate steering 6 - 55....................................................................165 6.4.1 Unlocking the 4th axle line steering, connecting 4th and 5th axle lines 6 - 56.......166 6.4.2 Steering the 4th and 5th axle lines 6 - 56............................................166 6.4.3 Separating 4th and 5th axle line, locking steering of 4th axle line 6 - 57............167 6.5 Heating and ventilation 6 - 59..............................................................169 6.5.1 Driver™s cab heating system 6 - 59....................................................169 6.5.2 Roof blower (additional equipment) 6 - 61............................................171 6.5.3 Additional water heating system (additional equipment) 6 - 62.........................172 6.5.4 Additional heating system with timer (additional equipment) 6 - 64....................174 6.6 Air-conditioning system (additional equipment) 6 - 67......................................177 6.6.1 Switching on 6 - 67...................................................................177 6.6.2 Switching off 6 - 67..................................................................177 6.6.3 Air conditioning 6 - 68...............................................................178 6.7 Towing a trailer (additional equipment) 6 - 71..............................................181 7 Malfunctions on the carrier 7 - 1.................................................................187 7.1 Emergency stop device on carrier 7 - 1.....................................................189 7.2 Breakdown in road traffic 7 - 3.............................................................191 7.3 Towing the truck crane 7 - 5...............................................................193 7.4 Wheel change 7 - 13.........................................................................201 7.5 Electrical system 7 - 17...................................................................205 7.5.1 Plug-in modules 7 - 17................................................................205 7.5.2 Fuses 7 - 19.........................................................................207 7.6 Troubleshooting and malfunction correction 7 - 25...........................................213 7.6.1 Vehicle engine malfunctions 7 - 25....................................................213 7.6.2 Malfunctions of the transmission with automatic gear change 7 - 28....................216 7.6.3 Differential lock malfunctions 7 - 29.................................................217 7.6.4 Service brake malfunctions 7 - 30....................................................218 7.6.5 Steering system malfunctions 7 - 31...................................................219 7.6.6 Tachograph malfunctions 7 - 32........................................................220 7.6.7 Outrigger malfunctions 7 - 33.........................................................221 7.6.8 Suspension locking system malfunctions 7 - 33.........................................221 7.6.9 Level adjustment system malfunctions 7 - 33...........................................221 7.7 Procedure in the event of malfunctions 7 - 35...............................................223 7.7.1 Switching the fan thermostat to emergency operation 7 - 35...........................223 7.7.2 What to do if there is a transmission malfunction 7 - 36..............................224 7.7.3 Emergency operation of the solenoid valves for the outriggers 7 - 43..................231 8 Technical specifications carrier 8 - 1............................................................235 8.1 Technical description of the carrier 8 - 1.................................................237 8.1.1 Crane carrier 8 - 1...................................................................237 8.1.2 Driver™s cab 8 - 1...................................................................237 8.1.3 Drive units 8 - 1.....................................................................237 8.1.4 Engine and gearbox cooling system 8 - 2..............................................238 8.1.5 Hydraulic system 8 - 2................................................................238 8.1.6 Steering 8 - 2.......................................................................238 8.1.7 Suspension system 8 - 3...............................................................239 8.1.8 Outrigger 8 - 4......................................................................240 8.1.9 Compressed air system 8 - 4...........................................................240 8.1.10 Service brake 8 - 5.................................................................241 8.1.11 Parking brake 8 - 5..................................................................241 8.1.12 Retarder 8 - 5......................................................................241 8.1.13 Secondary consumers 8 - 6............................................................242 8.1.14 Towing the crane 8 - 6..............................................................242 8.1.15 Towing a trailer 8 - 6...............................................................242 8.1.16 Electrical system 8 - 6.............................................................242 8.1.17 Slewing duct 8 - 6...................................................................242 8.2 Technical specifications 8 - 7.............................................................243 8.2.1 Measurements and weights of the truck crane 8 - 8.....................................244 8.2.2 Dimensions and weights of removable parts 8 - 9.......................................245 8.2.3 Carrier 8 - 10........................................................................246 9 Alphabetical index 9 - 1..........................................................................251 Alphabetical index................................................................................253 A.............................................................................................253 Access ladders to the superstructure 4-44................................................. 88 Activating the ignition...................................................................253 carrier 5-9..............................................................................103 superstructure 11-10.....................................................................350 Adding oil................................................................................253 in the crane engine 11-5.................................................................345 Additional heating system 4-35, 6-62...................................................... 79 deactivating 6-63........................................................................173 display time, setting 4-36............................................................... 80 switching on 6-62........................................................................172 additional heating system ................................................................253 superstructure 12-108....................................................................466 Additional heating system with timer 6-64.................................................174 automatic heating start, switch on and save 6-65.........................................175 switching off automatic heating start 6-66..............................................176 switching on/off 6-64....................................................................174 time, display/setting 6-65...............................................................175 Additional water heating system...........................................................253 see Additional heating system............................................................253 Adjusting the mirrors 6-19................................................................129 on the superstructure 12-12..............................................................370 Adjusting the seat........................................................................253 in the crane cab 10-58...................................................................334 in the driver™s cab 6-18.................................................................128 Air-conditioning system...................................................................253 in the crane cab 10-55, 12-110 to 12-112.................................................331 in the driver™s cab 4-41, 6-67 to 6-70................................................... 85 All-wheel steering: 6-55..................................................................165 Anemometer................................................................................253 installing on the main boom 13-84........................................................556 on the main boom 12-36...................................................................394 Auxiliary hoist...........................................................................253 malfunctions 14-19.......................................................................577 working with the auxiliary hoist 12-44...................................................402 Auxiliary hoist gear......................................................................253 display and operating instruments 10-34..................................................310 Axle drive................................................................................253 display and operating instruments in the driver™s cab 4-25.............................. 69 B.............................................................................................253 Battery master switch.....................................................................253 Carrier 5-7..............................................................................101 superstructure 11-7......................................................................347 bonnet....................................................................................253 opening and closing 4-46................................................................ 90 Boom floating position....................................................................253 switching off 12-6.......................................................................364 switching on 6-13........................................................................123 Boom initial tension......................................................................253 switching off 12-6......................................................................364 switching on 6-14........................................................................124 Brakes....................................................................................253 auxiliary brake 4-27..................................................................... 71 checking the brakes system 6-9...........................................................119 compressed-air supply for engine failure 7-7.............................................195 display and operating instruments in the driver™s cab 4-26.............................. 70 eddy current retarder 6-38...............................................................148 parking brake 4-27....................................................................... 71 retarder 6-37............................................................................147 Breakdown.................................................................................253 procedure in road traffic 7-3 to 7-4.....................................................191 towing 7-5 to 7-12.......................................................................193 C.............................................................................................253 Carrier hydraulic system..................................................................253 check the oil level 5-7..................................................................101 checking the position of the stop cocks 5-8..............................................102 Charge indicator..........................................................................253 warning lamp 4-30........................................................................ 74 Charge indicator lamp.....................................................................253 after ignition has been switched on 5-9, 11-11...........................................103 after the engine has been started 11-13..................................................353 after the vehicle engine has been started 5-13...........................................107 Check the oil level.......................................................................253 in the carrier hydraulic system 5-7......................................................101 in the superstructure hydraulic system 11-6..............................................346 Checking the coolant level................................................................253 in the crane engine 11-8.................................................................348 in the vehicle engine 5-6................................................................100 Checking the oil level....................................................................253 in the crane engine 11-4.................................................................344 in the vehicle engine 5-4................................................................ 98 Checking the steering lock 6-11...........................................................121 Checking the tyres 6-12...................................................................122 Checking the windscreen washing system....................................................253 in the crane cab 12-13...................................................................371 in the driver™s cab 6-18.................................................................128 CHECKLIST.................................................................................253 before starting crane work in winter 11-3................................................343 condition of the truck crane for on-road driving 6-1.....................................111 extending the outriggers 13-13..........................................................485 retracting the outriggers 13-15 to 13-40.................................................487 rigging for crane operation with main boom 13-1.........................................473 rigging mode when truck crane is rigged 12-1.............................................359 rigging the counterweight 13-46..........................................................518 starting the crane engine 11-1...........................................................341 starting vehicle engine 5-1.............................................................. 95 unrigging for crane operation with main boom 13-4........................................476 unrigging the counterweight 13-48........................................................520 working with the crane in winter 5-3.................................................... 97 Checks....................................................................................253 after starting the crane engine 11-13....................................................353 after the engine has been started 5-12...................................................106 before driving 6-9.......................................................................119 before starting the crane engine 11-4....................................................344 boom not set down warning lamp 6-11.....................................................121 of the safety equipment 12-14............................................................372 prior to starting vehicle engine 5-4.................................................... 98 while driving 6-32.......................................................................142 Choosing the site 13-6 to 13-12..........................................................478 Compressed air system.....................................................................253 see Brakes...............................................................................253 Constant engine speed 12-95...............................................................453 Constant speed............................................................................253 see Tempostat............................................................................253 Control lever emergency program 14-68.....................................................626 Conversion table 1-17..................................................................... 23 Counterweight lifting unit................................................................253 2 t counterweight section on the turntable, locking/releasing 13-62......................534 3 t base plate, placing onto the counterweight platform 13-50...........................522 3 t counterweight section, installing/removing 13-64.....................................536 current status, checking 13-58...........................................................530 extending/retracting the lifting cylinder 13-59..........................................531 indication of a malfunction 13-58........................................................530 release/block 13-58......................................................................530 unlock/lock 13-60........................................................................532 Crab travel mode: 6-55....................................................................165 Crane cab.................................................................................253 heating 10-53, 12-106....................................................................329 inclining 12-96.........................................................................454 overview 10-4............................................................................280 ventilating 12-109.......................................................................467 Crane cab windscreen wipers 10-50.........................................................326 Crane control.............................................................................253 see Acknowledging error messages.........................................................253 display and operating instruments 10-31..................................................307 display of an error message 12-93........................................................451 emergency stop switch 14-2...............................................................560 enter telescope status menu 14-76........................................................634 entering power unit speeds menu 12-89....................................................447 error memory sub-menu 12-86..............................................................444 error messages 14-57 to 14-78............................................................615 menu Display states 12-85................................................................443 menu Display telescoping status 12-88....................................................446 menus on the display 12-85...............................................................443 Crane control emergency stop switch 14-2.................................................560 Crane control error messages 14-57 to 14-78...............................................615 Crane engine..............................................................................253 checking the oil level 11-4..............................................................344 checks before starting 11-4..............................................................344 display and operating instruments 10-25..................................................301 inspections after starting 11-13........................................................353 malfunctions 14-15.......................................................................573 setting a constant engine speed 12-95...................................................453 start-up 11-11...........................................................................351 starting Œ CHECKLIST 11-1................................................................341 turning off 11-15........................................................................355 VDO electronics 10-58....................................................................334 Crane work................................................................................253 critical load control 12-96..............................................................454 during the winter Œ CHECKLIST 5-3........................................................ 97 in winter Œ CHECKLIST 11-3...............................................................343 permissible slewing ranges 12-39.........................................................397 preheating the hydraulic oil 12-5........................................................363 troubleshooting for malfunctions 14-3 to 14-4............................................561 Crane work with main boom.................................................................253 rigging Œ CHECKLIST 13-1.................................................................473 unrigging Œ CHECKLIST 13-4...............................................................476 Critical load control 12-96...............................................................454 D.............................................................................................253 Dead man™s switch system 10-62...........................................................338 Derricking gear...........................................................................253 display and operating instruments 10-36.................................................312 lowering the main boom for maintenance 12-83.............................................441 malfunctions 14-21.......................................................................579 working with the derricking gear 12-46...................................................404 Differential locks........................................................................253 see Transverse differential locks........................................................253 Door......................................................................................253 crane cab 10-56..........................................................................332 driver™s cab 4-43........................................................................ 87 Drive of third axle line / longitudinal differential locks 7-8............................196 checking 6-11...........................................................................121 switching off 6-47.......................................................................157 switching on 6-46........................................................................156 Driver™s cab..............................................................................253 adjusting the mirrors 6-19...............................................................129 adjusting the seat 6-18..................................................................128 heating 6-59.............................................................................169 overview 4-4............................................................................. 48 ventilating 6-61.........................................................................171 Driving...................................................................................253 breakdown procedure 7-3 to 7-4...........................................................191 checks before driving 6-9................................................................119 checks while driving 6-32................................................................142 downhill slopes 6-36.....................................................................146 off-road 6-45 to 6-54....................................................................155 on uphill slopes 6-39....................................................................149 with a rigged crane 12-99 to 12-104......................................................457 Driving direction indicator 4-31.......................................................... 75 Driving mode table 6-4....................................................................114 E.............................................................................................253 Earthing..................................................................................253 of the truck crane 13-12.................................................................484 Eddy current retarder.....................................................................253 see Brakes...............................................................................253 Electrical system.........................................................................253 connection between the carrier and superstructure 6-24...................................134 display and operating instruments in the crane cab 10-49................................325 display and operating instruments in the driver™s cab 4-30............................... 74 fuses in the carrier 7-19................................................................207 fuses in the superstructure 14-7.........................................................565 plug-in modules and consoles in the crane cab 14-5.......................................563 plug-in modules in the driver™s cab 7-17................................................205 SLI fuses 14-13..........................................................................571 Electronic level..........................................................................253 in the crane cab 10-52...................................................................328 on the carrier 13-36.....................................................................508 Emergency operation.......................................................................253 solenoid valves for the outriggers 7-43..................................................231 Emergency operation submenu on the Crane control display) 14-75...........................633 Emergency stop device.....................................................................253 on the carrier 7-1 to 7-2................................................................189 on the superstructure 14-1 to 14-2.......................................................559 Enlarging the surface area of the outrigger 13-8..........................................480 Error messages............................................................................253 control units 14-57......................................................................615 power units 14-58........................................................................616 SLI, table 14-30.........................................................................588 F.............................................................................................253 Fast speed 12-84..........................................................................442 Fire extinguisher.........................................................................253 in the crane cab 10-57...................................................................333 in the driver™s cab 4-47................................................................. 91 Flame start system........................................................................253 in the crane engine 11-11................................................................351 in the vehicle engine 5-10...............................................................104 Fuel tank.................................................................................253 crane engine 11-9........................................................................349 vehicle engine 6-17......................................................................127 Fuses.....................................................................................253 in the carrier 7-19.....................................................................207 in the superstructure 14-7...............................................................565 of the SLI 14-13.........................................................................571 H.............................................................................................253 Hazard warning system 4-30................................................................ 74 Heating system............................................................................253 crane cab 10-53, 12-106..................................................................329 driver™s cab 4-34, 6-59.................................................................. 78 Hoist rope 13-73..........................................................................545 checking the position 12-12.............................................................370 reeving on the main boom 13-75...........................................................547 Hoists 12-41.............................................................................399 Hook block................................................................................253 on a separate vehicle 13-71..............................................................543 on the bumper 13-69......................................................................541 Hydraulic system..........................................................................253 display and control instruments 4-28..................................................... 72 I.............................................................................................253 Identification............................................................................253 of the truck crane 1-1 to 1-3............................................................ 7 Instrument panels.........................................................................253 in the crane cab Œ overview 10-6 to 10-24................................................282 in the driver™s cab Œ overview 4-8...................................................... 52 K.............................................................................................253 Keys......................................................................................253 crane cab 10-56..........................................................................332 driver™s cab 4-43........................................................................ 87 L.............................................................................................253 Ladders 4-45.............................................................................. 89 Lamp test SLI 12-19......................................................................377 Level adjustment system 6-49..............................................................159 deactivating 6-52........................................................................162 display and operating instruments 4-31................................................... 75 moving the truck crane into on-road driving position 6-52...............................162 raising or lowering the entire truck crane 6-50..........................................160 switching on 6-50........................................................................160 tilting the truck crane lengthwise or crosswise 6-51.....................................161 Level of on-road driving..................................................................253 see On-the-road level....................................................................253 Lifting limit switch......................................................................253 on the main boom 12-43...................................................................401 Lifting limit switch weight 13-79.........................................................551 Load bearing capacity of the ground 13-6..................................................478 table 13-7...............................................................................479 Locking the superstructure 12-9...........................................................367 Lowering limit switch 10-60...............................................................336 M.............................................................................................253 Main boom.................................................................................253 lower the boom for maintenance purposes 12-83............................................441 rigging work 13-69.......................................................................541 Main hoist................................................................................253 display and operating instruments 10-33..................................................309 malfunctions 14-17.......................................................................575 working with the main hoist 12-41........................................................399 Main rope, possible reeving methods.......................................................253 on the main boom 13-80...................................................................552 Malfunctions..............................................................................253 counterweight lifting unit 14-26.........................................................584 crane control 14-27......................................................................585 differential locks 7-29..................................................................217 hydraulic oil cooler for superstructure 14-28............................................586 on crane control 14-28...................................................................586 on the SLI 14-29.........................................................................587 outrigger 7-33...........................................................................221 procedure in the event of malfunctions 7-35 to 7-46......................................223 service brake 7-30.......................................................................218 sevel adjustment system 7-33.............................................................221 steering 7-31............................................................................219 suspension locking system 7-33...........................................................221 tachograph 7-32..........................................................................220 transmission with automatic gear change 7-28............................................216 vehicle engine 7-25......................................................................213 when working with the crane 14-3.........................................................561 Mirror heating 4-31....................................................................... 75 Mounting wheel............................................................................253 on the spare wheel holder 7-14...........................................................202 on the truck crane 7-15.................................................................203 Movements which can be carried out simultaneously.........................................253 for operation with the main boom 12-98..................................................456 multipurpose switch 4-40.................................................................. 84 O.............................................................................................253 Off-road driving 6-45 to 6-54.............................................................155 On-the-road level.........................................................................253 checking 6-10............................................................................120 moving the crane into on-the-road level 6-52.............................................162 Operating hour counter....................................................................253 see crane control, display status menu...................................................253 Outrigger 13-13 to 13-14..................................................................485 actuating 13-23..........................................................................495 display and operating instruments 10-26..................................................302 extending Œ CHECKLIST 13-13..............................................................485 see also Level adjustment system.........................................................253 retracting Œ CHECKLIST 13-15 to 13-40...................................................487 variants 13-17...........................................................................489 Outrigger beams...........................................................................253 extending 13-23..........................................................................495 retracting 13-26.........................................................................498 Outrigger cylinders.......................................................................253 extending 13-30..........................................................................502 retracting 13-32, 13-40.................................................................504 Outrigger pads............................................................................253 moving into driving position 13-29......................................................501 moving into working position 13-28.......................................................500 Outrigger pressure displays..............................................................253 in the crane cab 10-54...................................................................330 on the carrier 13-39....................................................................511 Outrigger spans 13-17.....................................................................489 Overview..................................................................................253 crane cab 10-4...........................................................................280 crane section 10-1.......................................................................277 display and operating instruments 4-1 to 4-20............................................ 45 driver™s cab 4-4......................................................................... 48 of display and operating instruments 10-1 to 10-5........................................277 vehicle 4-1.............................................................................. 45 P.............................................................................................253 Parking brake.............................................................................253 display and operating instruments 4-27.................................................. 71 releasing mechanically 7-9...............................................................197 removing the mechanical lock 7-10.......................................................198 while towing 7-8.........................................................................196 Possible reeving methods..................................................................253 on the main boom 13-80...................................................................552 Power unit speed..........................................................................253 see Crane control, entering power unit speeds............................................253 R.............................................................................................253 Refuelling................................................................................253 fuel for the crane engine 11-9...........................................................349 fuel for the vehicle engine 6-17.........................................................127 Removing the tyre.........................................................................253 from the truck crane 7-13...............................................................201 Rigging mode..............................................................................253 before starting work Œ CHECKLIST 12-1...................................................359 setting on the SLI 12-20.................................................................378 Rigging work..............................................................................253 main boom 13-69..........................................................................541 outrigger 13-13 to 13-14.................................................................485 rigging for crane operation Œ CHECKLIST 13-1.............................................473 unrigging after crane work Œ CHECKLIST 13-4.............................................476 Roof ventilator 6-61......................................................................171 Rope end clamp 13-73......................................................................545 Rotating warning light 4-30............................................................... 74 S.............................................................................................253 Safe distance.............................................................................253 from banks and pits 13-9.................................................................481 from electrical lines 13-9...............................................................481 Safe load indicator.......................................................................253 see SLI.................................................................................253 Safety equipment..........................................................................253 checks 12-14.............................................................................372 functional description 10-59 to 10-62....................................................335 Sensor/indicator..........................................................................253 releasing shutdown 14-38.................................................................596 switch off during malfunction 14-38......................................................596 Separate steering.........................................................................253 checking the steering lock 6-11..........................................................121 unlocking fourth axle line steering 6-56 to 6-57.........................................166 general 6-55 to 6-58.....................................................................165 steering the 4th and 5th axle lines 6-56.................................................166 Slewing gear 12-48........................................................................406 display and operating instruments 10-35..................................................311 malfunctions 14-25.......................................................................583 slewing 12-48............................................................................406 slewing gear permanent brake 12-48.......................................................406 tracking 12-50...........................................................................408 Slewing gear freewheel....................................................................253 switching off 12-8.......................................................................366 switching on 6-16........................................................................126 SLI.......................................................................................253 display and operating instruments 10-41..................................................317 during crane work 12-29..................................................................387 error messages 12-32.....................................................................390 functional description 10-59.............................................................335 fuses 14-13..............................................................................571 input of values 12-21....................................................................379 lamp test 12-19..........................................................................377 malfunctions 14-29.......................................................................587 override 12-34...........................................................................392 setting rigging mode 12-20...............................................................378 switching on 12-17......................................................................375 SLI error message table 14-30.............................................................588 Spotlight for working area 10-49.........................................................325 Steering..................................................................................253 display and operating instruments in the driver™s cab 4-29............................. 73 Steering column...........................................................................253 operating instruments on the steering column 4-20....................................... 64 setting 6-19.............................................................................129 Stop engine cable.........................................................................253 see Emergency stop device................................................................253 Superstructure hydraulic system...........................................................253 check the oil level 11-6.................................................................346 checking the position of the stop cock 11-7.............................................347 cooling the hydraulic oil 12-97..........................................................455 display and control instruments 10-49...................................................325 preheating the hydraulic oil 12-5........................................................363 Superstructure lock 12-9..................................................................367 Superstructure, access ladder 4-44........................................................ 88 Suspension................................................................................253 checking 6-9.............................................................................119 locking 4-28............................................................................. 72 Switching off the.........................................................................253 crane engine 14-1........................................................................559 Switching the fan thermostat to emergency operation 7-35..................................223 Symbols in the operating instructions, explanation 2-1.................................... 27 T.............................................................................................253 Tachograph 6-20...........................................................................130 diagram sheets, inserting 6-22...........................................................132 open the drawer and check the time settings 6-21.........................................131 time group, setting 6-23.................................................................133 Technical data............................................................................253 superstructure 15-7 to 15-16.............................................................645 Technical description of the carrier 8-1 to 8-6...........................................237 Technical description of the truck crane..................................................253 superstructure 15-1 to 15-6.............................................................639 Technical specifications 8-7 to 8-14......................................................243 Telescoping gear..........................................................................253 display and operating instruments 10-37..................................................313 example of procedures when telescoping 12-62............................................420 function of the control lever 12-60......................................................418 functioning 12-54.......................................................................412 main boom fixed length 12-55.............................................................413 main boom intermediate length 12-56.....................................................414 main boom telescoping length 12-56.......................................................414 malfunctions 14-22......................................................................580 telescope status, status display on the SLI 12-56........................................414 telescoping sequence 12-59...............................................................417 telescoping, indicated on the crane control display. 12-88...............................446 Tempomat 6-40.............................................................................150 driving with 6-40........................................................................150 switching off: 6-41......................................................................151 switching on 6-40........................................................................150 Temposet 6-42.............................................................................152 driving with 6-42........................................................................152 switching on 6-42........................................................................152 Time......................................................................................253 setting time in the crane cab 4-36....................................................... 80 Topping up oil............................................................................253 in the vehicle engine 5-5................................................................ 99 Tow starting 7-11.........................................................................199 Towing 7-5 to 7-12........................................................................193 compressed-air supply for engine failure 7-7............................................195 in case of motor damage 7-5..............................................................193 parking brake 7-8.......................................................................196 power supply 7-8.........................................................................196 with damaged transmission 7-7............................................................195 Towing a trailer 6-71 to 6-76.............................................................181 Towing free...............................................................................253 forwards 6-53............................................................................163 reverse 6-53.............................................................................163 Transmission with automatic gear change...................................................253 after ignition has been switched on 6-25.................................................135 directing of travel, changing 6-30.......................................................140 direction of travel and starting gear, select 6-27.......................................137 display and operating instruments 4-22................................................... 66 display and operating instruments in the driver™s cab 4-22.............................. 66 display of the engaged gears 6-27........................................................137 emergency gear shift 7-39...............................................................227 error messages on the gearbox control display 7-36.......................................224 gear, changing while driving 6-29........................................................139 operating mode, select 6-26..............................................................136 operation 6-25...........................................................................135 operation with clutch emergency pedal 7-37...............................................225 procedure in the event of malfunctions 7-36..............................................224 shift in neutral position 6-26...........................................................136 starting 6-28............................................................................138 stopping 6-31............................................................................141 Transverse differential locks.............................................................253 checking 6-10............................................................................120 Transverse differential locks in all driven axle lines 6-48..............................158 Truck crane...............................................................................253 checking horizontal alignment 12-35.....................................................393 earthing 13-12...........................................................................484 freeing the crane by its own power 6-52.................................................162 horizontally align 13-32.................................................................504 identification 1-1 to 1-3............................................................... 7 in on-road driving position 6-52.........................................................162 overview of the crane section 10-1......................................................277 overview of the vehicle section 4-1...................................................... 45 raising or lowering 6-50.................................................................160 rocking it free 6-52.....................................................................162 safe distance 12-35.....................................................................393 securing the truck crane from rolling 6-43...............................................153 tilting the crane lengthwise or crosswise 6-51..........................................161 towing free 6-53.........................................................................163 turning off 6-43.........................................................................153 Tyre change...............................................................................253 see Wheel change.........................................................................253 V.............................................................................................253 Vehicle engine............................................................................253 checking the oil level 5-4............................................................... 98 checks before starting 5-4............................................................... 98 diagnostics plug 4-46.................................................................... 90 display and operating instruments 4-21................................................... 65 inspections after starting 5-12..........................................................106 preheating 6-62, 6-64....................................................................172 start 5-9, 11-10.........................................................................103 start-up 5-10............................................................................104 starting Œ CHECKLIST 5-1................................................................. 95 starting a warm engine 5-11..............................................................105 starting cold vehicle engine 5-10........................................................104 turning off 5-14.........................................................................108 Ventilation...............................................................................253 crane cab 12-109.........................................................................467 driver™s cab 4-34, 6-61.................................................................. 78 W.............................................................................................253 Warning plates for vehicle width..........................................................253 connection between the carrier and superstructure 6-24..................................134 Wheel change 7-13 to 7-16.................................................................201 Wheel, removing...........................................................................253 from the spare wheel holder 7-14.........................................................202 Wind......................................................................................253 influence of wind on crane work 12-36....................................................394 permissible wind load 12-38.............................................................396 wind speed table 12-36...................................................................394 Work break 12-105.........................................................................463 for work breaks lasting more than 8 hours 12-105.........................................463 short work break 12-105.................................................................463 Operating Instructions Part 2 Superstructure .............................................................269 Additional page: GMK truck cranes ....................................................................271 Validity..........................................................................................271 Supplement to the technical data for the superstructure..........................................271 Information.......................................................................................271 10 Description of the truck crane – crane section 10 - 1............................................275 10.1 Overview of the operating and display instruments 10 - 1..................................277 10.1.1 Overview of crane section 10 - 1.....................................................277 10.1.2 Crane cab overview 10 - 4............................................................280 10.2 Instrument panel 10 - 6....................................................................282 10.2.1 Left control console 10 - 20.........................................................296 10.2.2 Right control console 10 - 21........................................................297 10.2.3 Controls and fittings behind the crane operator™s seat 10 - 22.......................298 10.2.4 Control box for operating the outriggers 10 - 23....................................299 10.2.5 Electronic level switch box (additional equipment) 10 - 24...........................300 10.3 Functional description of the display and operating instruments 10 - 25....................301 10.3.1 Crane work 10 - 25...................................................................301 10.3.2 Other operating instruments on the crane cab 10 - 56.................................332 10.4 Functional description of the safety devices 10 - 59.......................................335 10.4.1 Safe load indicator (SLI) 10 - 59...................................................335 10.4.2 Lowering limit switch 10 - 60........................................................336 10.4.3 Lifting limit switch 10 - 61.......................................................337 10.4.4 Dead man™s switch and seat contact switch 10 - 62....................................338 11 Crane engine 11 - 1..............................................................................339 11.1 Starting/turning off the crane engine 11 - 1..............................................341 11.1.1 CHECKLIST: Starting the crane engine 11 - 1..........................................341 11.1.2 CHECKLIST: In winter 11 - 3.........................................................343 11.1.3 Inspections before starting the crane engine 11 - 4..................................344 11.1.4 Starting the crane engine 11 - 10....................................................350 11.1.5 Inspections after starting crane engine 11 - 13......................................353 11.1.6 Switch off the crane engine 11 - 15..................................................355 12 Crane operation 12 - 1..........................................................................357 12.1 Checking the truck crane before working with the crane 12 - 1.............................359 12.1.1 CHECKLIST: When truck crane is rigged 12 - 1........................................359 12.1.2 Preheating the hydraulic oil 12 - 5..................................................363 12.1.3 Switching off the boom floating position (additional equipment) 12 - 6..............364 12.1.4 Switching off the slewing gear freewheel (additional equipment) 12 - 8...............366 12.1.5 Mechanical superstructure lock 12 - 9................................................367 12.1.6 Electrical system 12 - 11............................................................369 12.1.7 Adjusting the mirrors 12 - 12........................................................370 12.1.8 Check the position of the hoist ropes 12 - 12.......................................370 12.1.9 Checking the reservoir of the windscreen washing system 12 - 13......................371 12.1.10 Visual inspection of the entire crane 12 - 13.......................................371 12.1.11 Checking the safety devices 12 - 14................................................372 12.2 Operating the safe load indicator 12 - 17..................................................375 12.2.1 Switching on the SLI 12 - 17........................................................375 12.2.2 Setting rigging mode 12 - 20.........................................................378 12.2.3 Checks before working with the crane 12 - 27.........................................385 12.2.4 During crane work 12 - 29............................................................387 12.3 Crane work with the main boom 12 - 35......................................................393 12.3.1 External influences during crane operation 12 - 35..................................393 12.3.2 Slewing ranges permitted for working with the crane 12 - 39..........................397 12.3.3 Hoists 12 - 41.......................................................................399 12.3.4 Derricking gear 12 - 46..............................................................404 12.3.5 Slewing gear 12 - 48.................................................................406 12.3.6 Telescoping gear 12 - 53.............................................................411 12.3.7 Fast speed 12 - 84...................................................................442 12.3.8 Menus on the crane control display 12 - 85...........................................443 12.3.9 Setting a constant engine speed 12 - 95..............................................453 12.3.10 Critical load control 12 - 96.......................................................454 12.3.11 Incline crane cab (additional equipment) 12 - 96....................................454 12.3.12 Cooling the hydraulic oil 12 - 97..................................................455 12.3.13 Movements which can be carried out simultaneously 12 - 98...........................456 12.4 Driving with a rigged crane 12 - 99........................................................457 12.4.1 Driving route 12 - 99................................................................457 12.4.2 Position of the boom 12 - 100........................................................458 12.4.3 Driving the rigged truck crane 12 - 102.............................................460 12.5 Work break 12 - 105........................................................................463 12.5.1 Short work break 12 - 105...........................................................463 12.5.2 Work breaks lasting more than 8 hours 12 - 105.......................................463 12.6 Crane cab heating and ventilation 12 - 106.................................................464 12.6.1 Heating the crane cab 12 - 106.......................................................464 12.6.2 Additional water heating system (additional equipment) 12 - 107......................465 12.6.3 Additional heating system with timer (additional equipment) 12 - 108................466 12.6.4 Ventilating the crane cab 12 - 109...................................................467 12.7 Air-conditioning system (additional equipment) 12 - 110....................................468 12.7.1 Switching on 12 - 110................................................................468 12.7.2 Switching off 12 - 110...............................................................468 12.7.3 Air conditioning 12 - 111............................................................469 13 Rigging work 13 - 1..............................................................................471 13.1 Check lists for rigging work for crane operation with main boom 13 - 1....................473 13.1.1 CHECKLIST: Rigging 13 - 1............................................................473 13.1.2 CHECKLIST: Unrigging 13 - 4..........................................................476 13.2 Choosing a suitable site 13 - 6............................................................478 13.2.1 Load bearing capacity of the ground and the outrigger 13 - 6.........................478 13.2.2 Safe distance from banks and pits 13 - 9............................................481 13.2.3 Safe distance from electrical lines 13 - 9...........................................481 13.2.4 Earthing the truck crane 13 - 12.....................................................484 13.3 Outrigger 13 - 13..........................................................................485 13.3.1 CHECKLIST: Extending the outriggers 13 - 13..........................................485 13.4 CHECKLIST: Retracting outrigger 13 - 15....................................................487 13.4.1 Outrigger span 13 - 17...............................................................489 13.4.2 Extending/retracting the outrigger beams 13 - 23....................................495 13.4.3 Moving the outrigger pads into working/driving position 13 - 28......................500 13.4.4 Extending/retracting the support cylinders from the control box 13 - 30..............502 13.4.5 Extending/retracting the support cylinders from the crane cab (additional ............502 equipment) 13 - 33.........................................................................505 13.4.6 Check the alignment of the truck crane 13 - 36.......................................508 13.4.7 Outrigger pressure display (additional equipment) 13 - 39...........................511 13.5 Counterweight 13 - 41......................................................................513 13.5.1 Counterweight sections and identification 13 - 41....................................513 13.5.2 Counterweight versions 13 - 42.......................................................514 13.5.3 Slinging points on the counterweight sections 13 - 45................................517 13.5.4 CHECKLIST: Rigging the counterweight 13 - 46........................................518 13.5.5 CHECKLIST: Unrigging the counterweight 13 - 48.......................................520 13.5.6 Placing the 3 t base plate onto the counterweight platform 13 - 50...................522 13.5.7 Assembling the counterweight version 13 - 51........................................523 13.5.8 Counterweight lifting unit 13 - 57...................................................529 13.5.9 Locking/releasing the 2 t counterweight section on the turntable 13 - 62.............534 13.5.10 Removing or installing the 3 t counterweight section on the turntable 13 - 64......536 13.5.11 Rig the 3.5 t counterweight section (additional equipment) 13 - 66..................538 13.5.12 Slewing with the counterweight rigged 13 - 67.......................................539 13.6 Rigging work on the main boom 13 - 69.....................................................541 13.6.1 Hook block on the bumper 13 - 69.....................................................541 13.6.2 Hook block on a separate vehicle 13 - 71.............................................543 13.6.3 Reeving and unreeving the hoist rope 13 - 73.........................................545 13.6.4 Possible reeving methods on the main boom 13 - 80....................................552 13.6.5 Anemometer 13 - 84..................................................................556 14 Malfunctions on the superstructure 14 - 1........................................................557 14.1 Superstructure emergency stop device 14 - 1...............................................559 14.2 Troubleshooting for malfunctions that occur during crane ....................................559 operation 14 - 3...............................................................................561 14.3 Electrical system 14 - 5...................................................................563 14.3.1 Plug-in modules and consoles 14 - 5..................................................563 14.3.2 Fuses 14 - 7.........................................................................565 14.3.3 SLI fuses 14 - 13....................................................................571 14.4 Troubleshooting and malfunction correction 14 - 15.........................................573 14.4.1 Crane engine malfunctions 14 - 15....................................................573 14.4.2 Main hoist malfunctions 14 - 17.....................................................575 14.4.3 Auxiliary hoist malfunctions 14 - 19.................................................577 14.4.4 Derricking gear malfunctions 14 - 21.................................................579 14.4.5 Telescoping gear malfunctions 14 - 22................................................580 14.4.6 Slewing gear malfunctions 14 - 25....................................................583 14.4.7 Malfunctions at the counterweight hoist unit 14 - 26................................584 14.4.8 Crane control malfunctions 14 - 27...................................................585 14.4.9 Hydraulic system/hydraulic oil cooler malfunctions 14 - 28...........................586 14.4.10 Malfunctions on the SLI 14 - 29.....................................................587 14.4.11 Retraction emergency operation 14 - 42.............................................600 14.5 Crane control error messages 14 - 57......................................................615 14.5.1 Error messages about control units 14 - 57...........................................615 14.5.2 Error messages about power units 14 - 58.............................................616 14.5.3 Telescoping error messages 14 - 63...................................................621 14.5.4 Changing the connections in the control units 14 - 64................................622 14.5.5 Control lever emergency program 14 - 68.............................................626 14.5.6 Emergency operation submenu 14 - 70.................................................628 14.5.7 Entering telescope status after emergency operation menu 14 - 76.....................634 15 Technical information for superstructure 15 - 1..................................................637 15.1 Technical description of the superstructure 15 - 1........................................639 15.1.1 Turntable 15 - 1.....................................................................639 15.1.2 Crane operator™s cab 15 - 1..........................................................639 15.1.3 Crane engine and hydraulic system 15 - 2.............................................640 15.1.4 Control system 15 - 2................................................................640 15.1.5 Main boom 15 - 3.....................................................................641 15.1.6 Telescoping gear 15 - 3..............................................................641 15.1.7 Hoists 15 - 4........................................................................642 15.1.8 Slewing gear units 15 - 4............................................................642 15.1.9 Derricking cylinder 15 - 4...........................................................642 15.1.10 Electrical system 15 - 5............................................................643 15.1.11 Electrical connection to the carrier 15 - 5.........................................643 15.1.12 Counterweight 15 - 5................................................................643 15.1.13 Safety equipment 15 - 6.............................................................644 15.2 Technical data 15 - 7......................................................................645 15.2.1 Measurements and weights of the truck crane 15 - 8..................................646 15.2.2 Dimensions and weights of removable parts 15 - 9.....................................647 15.2.3 Technical data for superstructure 15 - 13............................................651 16 Alphabetical index 16 - 1........................................................................655 Alphabetical index................................................................................657 A.............................................................................................657 Access ladders to the superstructure 4-44................................................. 88 Activating the ignition...................................................................657 carrier 5-9..............................................................................103 superstructure 11-10.....................................................................350 Adding oil................................................................................657 in the crane engine 11-5.................................................................345 Additional heating system 4-35, 6-62...................................................... 79 deactivating 6-63........................................................................173 display time, setting 4-36............................................................... 80 switching on 6-62........................................................................172 additional heating system ................................................................657 superstructure 12-108....................................................................466 Additional heating system with timer 6-64.................................................174 automatic heating start, switch on and save 6-65.........................................175 switching off automatic heating start 6-66..............................................176 switching on/off 6-64....................................................................174 time, display/setting 6-65...............................................................175 Additional water heating system...........................................................657 see Additional heating system............................................................657 Adjusting the mirrors 6-19................................................................129 on the superstructure 12-12..............................................................370 Adjusting the seat........................................................................657 in the crane cab 10-58...................................................................334 in the driver™s cab 6-18.................................................................128 Air-conditioning system...................................................................657 in the crane cab 10-55, 12-110 to 12-112.................................................331 in the driver™s cab 4-41, 6-67 to 6-70................................................... 85 All-wheel steering: 6-55..................................................................165 Anemometer................................................................................657 installing on the main boom 13-84........................................................556 on the main boom 12-36...................................................................394 Auxiliary hoist...........................................................................657 malfunctions 14-19.......................................................................577 working with the auxiliary hoist 12-44...................................................402 Auxiliary hoist gear......................................................................657 display and operating instruments 10-34..................................................310 Axle drive................................................................................657 display and operating instruments in the driver™s cab 4-25.............................. 69 B.............................................................................................657 Battery master switch.....................................................................657 Carrier 5-7..............................................................................101 superstructure 11-7......................................................................347 bonnet....................................................................................657 opening and closing 4-46................................................................ 90 Boom floating position....................................................................657 switching off 12-6.......................................................................364 switching on 6-13........................................................................123 Boom initial tension......................................................................657 switching off 12-6......................................................................364 switching on 6-14........................................................................124 Brakes....................................................................................657 auxiliary brake 4-27..................................................................... 71 checking the brakes system 6-9...........................................................119 compressed-air supply for engine failure 7-7.............................................195 display and operating instruments in the driver™s cab 4-26.............................. 70 eddy current retarder 6-38...............................................................148 parking brake 4-27....................................................................... 71 retarder 6-37............................................................................147 Breakdown.................................................................................657 procedure in road traffic 7-3 to 7-4.....................................................191 towing 7-5 to 7-12.......................................................................193 C.............................................................................................657 Carrier hydraulic system..................................................................657 check the oil level 5-7..................................................................101 checking the position of the stop cocks 5-8..............................................102 Charge indicator..........................................................................657 warning lamp 4-30........................................................................ 74 Charge indicator lamp.....................................................................657 after ignition has been switched on 5-9, 11-11...........................................103 after the engine has been started 11-13..................................................353 after the vehicle engine has been started 5-13...........................................107 Check the oil level.......................................................................657 in the carrier hydraulic system 5-7......................................................101 in the superstructure hydraulic system 11-6..............................................346 Checking the coolant level................................................................657 in the crane engine 11-8.................................................................348 in the vehicle engine 5-6................................................................100 Checking the oil level....................................................................657 in the crane engine 11-4.................................................................344 in the vehicle engine 5-4................................................................ 98 Checking the steering lock 6-11...........................................................121 Checking the tyres 6-12...................................................................122 Checking the windscreen washing system....................................................657 in the crane cab 12-13...................................................................371 in the driver™s cab 6-18.................................................................128 CHECKLIST.................................................................................657 before starting crane work in winter 11-3................................................343 condition of the truck crane for on-road driving 6-1.....................................111 extending the outriggers 13-13..........................................................485 retracting the outriggers 13-15 to 13-40.................................................487 rigging for crane operation with main boom 13-1.........................................473 rigging mode when truck crane is rigged 12-1.............................................359 rigging the counterweight 13-46..........................................................518 starting the crane engine 11-1...........................................................341 starting vehicle engine 5-1.............................................................. 95 unrigging for crane operation with main boom 13-4........................................476 unrigging the counterweight 13-48........................................................520 working with the crane in winter 5-3.................................................... 97 Checks....................................................................................657 after starting the crane engine 11-13....................................................353 after the engine has been started 5-12...................................................106 before driving 6-9.......................................................................119 before starting the crane engine 11-4....................................................344 boom not set down warning lamp 6-11.....................................................121 of the safety equipment 12-14............................................................372 prior to starting vehicle engine 5-4.................................................... 98 while driving 6-32.......................................................................142 Choosing the site 13-6 to 13-12..........................................................478 Compressed air system.....................................................................657 see Brakes...............................................................................657 Constant engine speed 12-95...............................................................453 Constant speed............................................................................657 see Tempostat............................................................................657 Control lever emergency program 14-68.....................................................626 Conversion table 1-17..................................................................... 23 Counterweight lifting unit................................................................657 2 t counterweight section on the turntable, locking/releasing 13-62......................534 3 t base plate, placing onto the counterweight platform 13-50...........................522 3 t counterweight section, installing/removing 13-64.....................................536 current status, checking 13-58...........................................................530 extending/retracting the lifting cylinder 13-59..........................................531 indication of a malfunction 13-58........................................................530 release/block 13-58......................................................................530 unlock/lock 13-60........................................................................532 Crab travel mode: 6-55....................................................................165 Crane cab.................................................................................657 heating 10-53, 12-106....................................................................329 inclining 12-96.........................................................................454 overview 10-4............................................................................280 ventilating 12-109.......................................................................467 Crane cab windscreen wipers 10-50.........................................................326 Crane control.............................................................................657 see Acknowledging error messages.........................................................657 display and operating instruments 10-31..................................................307 display of an error message 12-93........................................................451 emergency stop switch 14-2...............................................................560 enter telescope status menu 14-76........................................................634 entering power unit speeds menu 12-89....................................................447 error memory sub-menu 12-86..............................................................444 error messages 14-57 to 14-78............................................................615 menu Display states 12-85................................................................443 menu Display telescoping status 12-88....................................................446 menus on the display 12-85...............................................................443 Crane control emergency stop switch 14-2.................................................560 Crane control error messages 14-57 to 14-78...............................................615 Crane engine..............................................................................657 checking the oil level 11-4..............................................................344 checks before starting 11-4..............................................................344 display and operating instruments 10-25..................................................301 inspections after starting 11-13........................................................353 malfunctions 14-15.......................................................................573 setting a constant engine speed 12-95...................................................453 start-up 11-11...........................................................................351 starting Œ CHECKLIST 11-1................................................................341 turning off 11-15........................................................................355 VDO electronics 10-58....................................................................334 Crane work................................................................................657 critical load control 12-96..............................................................454 during the winter Œ CHECKLIST 5-3........................................................ 97 in winter Œ CHECKLIST 11-3...............................................................343 permissible slewing ranges 12-39.........................................................397 preheating the hydraulic oil 12-5........................................................363 troubleshooting for malfunctions 14-3 to 14-4............................................561 Crane work with main boom.................................................................657 rigging Œ CHECKLIST 13-1.................................................................473 unrigging Œ CHECKLIST 13-4...............................................................476 Critical load control 12-96...............................................................454 D.............................................................................................657 Dead man™s switch system 10-62...........................................................338 Derricking gear...........................................................................657 display and operating instruments 10-36.................................................312 lowering the main boom for maintenance 12-83.............................................441 malfunctions 14-21.......................................................................579 working with the derricking gear 12-46...................................................404 Differential locks........................................................................657 see Transverse differential locks........................................................657 Door......................................................................................657 crane cab 10-56..........................................................................332 driver™s cab 4-43........................................................................ 87 Drive of third axle line / longitudinal differential locks 7-8............................196 checking 6-11...........................................................................121 switching off 6-47.......................................................................157 switching on 6-46........................................................................156 Driver™s cab..............................................................................657 adjusting the mirrors 6-19...............................................................129 adjusting the seat 6-18..................................................................128 heating 6-59.............................................................................169 overview 4-4............................................................................. 48 ventilating 6-61.........................................................................171 Driving...................................................................................657 breakdown procedure 7-3 to 7-4...........................................................191 checks before driving 6-9................................................................119 checks while driving 6-32................................................................142 downhill slopes 6-36.....................................................................146 off-road 6-45 to 6-54....................................................................155 on uphill slopes 6-39....................................................................149 with a rigged crane 12-99 to 12-104......................................................457 Driving direction indicator 4-31.......................................................... 75 Driving mode table 6-4....................................................................114 E.............................................................................................657 Earthing..................................................................................657 of the truck crane 13-12.................................................................484 Eddy current retarder.....................................................................657 see Brakes...............................................................................657 Electrical system.........................................................................657 connection between the carrier and superstructure 6-24...................................134 display and operating instruments in the crane cab 10-49................................325 display and operating instruments in the driver™s cab 4-30............................... 74 fuses in the carrier 7-19................................................................207 fuses in the superstructure 14-7.........................................................565 plug-in modules and consoles in the crane cab 14-5.......................................563 plug-in modules in the driver™s cab 7-17................................................205 SLI fuses 14-13..........................................................................571 Electronic level..........................................................................657 in the crane cab 10-52...................................................................328 on the carrier 13-36.....................................................................508 Emergency operation.......................................................................657 solenoid valves for the outriggers 7-43..................................................231 Emergency operation submenu on the Crane control display) 14-75...........................633 Emergency stop device.....................................................................657 on the carrier 7-1 to 7-2................................................................189 on the superstructure 14-1 to 14-2.......................................................559 Enlarging the surface area of the outrigger 13-8..........................................480 Error messages............................................................................657 control units 14-57......................................................................615 power units 14-58........................................................................616 SLI, table 14-30.........................................................................588 F.............................................................................................657 Fast speed 12-84..........................................................................442 Fire extinguisher.........................................................................657 in the crane cab 10-57...................................................................333 in the driver™s cab 4-47................................................................. 91 Flame start system........................................................................657 in the crane engine 11-11................................................................351 in the vehicle engine 5-10...............................................................104 Fuel tank.................................................................................657 crane engine 11-9........................................................................349 vehicle engine 6-17......................................................................127 Fuses.....................................................................................657 in the carrier 7-19.....................................................................207 in the superstructure 14-7...............................................................565 of the SLI 14-13.........................................................................571 H.............................................................................................657 Hazard warning system 4-30................................................................ 74 Heating system............................................................................657 crane cab 10-53, 12-106..................................................................329 driver™s cab 4-34, 6-59.................................................................. 78 Hoist rope 13-73..........................................................................545 checking the position 12-12.............................................................370 reeving on the main boom 13-75...........................................................547 Hoists 12-41.............................................................................399 Hook block................................................................................657 on a separate vehicle 13-71..............................................................543 on the bumper 13-69......................................................................541 Hydraulic system..........................................................................657 display and control instruments 4-28..................................................... 72 I.............................................................................................657 Identification............................................................................657 of the truck crane 1-1 to 1-3............................................................ 7 Instrument panels.........................................................................657 in the crane cab Œ overview 10-6 to 10-24................................................282 in the driver™s cab Œ overview 4-8...................................................... 52 K.............................................................................................657 Keys......................................................................................657 crane cab 10-56..........................................................................332 driver™s cab 4-43........................................................................ 87 L.............................................................................................657 Ladders 4-45.............................................................................. 89 Lamp test SLI 12-19......................................................................377 Level adjustment system 6-49..............................................................159 deactivating 6-52........................................................................162 display and operating instruments 4-31................................................... 75 moving the truck crane into on-road driving position 6-52...............................162 raising or lowering the entire truck crane 6-50..........................................160 switching on 6-50........................................................................160 tilting the truck crane lengthwise or crosswise 6-51.....................................161 Level of on-road driving..................................................................657 see On-the-road level....................................................................657 Lifting limit switch......................................................................657 on the main boom 12-43...................................................................401 Lifting limit switch weight 13-79.........................................................551 Load bearing capacity of the ground 13-6..................................................478 table 13-7...............................................................................479 Locking the superstructure 12-9...........................................................367 Lowering limit switch 10-60...............................................................336 M.............................................................................................657 Main boom.................................................................................657 lower the boom for maintenance purposes 12-83............................................441 rigging work 13-69.......................................................................541 Main hoist................................................................................657 display and operating instruments 10-33..................................................309 malfunctions 14-17.......................................................................575 working with the main hoist 12-41........................................................399 Main rope, possible reeving methods.......................................................657 on the main boom 13-80...................................................................552 Malfunctions..............................................................................657 counterweight lifting unit 14-26.........................................................584 crane control 14-27......................................................................585 differential locks 7-29..................................................................217 hydraulic oil cooler for superstructure 14-28............................................586 on crane control 14-28...................................................................586 on the SLI 14-29.........................................................................587 outrigger 7-33...........................................................................221 procedure in the event of malfunctions 7-35 to 7-46......................................223 service brake 7-30.......................................................................218 sevel adjustment system 7-33.............................................................221 steering 7-31............................................................................219 suspension locking system 7-33...........................................................221 tachograph 7-32..........................................................................220 transmission with automatic gear change 7-28............................................216 vehicle engine 7-25......................................................................213 when working with the crane 14-3.........................................................561 Mirror heating 4-31....................................................................... 75 Mounting wheel............................................................................657 on the spare wheel holder 7-14...........................................................202 on the truck crane 7-15.................................................................203 Movements which can be carried out simultaneously.........................................657 for operation with the main boom 12-98..................................................456 multipurpose switch 4-40.................................................................. 84 O.............................................................................................657 Off-road driving 6-45 to 6-54.............................................................155 On-the-road level.........................................................................657 checking 6-10............................................................................120 moving the crane into on-the-road level 6-52.............................................162 Operating hour counter....................................................................657 see crane control, display status menu...................................................657 Outrigger 13-13 to 13-14..................................................................485 actuating 13-23..........................................................................495 display and operating instruments 10-26..................................................302 extending Œ CHECKLIST 13-13..............................................................485 see also Level adjustment system.........................................................657 retracting Œ CHECKLIST 13-15 to 13-40...................................................487 variants 13-17...........................................................................489 Outrigger beams...........................................................................657 extending 13-23..........................................................................495 retracting 13-26.........................................................................498 Outrigger cylinders.......................................................................657 extending 13-30..........................................................................502 retracting 13-32, 13-40.................................................................504 Outrigger pads............................................................................657 moving into driving position 13-29......................................................501 moving into working position 13-28.......................................................500 Outrigger pressure displays..............................................................657 in the crane cab 10-54...................................................................330 on the carrier 13-39....................................................................511 Outrigger spans 13-17.....................................................................489 Overview..................................................................................657 crane cab 10-4...........................................................................280 crane section 10-1.......................................................................277 display and operating instruments 4-1 to 4-20............................................ 45 driver™s cab 4-4......................................................................... 48 of display and operating instruments 10-1 to 10-5........................................277 vehicle 4-1.............................................................................. 45 P.............................................................................................657 Parking brake.............................................................................657 display and operating instruments 4-27.................................................. 71 releasing mechanically 7-9...............................................................197 removing the mechanical lock 7-10.......................................................198 while towing 7-8.........................................................................196 Possible reeving methods..................................................................657 on the main boom 13-80...................................................................552 Power unit speed..........................................................................657 see Crane control, entering power unit speeds............................................657 R.............................................................................................657 Refuelling................................................................................657 fuel for the crane engine 11-9...........................................................349 fuel for the vehicle engine 6-17.........................................................127 Removing the tyre.........................................................................657 from the truck crane 7-13...............................................................201 Rigging mode..............................................................................657 before starting work Œ CHECKLIST 12-1...................................................359 setting on the SLI 12-20.................................................................378 Rigging work..............................................................................657 main boom 13-69..........................................................................541 outrigger 13-13 to 13-14.................................................................485 rigging for crane operation Œ CHECKLIST 13-1.............................................473 unrigging after crane work Œ CHECKLIST 13-4.............................................476 Roof ventilator 6-61......................................................................171 Rope end clamp 13-73......................................................................545 Rotating warning light 4-30............................................................... 74 S.............................................................................................657 Safe distance.............................................................................657 from banks and pits 13-9.................................................................481 from electrical lines 13-9...............................................................481 Safe load indicator.......................................................................657 see SLI.................................................................................657 Safety equipment..........................................................................657 checks 12-14.............................................................................372 functional description 10-59 to 10-62....................................................335 Sensor/indicator..........................................................................657 releasing shutdown 14-38.................................................................596 switch off during malfunction 14-38......................................................596 Separate steering.........................................................................657 checking the steering lock 6-11..........................................................121 unlocking fourth axle line steering 6-56 to 6-57.........................................166 general 6-55 to 6-58.....................................................................165 steering the 4th and 5th axle lines 6-56.................................................166 Slewing gear 12-48........................................................................406 display and operating instruments 10-35..................................................311 malfunctions 14-25.......................................................................583 slewing 12-48............................................................................406 slewing gear permanent brake 12-48.......................................................406 tracking 12-50...........................................................................408 Slewing gear freewheel....................................................................657 switching off 12-8.......................................................................366 switching on 6-16........................................................................126 SLI.......................................................................................657 display and operating instruments 10-41..................................................317 during crane work 12-29..................................................................387 error messages 12-32.....................................................................390 functional description 10-59.............................................................335 fuses 14-13..............................................................................571 input of values 12-21....................................................................379 lamp test 12-19..........................................................................377 malfunctions 14-29.......................................................................587 override 12-34...........................................................................392 setting rigging mode 12-20...............................................................378 switching on 12-17......................................................................375 SLI error message table 14-30.............................................................588 Spotlight for working area 10-49.........................................................325 Steering..................................................................................657 display and operating instruments in the driver™s cab 4-29............................. 73 Steering column...........................................................................657 operating instruments on the steering column 4-20....................................... 64 setting 6-19.............................................................................129 Stop engine cable.........................................................................657 see Emergency stop device................................................................657 Superstructure hydraulic system...........................................................657 check the oil level 11-6.................................................................346 checking the position of the stop cock 11-7.............................................347 cooling the hydraulic oil 12-97..........................................................455 display and control instruments 10-49...................................................325 preheating the hydraulic oil 12-5........................................................363 Superstructure lock 12-9..................................................................367 Superstructure, access ladder 4-44........................................................ 88 Suspension................................................................................657 checking 6-9.............................................................................119 locking 4-28............................................................................. 72 Switching off the.........................................................................657 crane engine 14-1........................................................................559 Switching the fan thermostat to emergency operation 7-35..................................223 Symbols in the operating instructions, explanation 2-1.................................... 27 T.............................................................................................657 Tachograph 6-20...........................................................................130 diagram sheets, inserting 6-22...........................................................132 open the drawer and check the time settings 6-21.........................................131 time group, setting 6-23.................................................................133 Technical data............................................................................657 superstructure 15-7 to 15-16.............................................................645 Technical description of the carrier 8-1 to 8-6...........................................237 Technical description of the truck crane..................................................657 superstructure 15-1 to 15-6.............................................................639 Technical specifications 8-7 to 8-14......................................................243 Telescoping gear..........................................................................657 display and operating instruments 10-37..................................................313 example of procedures when telescoping 12-62............................................420 function of the control lever 12-60......................................................418 functioning 12-54.......................................................................412 main boom fixed length 12-55.............................................................413 main boom intermediate length 12-56.....................................................414 main boom telescoping length 12-56.......................................................414 malfunctions 14-22......................................................................580 telescope status, status display on the SLI 12-56........................................414 telescoping sequence 12-59...............................................................417 telescoping, indicated on the crane control display. 12-88...............................446 Tempomat 6-40.............................................................................150 driving with 6-40........................................................................150 switching off: 6-41......................................................................151 switching on 6-40........................................................................150 Temposet 6-42.............................................................................152 driving with 6-42........................................................................152 switching on 6-42........................................................................152 Time......................................................................................657 setting time in the crane cab 4-36....................................................... 80 Topping up oil............................................................................657 in the vehicle engine 5-5................................................................ 99 Tow starting 7-11.........................................................................199 Towing 7-5 to 7-12........................................................................193 compressed-air supply for engine failure 7-7............................................195 in case of motor damage 7-5..............................................................193 parking brake 7-8.......................................................................196 power supply 7-8.........................................................................196 with damaged transmission 7-7............................................................195 Towing a trailer 6-71 to 6-76.............................................................181 Towing free...............................................................................657 forwards 6-53............................................................................163 reverse 6-53.............................................................................163 Transmission with automatic gear change...................................................657 after ignition has been switched on 6-25.................................................135 directing of travel, changing 6-30.......................................................140 direction of travel and starting gear, select 6-27.......................................137 display and operating instruments 4-22................................................... 66 display and operating instruments in the driver™s cab 4-22.............................. 66 display of the engaged gears 6-27........................................................137 emergency gear shift 7-39...............................................................227 error messages on the gearbox control display 7-36.......................................224 gear, changing while driving 6-29........................................................139 operating mode, select 6-26..............................................................136 operation 6-25...........................................................................135 operation with clutch emergency pedal 7-37...............................................225 procedure in the event of malfunctions 7-36..............................................224 shift in neutral position 6-26...........................................................136 starting 6-28............................................................................138 stopping 6-31............................................................................141 Transverse differential locks.............................................................657 checking 6-10............................................................................120 Transverse differential locks in all driven axle lines 6-48..............................158 Truck crane...............................................................................657 checking horizontal alignment 12-35.....................................................393 earthing 13-12...........................................................................484 freeing the crane by its own power 6-52.................................................162 horizontally align 13-32.................................................................504 identification 1-1 to 1-3............................................................... 7 in on-road driving position 6-52.........................................................162 overview of the crane section 10-1......................................................277 overview of the vehicle section 4-1...................................................... 45 raising or lowering 6-50.................................................................160 rocking it free 6-52.....................................................................162 safe distance 12-35.....................................................................393 securing the truck crane from rolling 6-43...............................................153 tilting the crane lengthwise or crosswise 6-51..........................................161 towing free 6-53.........................................................................163 turning off 6-43.........................................................................153 Tyre change...............................................................................657 see Wheel change.........................................................................657 V.............................................................................................657 Vehicle engine............................................................................657 checking the oil level 5-4............................................................... 98 checks before starting 5-4............................................................... 98 diagnostics plug 4-46.................................................................... 90 display and operating instruments 4-21................................................... 65 inspections after starting 5-12..........................................................106 preheating 6-62, 6-64....................................................................172 start 5-9, 11-10.........................................................................103 start-up 5-10............................................................................104 starting Œ CHECKLIST 5-1................................................................. 95 starting a warm engine 5-11..............................................................105 starting cold vehicle engine 5-10........................................................104 turning off 5-14.........................................................................108 Ventilation...............................................................................657 crane cab 12-109.........................................................................467 driver™s cab 4-34, 6-61.................................................................. 78 W.............................................................................................657 Warning plates for vehicle width..........................................................657 connection between the carrier and superstructure 6-24..................................134 Wheel change 7-13 to 7-16.................................................................201 Wheel, removing...........................................................................657 from the spare wheel holder 7-14.........................................................202 Wind......................................................................................657 influence of wind on crane work 12-36....................................................394 permissible wind load 12-38.............................................................396 wind speed table 12-36...................................................................394 Work break 12-105.........................................................................463 for work breaks lasting more than 8 hours 12-105.........................................463 short work break 12-105.................................................................463
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