Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084753 – PDF DOWNLOAD

Description

Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084753 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084753 – PDF DOWNLOAD

Language : English
Pages : 788
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084753 – PDF DOWNLOAD

Overview:
1.1 Vehicle identification:

These operating instructions are intended only for the truck crane whose serial number is specified on the front cover.

The following plates and numbers have been fitted to the truck crane for identification:
1 the chassis number on the front right-hand side behind the first axle line,
2 the model plate on the passenger seat console containing the chassis number and designation of the crane model,
3 the name plate at the front of the crane operator’s cab containing serial number and designation of the crane model,
4 the CE mark on the name plate.
The location of ID numbers for removable rigging parts (e.g. counterweights, lattice extension, auxiliary hoist) is specified in the corresponding chapters.

Overview and contents of truck crane user information:
Operating Instructions:

These operating instructions contain information required to operate the truck crane.

• The operating instructions are divided into two parts. Part 1 with chapters 1
  to 10 contains the Description of the vehicle section of the truck crane; Part 2
  with chapters 11 to 18 contains the Description of the crane section.
• In Chapter 2 you will find Basic safety instructions. Please read and observe
  these instructions, even if you are familiar with the safety manual. The Basic
  safety instructions are contained in this chapter only. Special safety instructions
  that relate to specific hazards are described in the section containing
  the operation with which the hazard is associated.
• Chapter 3 contains Information for 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.

• In Chapter 4 to 6 you will find information required for Driving the truck
  crane: a description of all structural and operational components, clearly defined
  checklists for rigging modes and work, and the operating instructions
  for on-road and off-road driving and the removal and installation of the auxiliary
  hoist.
• Rigging for on-road driving is described in Chapter 7.
• In Chapter 8, there is information on Troubleshooting on the vehicle section
  of the truck crane.
• Chapter 9 contains the Technical description of the individual parts and
  functional elements of the vehicle parts as well as the Technical data.
• Chapter 10 contains the Index. This helps you when you are looking for certain
  procedures and terms in the operating instructions.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084753 – PDF DOWNLOAD

GMK 6220-L..............................................................................................................  1
	Operating instructions Part 1 Driving...............................................................................  1
		Additional pages - Emergency operation/Emergency program telescoping ...........................................  3
		1 Overview......................................................................................................  7
			1.1 Vehicle identification..................................................................................  9
			1.2 EC declaration of conformity............................................................................ 12
			1.3 Overview and contents of truck crane user information................................................... 13
				1.3.1 Operating Instructions............................................................................ 13
				1.3.2 Lattice extension operating manual (additional equipment)......................................... 14
				1.3.3 Maintenance manual................................................................................ 14
				1.3.4 Lifting capacity table............................................................................ 15
				1.3.5 Outrigger load table.............................................................................. 15
				1.3.6 Safety manual..................................................................................... 15
				1.3.7 Circuit diagrams.................................................................................. 15
				1.3.8 Spare parts list.................................................................................. 16
			1.4 Instructions for use of this document................................................................... 16
				1.4.1 How are the operating instructions laid out?...................................................... 16
				1.4.2 How are the pages of the operating manual formatted?.............................................. 17
				1.4.3 How can I find the necessary information quickly and easily?...................................... 18
					Example of cross- reference usage................................................................... 19
					Explanations of how to use the index............................................................... 24
				1.4.4 Definition of direction information............................................................... 24
					Basic rule.......................................................................................... 24
					Buttons and switches............................................................................... 24
				1.4.5 Conversion table for US measurements.............................................................. 25
		2 Fundamental safety instructions for crane operators.......................................................... 27
			2.1 Warnings and symbols.................................................................................... 29
			2.2 Proper use.............................................................................................. 30
			2.3 Organisational measures................................................................................. 32
			2.4 Personnel qualifications................................................................................ 34
			2.5 Safety instructions that apply to truck crane driving................................................... 35
			2.6 Safety instructions for truck crane work................................................................ 35
		3 Information for applications engineering...................................................................... 37
			3.1 Safety instructions..................................................................................... 39
				3.1.1 Proper use........................................................................................ 39
				3.1.2 Organizational measures........................................................................... 39
				3.1.3 Personnel qualifications.......................................................................... 40
			3.2 Applications engineering................................................................................ 41
				3.2.1 Application engineering requirements.............................................................. 41
				3.2.2 Details about applications engineering contained in the user information......................... 42
		4 Description of the truck crane – vehicle section.............................................................. 43
			4.1 Overview of the operating and display instruments....................................................... 45
				4.1.1 Overview of the vehicle........................................................................... 45
				4.1.2 Overview of driver’s cab.......................................................................... 48
					Over the windscreen................................................................................. 50
				4.1.3 Front instrument panel............................................................................ 52
				4.1.4 Side instrument panel............................................................................. 60
			4.2 Functional description of the display and operating instruments........................................ 67
				4.2.1 On the instrument panels.......................................................................... 67
					Vehicle engine...................................................................................... 67
					Automatic gearbox.................................................................................. 68
					Transfer case....................................................................................... 70
					Axle drive.......................................................................................... 71
					Brakes.............................................................................................. 72
					Suspension.......................................................................................... 73
					Hydraulics.......................................................................................... 74
					Steering............................................................................................ 75
					Electrical system................................................................................... 76
					Level adjustment.................................................................................... 78
					Driver’s cab heating system........................................................................ 79
					Auxiliary heater with timer (additional equipment).................................................. 81
					Air-conditioning system additional equipment........................................................ 82
					Cab lighting........................................................................................ 84
					Other operating instruments........................................................................ 84
				4.2.2 Other operating instruments in the vehicle section................................................ 85
					Keys, doors, windows................................................................................ 85
					Access ladders...................................................................................... 86
					Ladders............................................................................................. 87
					Vehicle engine diagnostic plug...................................................................... 88
					Fire extinguisher (additional equipment)........................................................... 89
					Folding bunk (additional equipment)................................................................. 89
		5 Vehicle engine................................................................................................ 91
			5.1 Starting/turning off vehicle engine..................................................................... 93
				5.1.1 CHECKLIST: Starting vehicle engine................................................................ 93
				5.1.2 CHECKLIST: In winter.............................................................................. 96
				5.1.3 Checks before starting up vehicle engine.......................................................... 97
					Checking the hydraulic system stop cocks........................................................... 97
					Switching on the battery master switch.............................................................. 97
					Pre-checking the oil level in the automatic gearbox................................................. 98
					Checking the coolant level......................................................................... 99
					Checking hydraulic oil level........................................................................100
					Checking the engine oil level......................................................................100
					Topping up engine oil...............................................................................101
				5.1.4 Refuelling........................................................................................102
				5.1.5 Starting vehicle engine...........................................................................103
					Activating the ignition............................................................................103
					Starting the vehicle engine........................................................................105
				5.1.6 Inspections after the engine has been started.....................................................107
					Checking instruments...............................................................................107
					Checking oil level in the automatic gearbox.........................................................108
				5.1.7 Turning off the vehicle engine....................................................................111
				5.1.8 Emergency stop via the air intake inhibitor (additional equipment)................................112
					Switching on the air intake inhibitor...............................................................112
					Releasing the air intake inhibitor manually.........................................................113
		6 Driving the truck crane.......................................................................................115
			6.1 Checking the truck crane before driving.................................................................117
				6.1.1 CHECKLIST: Condition of the truck crane for on-road driving.......................................117
				6.1.2 On-road driving mode table........................................................................121
					Axle loads in driving mode..........................................................................122
				6.1.3 Checking the condition of the truck crane.........................................................124
					Checking the reservoir of the windscreen washing system...........................................124
					Warning plates for vehicle width....................................................................124
					Checking the tyres.................................................................................125
					Checking the electrical system......................................................................125
					Adjusting the mirrors..............................................................................126
					Check the compressed air and brake systems..........................................................126
					Checking suspension.................................................................................127
					Check the on-the- road level........................................................................127
					Checking the transverse differential locks..........................................................128
					Check the drive of the second axle line/longitudinal differential locks.............................128
					Checking the transfer case..........................................................................128
					Checking the steering locks........................................................................128
					Checking the Boom not set down warning lamp.........................................................129
				6.1.4 Adjusting the seat and the steering column........................................................130
					Adjusting the driver’s seat.......................................................................130
					Adjusting the steering column......................................................................130
				6.1.5 Trip recorder.....................................................................................131
					Inserting the 24hour disc in the trip recorder.....................................................131
			6.2 General operation.......................................................................................133
				6.2.1 Operating the automatic gearbox...................................................................133
					Driving range of the automatic gearbox.............................................................133
					Automatic gearbox diagnosis switch.................................................................135
					Automatic gearbox driving modes....................................................................135
					Starting and stopping..............................................................................136
					Upshifting the automatic gearbox...................................................................137
				6.2.2 Monitoring the control instruments while driving..................................................138
				6.2.3 Driving on downhill slopes........................................................................143
					Retarder............................................................................................143
					Preselecting gears..................................................................................144
				6.2.4 Driving on uphill slopes..........................................................................144
				6.2.5 Cruise control....................................................................................145
					Activating the cruise control.......................................................................145
					Driving with cruise control........................................................................146
					Deactivating the cruise control.....................................................................146
					Eddy current retarder (additional equipment)........................................................146
				6.2.6 Turning off the truck crane.......................................................................148
					Locking the parking brake..........................................................................148
					Automatic gearbox in neutral position............................................................148
					Turning off the vehicle engine.....................................................................148
					Securing the truck crane from rolling...............................................................148
					Switch off the battery master switch if the truck crane is idle for a longer period of time........149
					Securing the truck crane against unauthorised use..................................................149
			6.3 Off-the-road driving....................................................................................151
				6.3.1 Off-the-road gear.................................................................................152
					Engage the off- the-road gear.......................................................................152
					Deactivating off- the-road gear....................................................................152
				6.3.2 Drive of the second axle line/longitudinal differential locks.....................................153
					Switching on drive/longitudinal differential locks.................................................153
					Switching off drive/longitudinal differential locks.................................................154
				6.3.3 Transverse differential locks in all driven axle lines............................................155
					Activating transverse differential locks............................................................155
					Deactivating transverse differential locks.........................................................156
				6.3.4 Level adjustment system...........................................................................157
					Activating the level adjustment system.............................................................157
					Raising or lowering the entire truck crane.........................................................158
					Tilting the truck crane lengthwise or crosswise.....................................................159
					Moving the truck crane into position On-the-road level.............................................160
					Deactivating the level adjustment system............................................................160
				6.3.5 Freeing an immobilised truck crane................................................................161
					Freeing the truck crane by oneself..................................................................161
					Towing in reverse..................................................................................162
					Towing free forward................................................................................162
			6.4 Separate steering.......................................................................................163
				6.4.1 Switching on separate steering....................................................................165
				6.4.2 Steering axle lines with separate steering........................................................166
					All-wheel steering..................................................................................166
					Crab travel mode....................................................................................166
				6.4.3 Switching off separate steering and locking steering..............................................167
					Locking the steering in straight ahead position.....................................................167
					Locking in other positions..........................................................................168
				6.4.4 Matching steering angle...........................................................................169
			6.5 Heating and ventilation.................................................................................171
				6.5.1 Driver’s cab heating system.......................................................................171
					Ventilating the driver’s cab........................................................................173
				6.5.2 Additional water heating system (additional equipment)............................................174
					Preheating the vehicle engine......................................................................174
					Preheating the driver’s cab........................................................................174
					Switching on the additional heating system.........................................................174
					Deactivating the additional heating system.........................................................175
				6.5.3 Additional heating system with timer (additional equipment).......................................176
					Preheating the vehicle engine......................................................................176
					Preheating the driver’s cab........................................................................176
					Switching the auxiliary heater on/off...............................................................176
					Displaying and setting the current time.............................................................177
					Switching on and saving automatic heating start.....................................................177
					Switching off automatic heating start...............................................................178
				6.5.4 Roof blower (additional equipment)................................................................179
			6.6 Air-conditioning system (additional equipment)..........................................................181
				6.6.1 Switching on......................................................................................181
				6.6.2 Switching off.....................................................................................181
				6.6.3 Air conditioning..................................................................................182
					How to ensure pleasant air- conditioning............................................................182
					Dehumidifying the air in the driver’s cab..........................................................183
			6.7 Towing a trailer (additional equipment).................................................................185
				Effects on the axleloads...............................................................................185
				Coupling the trailer...................................................................................186
				Connecting supply cables................................................................................187
				Removing the supply lines...............................................................................188
				Uncoupling the trailer..................................................................................188
				Test position of the parking brake when towing a trailer................................................190
		7 Rigging for on-road driving...................................................................................191
			7.1 Rigging work for driving with a trailer.................................................................195
				7.1.1 Switch on slewing gear freewheel..................................................................196
				7.1.2 Switching on boom floating position...............................................................198
					Setting the main boom down on the trailer...........................................................198
				7.1.3 Switching on boom pretensioning...................................................................200
			7.2 Rigging the outrigger beams (additional equipment)......................................................203
				Equipment...............................................................................................203
				7.2.1 CHECKLIST: Removal of support beams...............................................................204
				7.2.2 CHECKLIST: Installation of outrigger beams........................................................206
				7.2.3 Preparing the truck crane for removal/installation................................................208
					Prerequisites for installation/removal..............................................................208
					Preparing the truck crane..........................................................................208
				7.2.4 Removing/inserting outrigger pads.................................................................209
					Removing spare wheel holder.........................................................................209
					Removing outrigger pads.............................................................................210
				7.2.5 Disconnecting/establishing hydraulic connection...................................................210
					Detach the hydraulic connection.....................................................................211
					Establishing the hydraulic connection...............................................................212
				7.2.6 Establishing/disconnecting the electrical connection for the outrigger pressure indicator.........213
				7.2.7 Transport position/operating position of the holding angle........................................214
				7.2.8 Locking/releasing the sliding cylinder locking pin................................................215
					Releasing the locking pin...........................................................................215
					Locking the sliding cylinder........................................................................216
				7.2.9 Extending/reinserting outrigger beams.............................................................216
					Extending the outrigger beams.......................................................................216
					Reinserting the outrigger beams.....................................................................219
				7.2.10 Transporting the outrigger beams/outrigger pads..................................................221
			7.3 Rigging the main boom...................................................................................223
				Additional equipment required...........................................................................223
				7.3.1 CHECKLIST: Removing the main boom.................................................................225
					Prerequisites.......................................................................................225
					Main boom removing..................................................................................225
				7.3.2 CHECKLIST: Mounting the main boom.................................................................228
					Prerequisites.......................................................................................228
					Installing the mainboom............................................................................228
				7.3.3 Supporting the truck crane while installing/removing the mainboom................................232
				7.3.4 Rigging work with the auxiliary crane.............................................................233
					Lifting the main boom from the turntable............................................................233
					Lifting the main boom onto the turntable............................................................234
				7.3.5 Establishing/disconnecting the hydraulic connection to the lattice extension additional equ.......235
					Breaking the hydraulic connection...................................................................235
					Establishing the hydraulic connection...............................................................236
				7.3.6 Pulling device on the bottom axle of the boom additional equipment................................237
					Bottom axle pin- type keepers.......................................................................237
					Hydraulic connection................................................................................238
					Retracting/extending pins...........................................................................239
				7.3.7 Locking pin at derricking cylinder head eyelet....................................................240
					Operating the lifting equipment....................................................................240
					Retracting/ extending pins.........................................................................242
				7.3.8 Hydraulic connections on the main boom............................................................243
					Removing/attaching the guide plates.................................................................244
					Establishing hydraulic connection...................................................................244
					Breaking the hydraulic connection...................................................................245
				7.3.9 Electrical connections on the main boom...........................................................246
				7.3.10 Checks following main jib mounting...............................................................247
					Hydraulic system check.............................................................................247
					Checking the electrical system.....................................................................248
				7.3.11 Before road driving..............................................................................250
					Securing the derricking cylinder for on-road driving................................................250
					Transporting the main boom..........................................................................250
				7.3.12 Derricking cylinder pressure relief..............................................................251
					Activating pressure relief..........................................................................251
					Deactivating pressure relief.......................................................................252
			7.4 Installing/removing the auxiliary hoist additional equipment............................................253
				7.4.1 Slinging points and transport.....................................................................253
					Slinging points.....................................................................................253
					Transport...........................................................................................254
				7.4.2 Mounting the auxiliary hoist......................................................................255
					Removing pin- type keeper and pins..................................................................255
					Attach the auxiliary hoist to the main hoist........................................................255
					Locking the auxiliary hoist.........................................................................256
					Establishing hydraulic and electrical connections...................................................256
				7.4.3 Removing the auxiliary hoist......................................................................257
				7.4.4 Permitted applications for the auxiliary hoist....................................................258
					Replacement for the main hoist......................................................................258
					Alternating operation with the main and auxiliary hoists............................................259
		8 Malfunctions on the carrier...................................................................................261
			8.1 Emergency stop device on carrier........................................................................263
				Turning off the vehicle engine.........................................................................263
			8.2 Breakdown in road traffic...............................................................................265
			8.3 Towing the truck crane..................................................................................267
				Towing with running vehicle engine.....................................................................267
				Towing when the vehicle engine isoff...................................................................268
				Compressed-air supply in the event of engine failure....................................................269
				Power supply............................................................................................269
				Gearbox.................................................................................................270
				Vehicle engine..........................................................................................270
				Parking brake...........................................................................................270
				Mechanically releasing the parking brake..............................................................271
				Towing procedure........................................................................................272
				Removing the mechanical locking from all spring- loaded brake cylinders...............................272
				Tow starting............................................................................................272
			8.4 Wheels..................................................................................................273
				8.4.1 Wheel change......................................................................................273
					Removing a damaged tyre............................................................................273
					Removing the wheel from the spare wheel holder.....................................................274
					Mounting a damaged wheel on the spare wheel holder.................................................275
					Mounting the spare wheel...........................................................................276
				8.4.2 Filling the tyres yourself........................................................................277
					Connecting the filling hose.........................................................................277
					Filling the tyres...................................................................................278
					Removing the tyre inflator hose.....................................................................278
			8.5 Electrical system.......................................................................................279
				8.5.1 Inserts...........................................................................................280
					Front plug-in module................................................................................280
				8.5.2 Fuses.............................................................................................282
					Group F1 to F6....................................................................................282
					Groups F7 to F9...................................................................................286
			8.6 Troubleshooting and malfunction correction..............................................................287
				8.6.1 Vehicle engine malfunctions.......................................................................287
				8.6.2 Automatic gearbox malfunctions....................................................................289
				8.6.3 Transfer case malfunctions........................................................................290
				8.6.4 Differential lock malfunctions....................................................................291
				8.6.5 Service brake malfunctions........................................................................292
				8.6.6 Steering system malfunctions......................................................................293
				8.6.7 Outrigger malfunctions............................................................................294
				8.6.8 Suspension locking system malfunctions............................................................294
				8.6.9 Level adjustment system malfunctions..............................................................294
			8.7 Procedure in the event of malfunctions..................................................................295
				8.7.1 Switching the fan thermostat to emergency operation...............................................295
				8.7.2 Troubleshooting for malfunctions in the automatic gearbox.........................................296
					Resetting the gearbox control......................................................................296
				8.7.3 Emergency operation of the solenoid valves for the outriggers.....................................297
				8.7.4 Separate steering emergency operation.............................................................300
					Moving the steering into on-road driving............................................................301
		9 Technical specifications carrier..............................................................................303
			9.1 Technical description of the carrier....................................................................305
				9.1.1 Crane carrier.....................................................................................305
				9.1.2 Driver’s cab......................................................................................305
				9.1.3 Drive units.......................................................................................306
				9.1.4 Engine and gearbox cooling system................................................................306
				9.1.5 Hydraulic system..................................................................................306
				9.1.6 Steering..........................................................................................307
				9.1.7 Suspension system................................................................................307
				9.1.8 Outrigger.........................................................................................308
				9.1.9 Compressed air system.............................................................................308
				9.1.10 Service brake....................................................................................309
				9.1.11 Parking brake....................................................................................309
				9.1.12 Retarder.........................................................................................309
				9.1.13 Secondary consumers.............................................................................309
				9.1.14 Towing the crane.................................................................................309
				9.1.15 Towing a trailer.................................................................................310
				9.1.16 Electrical system................................................................................310
				9.1.17 Slewing duct.....................................................................................310
			9.2 Technical specifications................................................................................311
				9.2.1 Measurements and weights of the truck crane.......................................................312
					Dimensions for driving on public roads.............................................................313
				9.2.2 Dimensions and weights of removable parts.........................................................314
					Spare wheel (additional equipment)..................................................................314
					Main boom...........................................................................................314
					Outriggers..........................................................................................314
				9.2.3 Carrier technical data............................................................................315
					Vehicle engine......................................................................................315
					Power shift gear...................................................................................315
					Transfer case.......................................................................................315
					Axle lines..........................................................................................315
					Steering............................................................................................315
					Tyres...............................................................................................316
					Vehicle's electrical system.........................................................................316
					Tools...............................................................................................316
					Outriggers..........................................................................................317
					Driving speeds......................................................................................318
					Climbing ability....................................................................................318
					Turning circle radiuses............................................................................319
		10 Index........................................................................................................321
			A...........................................................................................................325
			B...........................................................................................................326
			C...........................................................................................................326
			D...........................................................................................................328
			E...........................................................................................................329
			F...........................................................................................................330
			H...........................................................................................................330
			I...........................................................................................................331
			K...........................................................................................................331
			L...........................................................................................................331
			M...........................................................................................................331
			O...........................................................................................................332
			P...........................................................................................................333
			R...........................................................................................................333
			S...........................................................................................................334
			T...........................................................................................................335
			U...........................................................................................................337
			V...........................................................................................................337
			W...........................................................................................................337
	Operating instructions Part 2 Crane operation.......................................................................341
		Additional pages - Emergency operation/Emergency program telescoping ...........................................343
		11 Description of the truck crane – crane section...............................................................347
			11.1 Overview of the operating and display instruments......................................................349
				11.1.1 Overview of crane section........................................................................349
				11.1.2 Crane cab overview...............................................................................352
				11.1.3 Instrument panel.................................................................................354
					Front instrument panel..............................................................................354
					Fittings behind the crane driver seat...............................................................367
				11.1.4 Left control console.............................................................................368
				11.1.5 Right control console............................................................................369
				11.1.6 Control lever configuration......................................................................370
					Version 1 (standard)................................................................................370
					Version 2 (additional equipment)....................................................................371
				11.1.7 Control box for operating the outriggers.........................................................372
				11.1.8 Counterweight hoisting gear switch unit..........................................................373
				11.1.9 Switch box for electronic level..................................................................374
			11.2 Functional description of the display and operating instruments.......................................375
				11.2.1 Crane work.......................................................................................375
					Crane engine........................................................................................375
					Outrigger operation................................................................................376
					Counterweight lifting gear and lock................................................................378
					Crane control.......................................................................................380
					Main hoist..........................................................................................382
					Auxiliary hoist (additional equipment).............................................................383
					Slewing gear........................................................................................384
					Derricking gear.....................................................................................385
					Telescoping gear....................................................................................386
					Safe load indicator................................................................................391
					Hydraulics..........................................................................................398
					Electronics.........................................................................................398
					Other operating instruments.........................................................................399
					Electronic level in crane cab.......................................................................401
					Toggle switch to change measuring range............................................................401
					Crane cab heating system...........................................................................402
					Auxiliary heater with time switch (additional equipment)............................................402
					Air-conditioning system (additional equipment)......................................................404
					Houselock (additional equipment)....................................................................405
					Anemometer..........................................................................................405
					Outrigger pressure display (additional equipment)...................................................406
				11.2.2 Other operating instruments on the crane cab.....................................................407
					Doors, keys, windows................................................................................407
					Fire extinguisher (additional equipment)............................................................408
					Crane engine diagnostics plug......................................................................409
			11.3 Functional description of the safety devices...........................................................411
				11.3.1 Safe load indicator (SLI)........................................................................411
				11.3.2 Lowering limit switch............................................................................412
				11.3.3 Lifting limit switch............................................................................413
					Overriding the lifting limit switch shutdown.......................................................413
				11.3.4 Dead man's switch and seat contact switch........................................................414
		12 Crane engine.................................................................................................415
			12.1 Starting/turning off the crane engine..................................................................417
				12.1.1 CHECKLIST: Starting the crane engine.............................................................417
				12.1.2 CHECKLIST: In winter.............................................................................419
				12.1.3 Inspections before starting the crane engine.....................................................420
					Checking the stop cock on the hydraulic system.....................................................420
					Switching on the battery master switch.............................................................420
					Checking coolant level..............................................................................421
					Checking the hydraulic oil level....................................................................422
					Checking the oil level in the crane engine........................................................422
					Topping up engineoil..............................................................................423
					Refuelling..........................................................................................424
				12.1.4 Starting the crane engine........................................................................425
					Switching on the ignition..........................................................................425
					Starting the crane engine..........................................................................426
				12.1.5 Inspections after starting the crane engine......................................................428
					Checking instruments...............................................................................428
			12.2 Switching off the crane engine.........................................................................431
				12.2.1 Emergency stop via the air intake inhibitor (additional equipment)...............................432
					Switching on the air intake inhibitor...............................................................432
					Manually releasing the air intake lock..............................................................433
		13 Crane operation..............................................................................................435
			13.1 Checking the truck crane before working with thecrane...............................................437
				13.1.1 CHECKLIST: When truck crane is rigged............................................................437
				13.1.2 Adjusting the crane operator's seat..............................................................441
				13.1.3 Checking the condition of the truck crane........................................................442
					Checking the reservoir of the windscreen washing system.............................................442
					Visual inspection of the entire crane...............................................................442
					Checking the position of the hoist ropes............................................................443
					Electrical system...................................................................................443
				13.1.4 Checking the safety devices......................................................................444
					Safe load indicator.................................................................................444
					Lifting limit switch................................................................................444
					Dead man's switch system............................................................................445
					Emergency stop switch for the crane control.........................................................445
				13.1.5 Preheating the hydraulic oil.....................................................................446
					With an oil temperature of between –15 C and 0C:.................................................446
					With an oil temperature below –15 C :..............................................................446
				13.1.6 Superstructure lock..............................................................................447
					Removing the lock..................................................................................448
					Engaging the lock..................................................................................448
				13.1.7 Houselock (additional equipment).................................................................449
					Switching on the houselock..........................................................................449
					Switching off the houselock.........................................................................450
				13.1.8 Adjusting the mirrors............................................................................451
			13.2 Operating the safe load indicator (SLI)................................................................453
				13.2.1 Switching on the SLI.............................................................................453
					Switching on........................................................................................453
					Lamp test on the SLI................................................................................455
					Dimmers for the SLI status displays................................................................455
				13.2.2 Setting rigging mode.............................................................................456
					Setting using the SLI code..........................................................................456
					Setting using individual components................................................................456
					General instructions...............................................................................457
					Sequence during setting.............................................................................457
					Switching on entry mode............................................................................458
					Entering values.....................................................................................459
					Confirming entry....................................................................................461
					Transferring values.................................................................................461
					Switching over hoist position lights...............................................................462
				13.2.3 Checks before working with the crane.............................................................463
				13.2.4 During crane work................................................................................465
					Continuous displays................................................................................465
					Optional status displays...........................................................................466
					SLI early warning...................................................................................467
					SLI shutdown........................................................................................467
					Error messages......................................................................................468
					Error messages with additional optical displays.....................................................469
					SLI override........................................................................................470
			13.3 Crane work with the main boom..........................................................................471
				13.3.1 External influences during crane operation.......................................................471
					Horizontal alignment...............................................................................471
					Safe distances......................................................................................471
					Effect of wind on crane operations..................................................................472
					Anemometer..........................................................................................472
					Permissible wind load...............................................................................473
					Earthing the load...................................................................................474
				13.3.2 Slewing ranges permitted for working with the crane..............................................475
					360 slewing range..................................................................................475
					Working position 0 to the rear.....................................................................475
				13.3.3 Hoists...........................................................................................476
					Main hoist..........................................................................................476
					Auxiliary hoist (additional equipment)..............................................................479
				13.3.4 Derricking gear..................................................................................481
				13.3.5 Slewing gear.....................................................................................483
					Slewing gear permanent brake........................................................................483
					Slewing.............................................................................................483
					Slewing speed.......................................................................................484
					Tracking the slewing gear..........................................................................484
					Maximum permitted slewing speed....................................................................485
				13.3.6 Telescoping gear.................................................................................487
					Structure of the chapter............................................................................487
					Description of functioning..........................................................................488
					Main boom fixed length, intermediate length, telescoping length.....................................489
					Telescope status....................................................................................490
					Notes on telescope sequence.........................................................................493
					Check before telescoping for the first time.........................................................493
					Function of the control lever.......................................................................494
					Example of procedures when telescoping..............................................................496
					Check initial position.............................................................................497
					Unlocking telescoping cylinder......................................................................500
					Extending/ retracting telescoping cylinder and locking.............................................502
					Unlock telescope section............................................................................505
					Telescoping telescope section to fixed length and lock..............................................507
					Telescoping telescope section to intermediate length................................................511
					Locking telescope section...........................................................................512
					Telescoping with fully automatic control............................................................513
					Example of telescoping with teleautomatic...........................................................515
					Lowering the main boom for maintenance..............................................................517
					Telescoping the main boom in the horizontal position...............................................517
				13.3.7 Fast speed.......................................................................................518
				13.3.8 Menus on the crane control display...............................................................519
					Menu Display states.................................................................................519
					Menu Display telescoping status and teleautomatic..................................................523
					Menu Power unit speeds/Critical load control........................................................523
					Access emergency operation menu.....................................................................527
					Display of an error message.........................................................................528
				13.3.9 Setting a constant engine speed..................................................................530
				13.3.10 Critical load control...........................................................................531
				13.3.11 Incline crane cab...............................................................................532
				13.3.12 Cooling the hydraulic oil.......................................................................533
					Standard oil cooler.................................................................................533
					Additional oil cooler...............................................................................533
				13.3.13 Movements which can be carried out simultaneously...............................................534
			13.4 Driving with a rigged crane............................................................................535
				13.4.1 Driving route....................................................................................535
				13.4.2 Rigging mode and axle loads......................................................................536
					Boom positions......................................................................................536
				13.4.3 Driving the rigged truck crane...................................................................538
					Locking the superstructure and engaging the slewing gear permanent brake..........................538
					Retracting the outriggers..........................................................................538
					Switching over the suspension locking system........................................................538
					Switching on separate steering......................................................................539
					Driving.............................................................................................540
					Extending the outriggers............................................................................540
			13.5 Work break.............................................................................................541
				13.5.1 Short work break.................................................................................541
				13.5.2 Work breaks lasting more than 8 hours............................................................541
			13.6 Crane cab heating and ventilation......................................................................543
				13.6.1 Heating the crane cab............................................................................543
				13.6.2 Additional water heating system (additional equipment)..........................................544
					Switching on the additional heating system.........................................................544
					Switching off the additional heating system........................................................545
				13.6.3 Auxiliary heater with timer (additional equipment)...............................................545
					Preheating crane engine............................................................................545
					Preheating cranecab...............................................................................546
					Switching the auxiliary heater on/off...............................................................546
					Displaying and setting the current time.............................................................546
					Switching on and saving the automatic heating start.................................................547
					Switching off the automatic heating start...........................................................548
				13.6.4 Ventilating the crane cab........................................................................549
			13.7 Air-conditioning system (additional equipment).........................................................551
				13.7.1 Switching on.....................................................................................551
				13.7.2 Switching off....................................................................................552
				13.7.3 Air conditioning.................................................................................552
					How to ensure pleasant air- conditioning............................................................552
					Dehumidifying crane cab air.........................................................................553
		14 Rigging work.................................................................................................555
			14.1 Check lists for rigging work for crane operation with main boom........................................559
				14.1.1 CHECKLIST: Rigging...............................................................................559
				14.1.2 CHECKLIST: Unrigging.............................................................................563
			14.2 Choosing a suitable site...............................................................................565
				14.2.1 Load bearing capacity of the ground and the outrigger............................................565
					Enlarging the surface area of the outrigger........................................................567
				14.2.2 Safe distance from banks and pits................................................................568
				14.2.3 Earthing the truck crane.........................................................................569
					Earthing the truck crane............................................................................569
				14.2.4 Safe distance from electrical lines..............................................................570
			14.3 Rigging work after driving with trailer................................................................573
				14.3.1 Switching off slewing gear freewheel (additional equipment)......................................574
					Before slewing......................................................................................575
				14.3.2 Switching off the boom floating position (additional equipment)..................................576
				14.3.3 Switching off boom pre-tensioning (additional equipment).........................................577
			14.4 Outrigger..............................................................................................579
				14.4.1 CHECKLIST: Extending the outriggers..............................................................579
				14.4.2 CHECKLIST: Retracting outrigger..................................................................581
				14.4.3 Outrigger span...................................................................................583
					Outrigger span 8.70 x 8.50 m........................................................................583
					Outrigger span 8.70 x 6.00 m........................................................................584
					Outrigger span 8.50 x 2.72 m........................................................................584
				14.4.4 Preparing the outriggers.........................................................................586
					Aligning the truck crane horizontally..............................................................586
					Locking the suspension.............................................................................586
					Safety for on-road driving..........................................................................586
					Safety during crane operation.......................................................................587
				14.4.5 Extending/retracting the outrigger beams.........................................................588
					Extending the outrigger beams.......................................................................588
					Retracting the outrigger beams.....................................................................592
				14.4.6 Moving the outrigger pads into working/driving position..........................................593
					Moving the outrigger pads into working position...................................................593
					Moving the outrigger pads into driving position..................................................594
				14.4.7 Extending/retracting the outrigger cylinders.....................................................595
					Retracting the outrigger cylinders.................................................................596
				14.4.8 Aligning the truck crane horizontally............................................................598
					Reading the status display..........................................................................598
					Switching over the measuring range..................................................................599
					Aligning the truck crane horizontally...............................................................599
				14.4.9 Outrigger pressure display (additional equipment)...............................................600
					Reading the status displays.........................................................................600
			14.5 Counterweight..........................................................................................602
				14.5.1 Counterweight sections and identification........................................................602
					Counterweight sections..............................................................................602
					Identification......................................................................................602
				14.5.2 Counterweight versions...........................................................................603
				14.5.3 Slinging points on the counterweight sections....................................................607
				14.5.4 CHECKLIST: Rigging the counterweight.............................................................608
					Rig counterweight...................................................................................608
				14.5.5 CHECKLIST: Unrigging the counterweight...........................................................611
					Unrig counterweight.................................................................................611
				14.5.6 Placing the counterweight........................................................................613
					5.4 t base plate on counterweight platform..........................................................614
					Stacking counterweight sections.....................................................................614
				14.5.7 Connecting/disconnecting the hydraulic connection................................................615
					Establishing hydraulic connection.................................................................615
					Disconnecting the hydraulic connection..............................................................616
				14.5.8 Assembling the counterweight version.............................................................617
				14.5.9 3.5 t counterweight section......................................................................622
					Rigging with assemble rods (additional equipment)...................................................622
					Locking the 3.5 t counterweight section.............................................................623
				14.5.10 Extending/retracting the lifting cylinders of the 5.4 t base plate or lifting/lowering c.......624
					Extend the lifting cylinders........................................................................625
					Retract hoist cylinder.............................................................................626
				14.5.11 Locking the counterweight on the turntable/releasing the locking pin...........................626
					Hasp positions......................................................................................627
					Safety cock.........................................................................................627
					Locking the counterweight..........................................................................628
					Unlocking the counterweight.........................................................................628
				14.5.12 Rigging 3.75 t counterweight section (additional equipment).....................................629
				14.5.13 Rigging 3 t counterweight blocks (additional equipment)........................................630
				14.5.14 Slewing with the counterweight rigged...........................................................631
			14.6 Rigging work on the main boom..........................................................................633
				14.6.1 Hook block on the bumper.........................................................................633
					Picking up the hook block...........................................................................633
					Attaching the hook block............................................................................634
				14.6.2 Hook block on a separate vehicle.................................................................635
					Picking up the hook block...........................................................................635
					Setting down the hook block and securing the hoist rope for on-road driving........................636
				14.6.3 Reeving and unreeving the hoist rope............................................................637
					Rope end clamp......................................................................................637
					Installing/removing front rope grab.................................................................639
					Reeving the hoist rope..............................................................................640
					Lifting limit switch on the main boom...............................................................642
				14.6.4 Possible reeving methods on the main boom........................................................645
				14.6.5 Anemometer.......................................................................................649
					Remove the anemometer..............................................................................650
				14.6.6 Rigging heavy duty equipment.....................................................................651
					Heavy duty equipment parts..........................................................................651
					Equipment required.................................................................................651
					Rigging heavy duty equipment........................................................................652
					Unrigging heavy duty equipment......................................................................655
					Reevings with heavy duty equipment..................................................................657
		15 Malfunctions on the superstructure...........................................................................659
			15.1 Superstructure emergency stop device...................................................................661
				Switching off the crane engine.........................................................................661
				Crane control emergency stop switch.....................................................................662
			15.2 Troubleshooting for malfunctions that occur during crane operation....................................663
				Load cannot be lowered..................................................................................663
			15.3 Electrical system......................................................................................665
				15.3.1 Plug-in modules and consoles.....................................................................666
				15.3.2 Fuses............................................................................................668
					Groups F1 to F9...................................................................................668
					Groups F10 to F13...................................................................................672
				15.3.3 SLI fuses........................................................................................673
					Replacing fuses.....................................................................................673
			15.4 Troubleshooting and malfunction correction.............................................................675
				15.4.1 Crane engine malfunctions........................................................................675
				15.4.2 Main hoist malfunctions..........................................................................676
				15.4.3 Auxiliary hoist malfunctions.....................................................................678
				15.4.4 Derricking gear malfunctions.....................................................................680
				15.4.5 Telescoping gear malfunctions....................................................................682
				15.4.6 Slewing gear malfunctions........................................................................684
				15.4.7 Counterweight lifting gear/lock malfunctions.....................................................685
				15.4.8 Hydraulic system/hydraulic oil cooler malfunctions...............................................686
				15.4.9 Crane control malfunctions.......................................................................686
				15.4.10 Malfunctions on the SLI.........................................................................687
					Other malfunctions on the SLI......................................................................687
					SLI error message table............................................................................688
					Switch off sensor/ indicator during malfunction.....................................................695
					Check that the remaining sensor/ indicator is working..............................................696
					Accepting the telescope status from the crane control...............................................697
					Checking SLI lines and connections.................................................................698
				15.4.11 Retraction emergency operation..................................................................700
					Check before all emergency operation................................................................700
					Procedure for retracting...........................................................................701
					Mechanical emergency operation......................................................................702
					Hydraulic emergency operation.......................................................................704
			15.5 Error messages crane control...........................................................................717
				15.5.1 Error messages about control units...............................................................717
				15.5.2 Error messages about power units.................................................................718
					Determining defective part..........................................................................719
					Determining error area..............................................................................720
					Error causes and effects............................................................................721
				15.5.3 Telescoping error messages.......................................................................723
				15.5.4 Changing the connections in the control units....................................................724
					Connections and control units.......................................................................724
					Unrigging mobile crane with defective control unit..................................................724
					Inserting and removing connections..................................................................727
				15.5.5 Control lever emergency program..................................................................728
					Indications on the display..........................................................................728
					Carrying out emergency program.....................................................................729
				15.5.6 Emergency operation submenu......................................................................730
					Retracting with an error on the length indicator....................................................731
					Retracting with an error on the proximity switch....................................................734
					Table for approaching the locking points............................................................735
				15.5.7 Entering telescope status after emergency operation menu.........................................736
			15.6 Hydraulic emergency stop according to ZH1/461 (additional equipment)...................................739
				15.6.1 Important instructions for hydraulic emergency operation.........................................739
				15.6.2 Functioning and accessories......................................................................741
				15.6.3 Connecting the transformer.......................................................................742
				15.6.4 Switching emergency operation on/off.............................................................743
				15.6.5 Establishing required hydraulic circuits.........................................................744
					Making connections on the plug- in field............................................................744
					Additional switches for hoisting gear and slewing gear.............................................745
				15.6.6 Executing emergency operation....................................................................746
					Driving hoisting gear emergency operation...........................................................746
					Emergency operation driving derricking gear.........................................................747
					Emergency operation driving the slewing gear........................................................747
				15.6.7 After the emergency operation....................................................................748
		16 Technical information for superstructure.....................................................................749
			16.1 Technical description of the superstructure............................................................751
				16.1.1 Turntable........................................................................................751
				16.1.2 Crane operator’s cab.............................................................................751
				16.1.3 Crane engine and hydraulic system................................................................752
				16.1.4 Control system...................................................................................752
				16.1.5 Main boom........................................................................................753
				16.1.6 Telescoping gear.................................................................................753
				16.1.7 Hoists...........................................................................................754
				16.1.8 Slewing gear units...............................................................................754
				16.1.9 Houselock (additional equipment).................................................................754
				16.1.10 Derricking cylinder.............................................................................754
				16.1.11 Electrical system..............................................................................755
				16.1.12 Counterweight...................................................................................755
				16.1.13 Safety equipment................................................................................756
			16.2 Technical data.........................................................................................757
				16.2.1 Maximum lifting capacity.........................................................................757
					DIN/ISO/EN..........................................................................................757
					ANSI B 30.5 (85%)...................................................................................757
				16.2.2 Guaranteed value specifications..................................................................757
				16.2.3 Measurements and weights of the truck crane......................................................758
					Dimensions for driving on public roads.............................................................759
				16.2.4 Dimensions and weights of removable parts........................................................760
					Counterweight parts................................................................................760
					Hook blocks and hook tackle.........................................................................761
					Auxiliary hoist.....................................................................................761
					Main boom...........................................................................................762
					Heavy dutyequipment................................................................................762
					Counterweight versions..............................................................................762
				16.2.5 Technical data for superstructure................................................................766
					Crane engine........................................................................................766
					Crane’s electrical system...........................................................................766
					Main hoist..........................................................................................766
					Auxiliary hoist (additional equipment)..............................................................767
					Slewing gears.......................................................................................767
					Derricking gear.....................................................................................767
					Main boom...........................................................................................767
					Operating speeds and times without a load..........................................................768
		17 Index........................................................................................................769
			A...........................................................................................................773
			B...........................................................................................................774
			C...........................................................................................................774
			D...........................................................................................................776
			E...........................................................................................................777
			F...........................................................................................................778
			H...........................................................................................................778
			I...........................................................................................................779
			K...........................................................................................................779
			L...........................................................................................................779
			M...........................................................................................................779
			O...........................................................................................................780
			P...........................................................................................................781
			R...........................................................................................................781
			S...........................................................................................................782
			T...........................................................................................................783
			U...........................................................................................................785
			V...........................................................................................................785
			W...........................................................................................................785

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