Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 2084897 – PDF DOWNLOAD
$35.95
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 2084897 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 2084897 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 2084897 – PDF DOWNLOAD
Language : English
Pages : 1118
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 2084897 – PDF DOWNLOAD
Intended use:
The truck crane GMK 7450 is constructed in accordance with the latest tech- nology and the
recognized safety regulations. Nevertheless, personal injury to the operator or a third party as
well as damage to the crane and other prop- erty may occur during use.
- The truck crane may only be modified with the consent of the manufacturer.
- The truck crane GMK 7450 may only be used in when in excellent working condition and for its
intended purpose, and with due attention to safe oper- ation and any possible hazards.
Malfunctions that may affect the safe operation of the unit are to be cor- rected immediately. - The GMK 7450 truck crane may only be operated at temperatures of between 25 to + 40 °C.
- The GMK 7450 truck crane may only be used to vertically lift loads in the authorized rigging modes
using a hook block that is reeved to the hoist rope. The weight and center of distribution of the
loads must be known. Any other use of the crane is not considered to represent intended use. - The manufacturer is not liable for damage resulting from the improper or unauthorized use of the
truck crane GMK 7450. The user shall take full responsibility for any such use.
Intended use also entails
– Observing the complete crane documentation consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– Observing the inspection and maintenance requirements specified in the
maintenance manual
TABLE OF CONTENTS:
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 2084897 – PDF DOWNLOAD
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 Conformity Declaration............................................................................... 13 1.3 Overview and contents of truck crane user information................................................... 15 1.3.1 Operating instructions for driving and crane operation............................................ 15 1.3.2 Operating instructions for the lattice extension (additionalequipment)........................... 16 1.3.3 Maintenance manual................................................................................ 16 1.3.4 Lifting capacity tables........................................................................... 17 1.3.5 Outrigger pressure tables......................................................................... 17 1.3.6 Safety manual..................................................................................... 17 1.3.7 Circuit diagrams.................................................................................. 17 1.3.8 Spare parts list.................................................................................. 18 1.4 Instructions for using this documentation............................................................... 18 1.4.1 How are the operating instructions laid out?...................................................... 18 1.4.2 How are the pages of the operating instructions formatted?........................................ 19 1.4.3 How can I find the necessary information quickly and easily?...................................... 20 Example of cross- reference usage................................................................... 21 How to use the index ............................................................................. 26 1.4.4 Definition of stated directions................................................................... 26 Basic rule.......................................................................................... 26 Buttons and switches............................................................................... 26 1.4.5 Conversion table for US measurements.............................................................. 27 2 Basic safety instructions for crane operators................................................................. 29 2.1 Warnings and symbols.................................................................................... 31 2.2 Intended use............................................................................................ 32 2.3 Organisational measures................................................................................. 34 2.4 Personnel qualifications................................................................................ 36 2.5 Safety instructions that apply to truck crane driving................................................... 37 2.6 Safety instructions for truck crane work................................................................ 37 3 Information for operations planning........................................................................... 41 3.1 Safety instructions..................................................................................... 43 3.1.1 Intended use...................................................................................... 43 3.1.2 Organisational measures........................................................................... 43 3.1.3 Personnel qualifications.......................................................................... 44 3.2 Operations planning..................................................................................... 45 3.2.1 Prerequisites for operations planning............................................................. 45 3.2.2 Information for operations planning contained in the information for use ........................ 46 4 Description of the truck crane vehicle section................................................................ 47 4.1 Overview of the operating and display elements.......................................................... 49 4.1.1 Overview of the vehicle........................................................................... 49 4.1.2 Overview of the driver's cab...................................................................... 52 Top view of driver's cab............................................................................ 52 Overhead in the driver's cab........................................................................ 54 Below the front instrument panel.................................................................... 55 4.1.3 Front instrument panel............................................................................ 56 Left-hand insert.................................................................................... 56 Tachograph insert................................................................................... 58 Speedometer insert................................................................................. 60 Right-hand insert................................................................................... 62 Heating insert...................................................................................... 64 4.1.4 Side instrument panel............................................................................. 66 Insert 1............................................................................................ 66 Insert 2............................................................................................ 68 Control unit for automatic transmission............................................................. 70 4.1.5 Switch boxes for the outrigger/electronic level/outrigger pressure indicator..................... 71 4.1.6 Operating elements on the steering column......................................................... 72 4.1.7 Control box for the locking pin of the rear housing/additionalaxis............................... 73 4.2 Functional description of the display and operating elements........................................... 75 4.2.1 On the instrument panels.......................................................................... 75 Vehicle engine...................................................................................... 75 Automatic transmission ........................................................................... 77 Transfer case....................................................................................... 79 Axle drive.......................................................................................... 80 Brakes.............................................................................................. 81 Steering............................................................................................ 82 Suspension.......................................................................................... 84 Hydraulic system.................................................................................... 85 Electrics........................................................................................... 86 Level adjustment system............................................................................ 88 Tachograph.......................................................................................... 90 Speedometer insert................................................................................. 90 Auxiliary heater.................................................................................... 91 Heating in the driver's cab........................................................................ 92 Auxiliary heater with timer (additional equipment)................................................. 93 Other operating elements........................................................................... 94 4.2.2 On the steering column............................................................................ 95 Ignition lock....................................................................................... 95 Multipurpose switch, right.......................................................................... 95 Multipurpose switch, left........................................................................... 97 4.2.3 Overhead in the driver's cab...................................................................... 98 Air-conditioning system (additional equipment)...................................................... 98 Cab lighting........................................................................................ 98 Cab lighting........................................................................................ 99 4.3 Other operating elements on the carrier................................................................. 101 Keys.................................................................................................... 101 Doors................................................................................................... 101 Windows................................................................................................. 103 Access ladders.......................................................................................... 104 Ladders................................................................................................. 104 Diagnostics for engine/ transmission/ electronics..................................................... 106 Front flap.............................................................................................. 106 Fire extinguisher (additional equipment)............................................................... 107 Folding berth (additional equipment).................................................................... 107 5 Vehicle engine................................................................................................ 109 5.1 Starting/turning off the vehicle engine................................................................. 111 5.1.1 CHECKLIST: Starting the vehicle engine............................................................ 111 5.1.2 CHECKLIST: In winter.............................................................................. 114 5.1.3 Checks prior to starting vehicle engine........................................................... 115 Checking the shut- off valves in the hydraulic system.............................................. 115 Switching on the battery master switch............................................................. 115 Pre-checking the oil level in the automatic transmission............................................ 116 Checking coolant level.............................................................................. 117 Checking the hydraulic oil level.................................................................... 118 Checking the engine oil level...................................................................... 118 Topping up motor oil................................................................................ 119 5.1.4 Refuelling........................................................................................ 120 5.1.5 Starting the vehicle engine....................................................................... 121 Switching on the ignition.......................................................................... 121 Starting the vehicle engine........................................................................ 123 Setting the idling speed............................................................................ 125 5.1.6 Checks after the engine has been started.......................................................... 127 Checking instruments............................................................................... 127 Checking the oil level in the automatic transmission.............................................. 129 5.2 Turning off the vehicle engine.......................................................................... 133 5.2.1 In a normal situation: ignition lock.............................................................. 133 5.2.2 In an emergency situation: vehicle engine emergency stopswitch................................... 134 5.2.3 In an emergency situation: using the air intake inhibitor (additional equipment).................. 135 Switching on the air intake inhibitor............................................................... 135 Releasing the air intake inhibitor manually........................................................ 136 6 Driving the truck crane....................................................................................... 137 6.1 Checks and adjustments before driving................................................................... 139 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving....................................... 139 6.1.2 Driving mode table............................................................................... 144 Axle loads in driving mode.......................................................................... 144 6.1.3 Checking the condition of the truck crane......................................................... 147 Checking the reservoir of the windscreen washing system............................................. 147 Warning plates for vehicle width.................................................................... 147 Checking the tyres................................................................................. 148 Checking the electrical system...................................................................... 148 Checking the mirror settings........................................................................ 149 Checking the compressed-air system................................................................. 149 Checking the suspension............................................................................ 150 Checking on-road level............................................................................ 150 Checking the transverse differential locks.......................................................... 151 Checking the longitudinal differential locks....................................................... 151 Checking the transfer case.......................................................................... 151 Checking the steering locks....................................................................... 151 Checking the Boom not set down warning lamp......................................................... 152 6.1.4 Adjusting the seat and the steering column........................................................ 153 Adjusting the driver's seat........................................................................ 153 Adjusting the passenger seat....................................................................... 154 Adjusting the steering column....................................................................... 155 6.1.5 Tachograph........................................................................................ 157 6.2 General operation....................................................................................... 163 6.2.1 Operating the automatic transmission.............................................................. 163 Switching on........................................................................................ 163 Automatic transmission box driving modes........................................................... 164 Selecting the driving direction.................................................................... 165 Starting............................................................................................ 166 Driving and changing transmissions.................................................................. 166 Switching the transmission to neutral position...................................................... 167 Changing the direction of travel.................................................................... 168 Stopping the truck crane............................................................................ 169 Driving in difficult terrain........................................................................ 169 Cold start program................................................................................. 170 On the roller type dynamometer...................................................................... 170 6.2.2 Monitoring the control instruments while driving.................................................. 171 6.2.3 Driving downhill.................................................................................. 174 Starting on a downward slope....................................................................... 174 Driving downhill.................................................................................... 175 Preselecting transmissions.......................................................................... 175 Engine brake........................................................................................ 176 Transmission retarder............................................................................... 177 6.2.4 Driving uphill.................................................................................... 178 Starting............................................................................................ 178 Driving............................................................................................. 178 6.2.5 Cruise control.................................................................................... 179 Activating the cruise control...................................................................... 179 Driving with the cruise control.................................................................... 179 Switching off the cruise control................................................................... 180 6.2.6 Temposet (max. speed selector).................................................................... 181 Switching on temposet.............................................................................. 181 Driving with the temposet.......................................................................... 181 Temposet switching off.............................................................................. 182 6.2.7 Parking the truck crane........................................................................... 182 Applying the holding brake.......................................................................... 182 Activating neutral position........................................................................ 182 Turning off the vehicle engine..................................................................... 182 Securing the truck crane against rolling............................................................ 183 Extended standstill................................................................................. 183 6.3 Off-road driving........................................................................................ 185 6.3.1 Off-road transmission............................................................................. 186 Engaging the off- road transmission................................................................ 186 Deactivating the off-road transmission............................................................. 186 6.3.2 Longitudinal differential locks................................................................... 187 Switching on the longitudinal differential locks.................................................... 187 Switching off the longitudinal differential locks................................................... 188 6.3.3 Transverse differential locks in all driven axle lines............................................ 189 Activating the transverse differential locks........................................................ 189 Deactivating the transverse differential locks...................................................... 190 6.3.4 Level adjustment system........................................................................... 191 Checks before level adjustment...................................................................... 191 Activating the level adjustment system.............................................................. 192 Raising or lowering the entire truck crane.......................................................... 192 Tilting the truck crane lengthwise or crosswise..................................................... 193 Bring the truck crane into On-road level............................................................ 194 Deactivating the level adjustment system............................................................ 194 6.3.5 Freeing an immobilized truck crane................................................................ 195 Freeing the truck crane by its own power.......................................................... 195 Towing free to the front........................................................................... 196 Towing free to the rear............................................................................ 196 6.4 Separate steering....................................................................................... 197 6.4.1 Switching on separate steering.................................................................... 199 6.4.2 Steering axle lines with separate steering........................................................ 200 All-wheel steering.................................................................................. 200 Crab travel mode.................................................................................... 200 6.4.3 Switching off separate steering and locking the steering.......................................... 201 Locking the steering in "straight ahead" position................................................... 201 Locking the steering in other positions............................................................. 202 6.5 Heating system and fan for driver's cab................................................................. 203 6.5.1 Heating in the driver's cab....................................................................... 203 Heating the driver's cab............................................................................ 203 Ventilating the driver's cab........................................................................ 205 6.5.2 Auxiliary water heating system.................................................................... 206 Preheating the vehicle engine....................................................................... 206 Switching on the auxiliary heating system........................................................... 206 Switching off the auxiliary heating system.......................................................... 208 6.5.3 Auxiliary heater with timer (additional equipment)................................................ 208 Preheating the diesel engine....................................................................... 208 Preheating the driver's cab........................................................................ 208 Switching on the auxiliary heating system........................................................... 209 Displaying and setting the current time............................................................. 210 Switching on and saving the automatic heating start................................................. 210 Switching on and saving the automatic heating start................................................. 211 6.6 Air-conditioning system (additional equipment).......................................................... 213 6.6.1 To switch on...................................................................................... 213 6.6.2 To switch off..................................................................................... 213 6.6.3 Air conditioning.................................................................................. 215 How to use the air conditioning effectively......................................................... 215 Dry air in the driver's cab......................................................................... 216 7 Rigging for on-road driving................................................................................... 217 7.1 Rigging work for driving with a trailer................................................................. 221 7.1.1 Switching on the slewing gear freewheel........................................................... 222 7.1.2 Switching on the boom floating position........................................................... 224 Placing the main boom on a trailer.................................................................. 224 7.1.3 Switching on boom pretensioning................................................................... 225 7.2 Rigging the front outrigger beams....................................................................... 227 Equipment............................................................................................... 227 7.2.1 CHECKLIST: Removing the outrigger beams........................................................... 228 7.2.2 CHECKLIST: Mounting of outrigger beams............................................................ 229 7.2.3 Preparing the truck crane for removal/installation................................................ 231 Prerequisites for installation/ removal............................................................. 231 Preparing the truck crane.......................................................................... 231 7.2.4 Removing/attaching outrigger pads................................................................. 233 Removing outrigger pads............................................................................. 233 Attaching the outrigger pads....................................................................... 234 7.2.5 Breaking/establishing the hydraulic connection.................................................... 234 Position of the valve blocks....................................................................... 235 Breaking the hydraulic connection................................................................... 236 Establishing the hydraulic connection............................................................... 237 7.2.6 Establishing/disconnecting the electrical connection for theoutrigger pressure indicator......... 238 7.2.7 Transport position/operating position of the holding angle........................................ 239 7.2.8 Locking/releasing the extension cylinder locking pin.............................................. 240 Releasing the lock.................................................................................. 240 Locking the extension cylinder...................................................................... 241 7.2.9 Extending/reinserting outrigger beams............................................................. 242 Turning down and adjusting the wear pads............................................................ 242 Extending the outrigger............................................................................ 242 Reinserting the outrigger beams.................................................................... 245 7.2.10 Transporting the outriggers/outrigger pads....................................................... 247 7.3 Rigging the rear outrigger housing...................................................................... 249 Required equipment...................................................................................... 249 7.3.1 CHECKLIST: Removal of the outrigger housing....................................................... 250 7.3.2 CHECKLIST: Installation of outrigger housing...................................................... 253 7.3.3 Rig the outrigger span 7.78x8.90/1.22m......................................................... 255 Preparations for installation....................................................................... 255 Preparations for removal............................................................................ 255 Supporting the truck crane with the jack stands.................................................... 256 Removing the jack stands............................................................................ 258 7.3.4 Crane movements when installing and removing...................................................... 258 Prerequisites....................................................................................... 258 Before installation................................................................................. 258 After removal...................................................................................... 259 7.3.5 Attachment points on the rear outrigger housing................................................... 259 7.3.6 Breaking/establishing the hydraulic connection.................................................... 260 Depressurizing the connections...................................................................... 260 Establishing the hydraulic connection............................................................. 261 Breaking the hydraulic connection................................................................... 261 7.3.7 Establishing/disconnecting electrical connection.................................................. 262 Establishing the electrical connection............................................................ 262 Breaking the electrical connection.................................................................. 263 7.3.8 Establishing/disconnecting pneumatic connection................................................... 264 7.3.9 Attaching/removing the outrigger housing with the truck crane..................................... 265 Raising the outrigger housing...................................................................... 266 Attaching the outrigger housing..................................................................... 266 7.3.10 Locking the outrigger housing to the carrier, unlocking.......................................... 267 Locking the outrigger housing....................................................................... 267 Releasing the lock.................................................................................. 267 Extending and retracting pins....................................................................... 268 7.3.11 Setting the outrigger box onto the support....................................................... 269 7.3.12 Transportation on a separate vehicle............................................................. 271 7.3.13 Installing/removing the rear bumper.............................................................. 272 Prerequisites....................................................................................... 272 Slinging the rear bumper............................................................................ 272 Installing the rear bumper.......................................................................... 273 Removing the rear bumper............................................................................ 274 7.3.14 Hook block in the rear bumper.................................................................... 276 Setting down the hook block........................................................................ 276 Picking up the hook block.......................................................................... 277 7.4 Rigging the main boom................................................................................... 279 Additional equipment required........................................................................... 279 7.4.1 CHECKLIST: Removing the main boom................................................................. 280 General prerequisites:.............................................................................. 280 Prerequisites in terms of the outriggers............................................................ 280 Removing main boom................................................................................. 281 7.4.2 CHECKLIST: Installing the main boom............................................................... 284 Prerequisites:...................................................................................... 284 7.4.3 Pushing the railings on the access ladder out/in................................................. 288 Pushing out the railings........................................................................... 288 Pushing in the railing............................................................................. 289 7.4.4 Rigging work with auxiliary crane................................................................. 289 Slinging points..................................................................................... 289 Lifting the main boom from the turntable........................................................... 290 Lifting the main boom onto the turntable........................................................... 291 7.4.5 Connecting and removing the hand-held control..................................................... 292 Connections on the superstructure................................................................... 292 Connecting/removing the hand-held control........................................................... 292 Connecting/removing the hand-held control........................................................... 293 7.4.6 Electrical connections on the main boom........................................................... 295 Breaking the electrical connections................................................................ 295 Establishing electrical connections................................................................. 296 7.4.7 Derricking the main boom with the hand-held control............................................... 296 Preparing the hand-held control..................................................................... 296 Derricking the main boom............................................................................ 297 7.4.8 Hydraulic connections on the main boom............................................................ 298 Removing/replacing guide plates..................................................................... 298 Connections for the telescoping mechanism........................................................... 299 Connections for the pulling devices................................................................. 300 7.4.9 Pulling device on the boom pivot pin.............................................................. 301 Removing/inserting the locking pin.................................................................. 301 Preparing the hand-held control..................................................................... 302 Retract/extend the boom pivot pin.................................................................. 303 7.4.10 Pulling devices on the head pins of the derricking cylinders..................................... 304 Attaching the derricking cylinder support........................................................... 304 Operating the lifting device....................................................................... 306 Releasing/ tightening the mechanical locks......................................................... 307 Preparing the hand-held control..................................................................... 308 Retracting the derricking cylinder head pin........................................................ 309 Extending the derricking cylinder head pin......................................................... 310 7.4.11 Checks after main boom installation.............................................................. 311 Checks at the Crane control display................................................................ 311 Hydraulic system check............................................................................. 312 7.4.12 Slewing the superstructure with main boom removed................................................ 313 Slewing to the front............................................................................... 313 Slewing to the rear................................................................................ 315 7.4.13 Before road driving.............................................................................. 318 Transport protection for the derricking cylinder.................................................... 318 Transporting the main boom.......................................................................... 319 7.4.14 Derricking cylinder pressure relief.............................................................. 320 Activating pressure relief.......................................................................... 320 Deactivating pressure relief........................................................................ 321 7.5 Installing/removing the additional axle................................................................. 323 Auxiliary equipment required............................................................................ 323 7.5.1 CHECKLIST: Installing the additional axle......................................................... 324 7.5.2 CHECKLIST: Removing the additional axle........................................................... 327 7.5.3 Outrigger span 7.78x8.90/1.22m for rigging the additional axle................................. 331 Supporting the truck crane with the connection pieces.............................................. 331 Removing the jack supports.......................................................................... 333 7.5.4 Slinging points on the additional axle............................................................ 333 7.5.5 Crane movements when installing and removing...................................................... 335 Prerequisites....................................................................................... 335 Before installation................................................................................. 335 After removal...................................................................................... 335 7.5.6 Breaking/establishing the hydraulic connections................................................... 336 Establishing the hydraulic connection............................................................. 336 Breaking the hydraulic connection................................................................... 337 7.5.7 Establishing/disconnecting electrical connection.................................................. 339 Establishing the electrical connection............................................................ 339 Breaking the electrical connection.................................................................. 340 7.5.8 Establishing/disconnecting the pneumatic connection............................................... 341 7.5.9 Attaching/removing the additional axle with the truck crane....................................... 342 Attaching the additional axle...................................................................... 343 Raising the additional axle........................................................................ 343 7.5.10 Locking the additional axle to the carrier, unlocking............................................ 344 Locking the additional axle........................................................................ 344 Releasing the lock.................................................................................. 344 Extending and retracting pins....................................................................... 345 7.5.11 Setting down the additional axle after removal................................................... 346 7.5.12 Locking/enabling the suspension on the additional axle........................................... 348 Locking the suspension............................................................................. 348 Enabling the suspension............................................................................ 349 7.5.13 Raising/lowering axle line....................................................................... 350 Raising the axle lines............................................................................. 350 Lowering the axle lines............................................................................ 351 8 Malfunctions in driving mode.................................................................................. 353 8.1 Emergency stop device on carrier........................................................................ 355 8.1.1 Emergency stop switch, vehicle engine............................................................. 355 8.2 Breakdown in road traffic............................................................................... 357 8.3 Towing the truck crane.................................................................................. 359 8.3.1 Towing in the case of engine or transmission damage............................................... 359 Towing the truck crane out of the danger area....................................................... 360 Longer distances.................................................................................... 360 Compressed-air supply in the event of engine failure................................................ 361 Power supply........................................................................................ 362 Axle drives......................................................................................... 362 Parking brake....................................................................................... 362 Mechanically releasing the parking brake............................................................ 363 Towing procedure.................................................................................... 363 Removing mechanical locking from all spring-loaded brake cylinders.................................. 364 Tow starting........................................................................................ 364 8.4 Wheels and tyres........................................................................................ 365 8.4.1 Wheel change...................................................................................... 365 Removing a damaged wheel............................................................................ 365 Lifting/setting down wheel.......................................................................... 366 Mounting the spare wheel........................................................................... 367 8.4.2 Filling the tyres yourself at tyre inflator connection............................................ 368 Connecting the filling hose......................................................................... 368 Filling the tyres................................................................................... 369 Removing the tyre inflator hose..................................................................... 369 8.5 Electrical system....................................................................................... 371 8.5.1 Inserts........................................................................................... 372 8.5.2 Fuses............................................................................................. 374 Fuses in the driver's cab........................................................................... 374 Fuses in battery box................................................................................ 378 Fuses on I/O circuit boards......................................................................... 379 8.6 Troubleshooting and remedy.............................................................................. 381 8.6.1 Vehicle engine malfunctions....................................................................... 381 8.6.2 Automatic transmission malfunctions............................................................... 383 8.6.3 Transfer case malfunctions........................................................................ 384 8.6.4 Differential lock malfunctions.................................................................... 384 8.6.5 Steering malfunctions............................................................................. 385 8.6.6 Service brake malfunctions........................................................................ 386 8.6.7 Outrigger malfunctions............................................................................ 386 8.6.8 Tachograph malfunctions........................................................................... 387 8.6.9 Suspension locking system malfunctions............................................................ 388 8.6.10 Level adjustment system malfunctions............................................................. 388 8.6.11 Malfunctions in the carrier electronic system.................................................... 389 Reading error messages on carrier................................................................... 389 8.7 Procedure in the event of malfunctions.................................................................. 391 8.7.1 Switching on emergency operation in cooling water circuit......................................... 391 On hydraulic cooler................................................................................. 391 On the vehicle engine.............................................................................. 392 8.7.2 Procedure in the event of malfunctions in the automatic transmission.............................. 393 Troubleshooting..................................................................................... 393 Effect oferror..................................................................................... 393 Reading off errorcodes............................................................................ 394 8.7.3 Emergency operation of the solenoid valves for the outriggers..................................... 396 Position and allocation of the solenoid valves...................................................... 398 8.7.4 Separate steering emergency operation............................................................. 400 Moving the steering into on-road driving............................................................ 400 9 Technical Information on Carrier.............................................................................. 403 9.1 Technical description of the carrier.................................................................... 405 9.1.1 Crane carrier..................................................................................... 405 9.1.2 Driver's cab...................................................................................... 405 9.1.3 Drive units....................................................................................... 406 9.1.4 Engine cooling system............................................................................. 406 9.1.5 Hydraulic system.................................................................................. 406 9.1.6 Steering.......................................................................................... 407 9.1.7 Suspension system................................................................................. 407 9.1.8 Outrigger......................................................................................... 408 9.1.9 Compressed air system............................................................................. 408 9.1.10 Service brake.................................................................................... 409 9.1.11 Parking brake.................................................................................... 409 9.1.12 Retarder......................................................................................... 409 9.1.13 Secondary consumers.............................................................................. 410 9.1.14 Towing the crane................................................................................. 410 9.1.15 Towing a trailer (trailer operation)............................................................. 410 9.1.16 Electrical system................................................................................ 410 9.1.17 Rotary transmission.............................................................................. 410 9.2 Technical data.......................................................................................... 411 9.2.1 Dimensions and weights of the truck crane......................................................... 412 Dimensions for driving on public roads.............................................................. 413 9.2.2 Dimensions and weights of removable parts......................................................... 414 Spare wheel (additional equipment).................................................................. 414 Main boom........................................................................................... 414 Outrigger........................................................................................... 415 Rear bumper......................................................................................... 415 Additional axle..................................................................................... 415 Derricking cylinder support......................................................................... 415 9.2.3 Carrier........................................................................................... 416 Vehicle engine...................................................................................... 416 On-load shift transmission.......................................................................... 416 Transfer case....................................................................................... 416 Axle lines.......................................................................................... 416 Steering............................................................................................ 417 Tyres............................................................................................... 417 Vehicle's electrical system......................................................................... 417 Tools............................................................................................... 417 Outrigger........................................................................................... 418 Driving speeds...................................................................................... 419 Climbing ability.................................................................................... 419 Turning circle radiuses............................................................................ 420 10 Index........................................................................................................ 421 A........................................................................................................... 425 B........................................................................................................... 426 C........................................................................................................... 427 D........................................................................................................... 429 E........................................................................................................... 430 F........................................................................................................... 430 G........................................................................................................... 431 H........................................................................................................... 431 I........................................................................................................... 432 K........................................................................................................... 432 L........................................................................................................... 432 M........................................................................................................... 432 O........................................................................................................... 433 P........................................................................................................... 434 R........................................................................................................... 434 S........................................................................................................... 435 T........................................................................................................... 437 V........................................................................................................... 439 W........................................................................................................... 439 Operating instructions Part 2 Crane Operation....................................................................... 443 Additional pages - Emergency operation/Emergency program telescoping ........................................... 445 Correction sheet -driving with rigged crane..................................................................... 727 11 Description of the crane section of the truckcrane.......................................................... 449 11.1 Overview of the operating and display instruments...................................................... 451 11.1.1 Overview of the crane section.................................................................... 451 11.1.2 Overview of crane cab............................................................................ 454 11.1.3 Operating elements on the front panel............................................................ 456 11.1.4 Operating elements on the front panel............................................................ 457 Left side of the side panel........................................................................ 457 Top of the side panel.............................................................................. 458 Heating system/ air-conditioning system............................................................ 460 Crane cab additional heating....................................................................... 461 11.1.5 Control consoles................................................................................. 462 Left-hand control console........................................................................... 462 Right-hand control console.......................................................................... 463 11.1.6 Control lever configuration...................................................................... 464 Version 1 (standard)................................................................................ 464 Version 2 (additional equipment).................................................................... 465 11.1.7 Crane control plug-in module..................................................................... 466 11.1.8 Main menu – crane control display................................................................ 468 11.1.9 Crane control display – submenus................................................................. 470 Submenu for Electronic level/ outrigger pressure indicator......................................... 470 Submenu for superstructure lock.................................................................. 471 Submenu for semi-automatic telescoping.............................................................. 472 Submenu for fully automatic telescoping............................................................. 473 Driving transmission speed submenu................................................................. 474 Submenu for settings/displays..................................................................... 475 Control instruments submenu......................................................................... 477 Error menu.......................................................................................... 479 Working area limitation submenu.................................................................... 480 11.1.10 SLI plug-in module.............................................................................. 482 11.1.11 Main menu – SLI display......................................................................... 485 11.1.12 Submenus – SLI display.......................................................................... 486 Submenu for entering rigging mode................................................................. 486 Submenu for SLI monitoring......................................................................... 488 Service submenu.................................................................................... 490 Submenu for error messages......................................................................... 491 11.1.13 Switch boxes for outrigger/electronic level/outrigger pressure display.......................... 492 Operating instruments for the outriggers............................................................ 493 Display elements for the outrigger pressure indicator............................................... 493 Operating and display elements for the electronic level............................................ 493 11.1.14 Hand-held control............................................................................... 494 11.2 Functional description of the display and operating elements.......................................... 495 11.2.1 Crane engine..................................................................................... 495 On the side panel.................................................................................. 495 On the crane control display........................................................................ 496 11.2.2 Crane control.................................................................................... 496 Crane control plug- in module....................................................................... 496 Crane control display............................................................................... 499 Display elements in main menu....................................................................... 500 11.2.3 Outriggers, electronic level, outrigger pressure indicator....................................... 501 On the display fields of the carrier................................................................ 501 Electronic level/ outrigger pressure indicator submenu............................................. 503 11.2.4 Submenu for superstructure lock.................................................................. 504 Turntable lock..................................................................................... 505 Houselock........................................................................................... 506 11.2.5 Hoists........................................................................................... 507 Main hoist.......................................................................................... 507 Auxiliary hoist (additional equipment).............................................................. 509 11.2.6 Slewing gear..................................................................................... 510 11.2.7 Derricking gear.................................................................................. 511 11.2.8 Telescoping gear................................................................................. 513 Control consoles.................................................................................... 513 Control lever for telescoping....................................................................... 513 Telescoping submenu................................................................................. 515 11.2.9 Safe load indicator (SLI)........................................................................ 523 SLI plug-in module.................................................................................. 523 SLI display......................................................................................... 524 Display elements in the main menu................................................................... 525 Enter rigging mode submenu.......................................................................... 526 In the SLI monitoring submenu...................................................................... 531 In the Servicing submenu............................................................................ 537 On the front console............................................................................... 537 11.2.10 Hydraulic system................................................................................ 539 Control consoles.................................................................................... 539 In submenu Settings/displays....................................................................... 539 In the submenu for control instruments.............................................................. 540 In the submenu for warning messages................................................................. 540 11.2.11 Electricity, lighting, windscreen wiper/washing system.......................................... 541 Electricity......................................................................................... 541 Lighting............................................................................................ 541 Windscreen wiper/ washing system................................................................... 542 11.2.12 Crane cab heating system........................................................................ 544 Crane cab heating.................................................................................. 544 Crane cab auxiliary heater......................................................................... 545 Air-conditioning system............................................................................. 546 11.2.13 On the hand-held control........................................................................ 547 Connections on the superstructure................................................................... 547 Crane engine operating field....................................................................... 548 Pre-selection button for emergency operation........................................................ 548 Pre-selection button for rigging................................................................... 549 Two-hand operatingfield............................................................................ 551 11.2.14 Other operating instruments in the crane cab.................................................... 554 Keys................................................................................................ 554 Crane cab door...................................................................................... 554 Windows............................................................................................. 555 Cab lighting........................................................................................ 556 Diagnostics plug.................................................................................... 557 Fire extinguisher (additional equipment)........................................................... 557 Railing by step..................................................................................... 558 11.3 Functional description of the safety devices........................................................... 559 11.3.1 Safe load indicator (SLI)........................................................................ 559 11.3.2 Lowering limit switch............................................................................ 561 11.3.3 Lifting limit switch............................................................................. 562 Overriding lifting limit switch shutdown............................................................ 562 11.3.4 Dead man's and seat contact switches............................................................. 564 12 Crane engine................................................................................................. 565 12.1 Starting the crane engine.............................................................................. 567 12.1.1 CHECKLIST: Starting the crane engine............................................................. 567 12.1.2 CHECKLIST: in winter............................................................................. 569 12.1.3 Inspections before starting the crane engine..................................................... 570 Check shut-off valves on the hydraulic system....................................................... 570 Switching on the battery master switch............................................................. 570 Checking coolant level.............................................................................. 571 Checking the hydraulic oil level.................................................................... 572 Checking the oil level in the crane engine.......................................................... 573 Topping up motor oil............................................................................... 574 Refuelling.......................................................................................... 574 12.1.4 Starting the crane engine........................................................................ 576 Switching on the ignition.......................................................................... 576 Starting the crane engine........................................................................... 578 12.1.5 Inspections after starting the crane engine...................................................... 580 Checks on the side panel............................................................................ 580 Checks on the Crane control display................................................................. 581 Warning messages.................................................................................... 582 12.2 Switching off the crane engine......................................................................... 583 12.2.1 Usually with the ignition lock/hand-held control................................................. 583 12.2.2 In an emergency, with the emergency stop switches................................................ 584 12.2.3 In an emergency, using the air intake inhibitor.................................................. 585 Switching on the air intake inhibitor............................................................... 585 Releasing the air intake inhibitor manually......................................................... 585 13 Crane operation.............................................................................................. 587 13.1 Checks and adjustments before crane operation.......................................................... 589 13.1.1 CHECKLIST: When truck crane is rigged............................................................ 589 13.1.2 Adjusting the front console and the crane cab seat............................................... 595 Adjusting the front console........................................................................ 595 Adjusting the crane cab............................................................................. 596 13.1.3 Checking the condition of the hoist rope......................................................... 597 Checking the reservoir of the windscreen washing system............................................. 597 Visual inspection of the entire crane............................................................... 597 Checking theposition of the hoist ropes............................................................ 598 Checking the electrical system...................................................................... 598 13.1.4 Checking the safety devices...................................................................... 599 Checking the safe load indicator.................................................................... 599 Checking the lifting limit switch.................................................................. 600 Checking the seat contact switch and dead man's switch system....................................... 600 Emergency stop switch for the crane control......................................................... 601 13.1.5 Preheating the hydraulic oil..................................................................... 602 When the oil temperatureis between –15 C and 0 C:................................................ 602 For oil temperatures below–15 C:................................................................ 602 13.1.6 Locking/unlocking the turntable.................................................................. 603 Superstructure lock submenu....................................................................... 604 Locking the turntable.............................................................................. 604 Unlocking the turntable............................................................................ 605 Display of errors related to the turntable lock.................................................... 606 13.1.7 Switching the houselock on/off................................................................... 607 Superstructure lock submenu....................................................................... 607 Switching on thehouselock......................................................................... 608 Switching off the houselock........................................................................ 609 13.2 Operating the safe load indicator (SLI)................................................................ 611 13.2.1 Switching on the SLI............................................................................. 611 Switching on........................................................................................ 611 Setting the brightness of the displays.............................................................. 613 Lamp test on theSLI................................................................................ 613 13.2.2 Entering the rigging mode........................................................................ 615 Entering new counterweight versions................................................................. 617 Entering a new outrigger span....................................................................... 620 Entering a new slewing range....................................................................... 621 Entering components for the lattice extension...................................................... 622 Entering a new reeving.............................................................................. 626 Entering the rigging mode using an SLI code......................................................... 627 13.2.3 Checks and displays in the SLI monitoring submenu................................................ 628 Submenu for SLI monitoring.......................................................................... 628 Checks to be carried out before starting........................................................... 628 Current displays during crane operation............................................................. 631 13.2.4 SLI pre-warning and SLI shutdown................................................................. 634 SLI early warning................................................................................... 634 SLI shutdown........................................................................................ 634 Error message....................................................................................... 637 Submenu for error messages.......................................................................... 638 SLI override....................................................................................... 640 13.3 Crane work with main boom.............................................................................. 641 13.3.1 External influences during crane operation....................................................... 641 Horizontal alignment................................................................................ 641 Safe distances..................................................................................... 641 Checking the wind speed............................................................................. 642 If the maximum permitted wind speed has been exceeded............................................... 643 Permissible wind load.............................................................................. 644 Earthing the load................................................................................... 645 13.3.2 Permissible slewing ranges and working positions for crane work.................................. 646 Slewing range 360 .................................................................................. 646 Limited slewing range ±15 .......................................................................... 646 Working position 0 to the rear..................................................................... 647 Working position 180 to the front.................................................................. 647 13.3.3 Main hoist....................................................................................... 649 Switching on the main hoist......................................................................... 649 Lifting and lowering............................................................................... 650 Switching off themain hoist....................................................................... 653 13.3.4 Auxiliary hoist (additional equipment)........................................................... 654 Switching on the auxiliary hoist................................................................... 654 Lifting and lowering............................................................................... 655 Switching off the auxiliary hoist.................................................................. 655 13.3.5 Derricking gear.................................................................................. 656 Switching on the derricking gear.................................................................... 656 Raising and lowering................................................................................ 657 Switching off the derricking gear.................................................................. 658 Maximum permissible derricking speed............................................................... 658 13.3.6 Slewing gear..................................................................................... 659 Switching on the slewing gear...................................................................... 659 Slewing............................................................................................. 660 Slewing speed and braking.......................................................................... 662 Tracking the slewing gear.......................................................................... 662 Switching off the slewing gear..................................................................... 663 Maximum permissible slewing speed.................................................................. 663 13.3.7 Telescoping gear................................................................................. 665 Structure of the chapter............................................................................ 665 Description offunctioning.......................................................................... 666 Main boom fixed length, intermediate length, telescoping length..................................... 667 Telescope status.................................................................................... 669 Notes on the telescoping sequence................................................................... 671 Checks before the first telescoping................................................................. 671 Switching on telescoping gear....................................................................... 672 Function of the control lever....................................................................... 672 Switching off telescoping gear...................................................................... 674 Example of the procedure for telescoping........................................................... 675 Checking the initial position....................................................................... 676 Unlocking the telescoping cylinder.................................................................. 681 Extend/retract telescoping cylinder................................................................. 684 Locking the telescoping cylinder.................................................................... 685 Unlocking the telescopic section.................................................................... 689 Telescoping the telescopic section................................................................. 691 Locking the telescopic section..................................................................... 693 Telescoping the telescopic section to an intermediate length........................................ 697 Lock telescopic section for on-road driving........................................................ 697 Telescoping with fully automatic control............................................................ 698 Lowering the main boom for maintenance............................................................. 703 Telescoping the main boom at anglesunder 10 ....................................................... 703 13.3.8 High-speed mode.................................................................................. 705 13.3.9 Special menus on the crane control display....................................................... 706 Operating hours meter submenu..................................................................... 706 Driving transmission speeds submenu.............................................................. 708 Warning message submenu............................................................................. 710 Error menu.......................................................................................... 712 Setting the brightnessof the displays.............................................................. 714 Control lever characteristic curve.................................................................. 715 13.3.10 Setting a constant engine speed................................................................. 717 13.3.11 Critical load control........................................................................... 718 Function............................................................................................ 718 Switching on and off.............................................................................. 718 13.3.12 Inclining the crane cab......................................................................... 720 13.3.13 Using the directional spotlight for the working area............................................ 721 Switching on/off.................................................................................... 721 Adjusting the direction............................................................................. 721 13.3.14 Cooling the hydraulic oil....................................................................... 722 Standard oil cooler................................................................................. 722 Additional oil cooler............................................................................... 722 13.3.15 Possible movement combinations.................................................................. 723 13.4 Driving with a rigged crane............................................................................ 725 13.4.1 Driving route.................................................................................... 725 13.4.2 Boom positions and axle loads.................................................................... 726 13.4.3 Driving the rigged crane......................................................................... 0 Switching on separate steering...................................................................... 729 Driving............................................................................................. 730 Extending the outrigger............................................................................ 730 13.5 Work breaks............................................................................................ 731 13.5.1 Short work breaks................................................................................ 731 13.5.2 Work breaks lasting more than 8 hours............................................................ 731 Securing the truck crane against unauthorized use................................................... 732 13.6 Crane cab heating and air-conditioning system.......................................................... 733 13.6.1 Engine-dependent crane cab heater................................................................ 733 Switching the heater on and off..................................................................... 733 Setting recirculated air/fresh air.................................................................. 734 Setting the air distribution....................................................................... 734 Adjusting the air vents............................................................................. 735 13.6.2 Engine-independent auxiliary crane cab heater.................................................... 736 Switching on the auxiliary heating system........................................................... 736 Regulating the temperature......................................................................... 737 Setting air distribution........................................................................... 737 Setting recirculated air/ fresh air operation....................................................... 737 Storing automatic heating start..................................................................... 737 Setting automatic heating duration.................................................................. 738 Switching automaticheating start on/off............................................................ 739 Setting remaining time.............................................................................. 739 Setting time and weekday............................................................................ 740 13.6.3 Air-conditioning system.......................................................................... 741 Switching on........................................................................................ 741 Setting the air distribution........................................................................ 742 To switch off....................................................................................... 742 How to use the airconditioning effectively......................................................... 742 Dehumidifying the crane cab air..................................................................... 743 13.7 Working range limiter.................................................................................. 745 13.7.1 Opening the working area limitation submenu...................................................... 746 13.7.2 Reading current settings......................................................................... 747 Display monitoring switched on/off.................................................................. 747 Reading the limit values entered................................................................... 747 13.7.3 Entering a limit value for a maximum overall height.............................................. 749 13.7.4 Entering a limit value for a maximum working radius.............................................. 750 13.7.5 Entering limit values for maximum slewing angles................................................. 751 Displays in the submenu Working area limitation..................................................... 751 Presentation of slewing angles...................................................................... 752 Entering the slewing angle.......................................................................... 753 13.7.6 Entering point data for objects.................................................................. 754 Presentation of defined objects.................................................................... 754 Selecting and deleting point data................................................................. 755 Entering point data................................................................................ 756 13.7.7 Entering limit values manually................................................................... 758 Limit values for overall height, working radius or slewing angle.................................... 758 Manual point data entry............................................................................. 759 13.7.8 Switching monitoring on and off.................................................................. 761 Switching monitoring on............................................................................. 761 Switching monitoringoff............................................................................ 762 13.8 Shutdown caused by working range limiter............................................................... 763 13.8.1 Crane movements which are switched off........................................................... 763 Bypassing shutdown................................................................................. 764 14 Rigging work................................................................................................. 765 14.1 Checklists for rigging work for crane operation with main boom......................................... 767 14.1.1 CHECKLIST: Rigging............................................................................... 767 14.1.2 CHECKLIST: Unrigging............................................................................. 771 14.2 Choosing a suitable site............................................................................... 775 14.2.1 Load bearing capacity of the ground and the outrigger............................................ 775 Enlarging the enlarge............................................................................... 777 14.2.2 Safe distance from banks and pits................................................................ 778 14.2.3 Earthing the truck crane......................................................................... 779 Earthing the truck crane............................................................................ 779 14.2.4 Safe distance from electrical lines.............................................................. 780 14.3 Rigging work after driving with trailer................................................................ 783 14.3.1 Switching off the boom floating position......................................................... 784 14.3.2 Switching off boom pre-tensioning................................................................ 784 14.3.3 Switching off slewing gear freewheel............................................................. 786 Before slewing...................................................................................... 787 14.4 Add-on parts in position for crane mode/driving mode................................................... 789 14.4.1 Swivelling the crane cab into position for crane mode/ drivingmode.............................. 790 Connecting/ removing the hand- held control........................................................ 790 Slewing into crane mode position.................................................................... 792 Slewing into the position driving mode............................................................. 794 14.4.2 Pushing the railings on the access ladder out/in................................................ 797 Pushing out the railings........................................................................... 797 Pushing in the railing............................................................................. 798 14.4.3 Folding the hoist mirror in/out.................................................................. 799 Folding the mirror out and adjusting it............................................................. 799 Folding in the mirror............................................................................. 799 14.4.4 Rigging work on the rear steps................................................................... 800 Before crane operation............................................................................ 800 After crane operation............................................................................. 801 14.5 Outriggers............................................................................................. 803 14.5.1 CHECKLIST: Extending the outrigger............................................................... 803 14.5.2 CHECKLIST: Retracting the outrigger.............................................................. 805 14.5.3 Permissible outrigger spans...................................................................... 807 Outrigger span 8.76 x 8.90 m........................................................................ 808 Outrigger span 8.76 x 6.10 m........................................................................ 808 Outrigger span 8.76 x 2.63 m........................................................................ 809 Outrigger span 7.78 x 8.90/1.22m................................................................... 810 14.5.4 Preparing the truck crane........................................................................ 811 Align horizontally................................................................................. 811 Locking the suspension............................................................................. 811 14.5.5 Securing/releasing outrigger beam................................................................ 812 Securing the outrigger beams....................................................................... 812 Releasing the outrigger beams...................................................................... 813 14.5.6 Extending/retracting the outrigger beams......................................................... 814 Setting outrigger spans............................................................................. 816 14.5.7 Moving the outrigger pads into working/driving position.......................................... 820 Moving the outrigger pads into working position.................................................... 820 Moving the outrigger pads into driving position.................................................... 821 14.5.8 Extending/retracting the outrigger cylinder...................................................... 822 Allocation of the button units..................................................................... 822 Extending the outrigger cylinders................................................................... 823 Retracting theoutrigger cylinders................................................................. 825 14.5.9 Checking the alignment of the truck crane........................................................ 827 Electronic level on the carrier................................................................... 827 Electronic levels on crane control display......................................................... 829 14.5.10 Aligning the truck crane horizontally........................................................... 832 If the boom is in the boom support................................................................ 832 If the boom is raised............................................................................. 832 14.5.11 Outrigger pressure display...................................................................... 833 Outrigger pressure display on thecarrier........................................................... 833 Outrigger pressure display on superstructure....................................................... 834 14.6 Rigging/unrigging the counterweight.................................................................... 835 14.6.1 Counterweight parts and identification........................................................... 835 Counterweight parts................................................................................. 835 Identification...................................................................................... 836 14.6.2 Counterweight versions........................................................................... 837 14.6.3 Slinging points on the counterweight sections.................................................... 840 14.6.4 CHECKLIST: Rigging the counterweight............................................................. 842 Prerequisites....................................................................................... 842 14.6.5 CHECKLIST: Unrigging the counterweight........................................................... 846 Prerequisites....................................................................................... 846 14.6.6 Setting down/picking up the counterweight platform – counterweight sections...................... 850 Setting down the 20 t base plate................................................................... 850 Picking up counterweight parts..................................................................... 851 14.6.7 Assembling the counterweight version............................................................. 852 14.6.8 Securing/releasing 10 t counterweight blocks..................................................... 856 Securing the counterweight blocks................................................................... 856 Releasing counterweight blocks...................................................................... 857 14.6.9 Establishing/disconnecting the hydraulic connection.............................................. 858 Establishing thehydraulic connection............................................................. 858 Breaking the hydraulic connection................................................................... 859 14.6.10 Establishing/disconnecting the electrical connection............................................ 859 Establishing the electrical connection............................................................ 860 Breaking the electrical connection.................................................................. 860 14.6.11 Hand-held control............................................................................... 861 Connecting the hand-held control.................................................................... 861 Starting the crane engine with the hand-held control................................................ 862 Turning off crane engine with the hand-held control................................................. 862 14.6.12 Extending/retracting the lifting cylinder of the 20 t base plate or lifting/lowering coun....... 863 Lifting cylinders: extend........................................................................... 864 Lifting cylinders: retracting....................................................................... 865 14.6.13 Locking/unlocking the counterweight to the turntable............................................ 866 Counterweight safety valve.......................................................................... 867 Locking the counterweight........................................................................... 868 Counterweight; unlocking............................................................................ 869 14.6.14 Slewing with the rigged counterweight........................................................... 870 14.6.15 Hoisting and setting down counterweight sections with mounted auxiliary hoist................... 872 14.7 Auxiliary hoist........................................................................................ 873 Required components..................................................................................... 873 14.7.1 Components and identification.................................................................... 874 14.7.2 Slinging points and transport.................................................................... 875 Slinging points..................................................................................... 875 Transport........................................................................................... 876 14.7.3 CHECKLIST: Mounting the auxiliary hoist.......................................................... 877 Prerequisites....................................................................................... 877 14.7.4 CHECKLIST: Dismantling the auxiliary hoist....................................................... 880 Prerequisites....................................................................................... 880 14.7.5 Hoist the auxiliary hoist onto the 20 t base plate............................................... 883 14.7.6 Raising and setting down the catcher............................................................. 883 Catcher 1........................................................................................... 884 Catcher 2........................................................................................... 886 14.7.7 Establishing/disconnecting the hydraulic connection.............................................. 887 Establishing a connection.......................................................................... 887 Disconnecting ..................................................................................... 887 14.7.8 Establishing/disconnecting the electrical connection............................................. 888 Establishing a connection.......................................................................... 888 Disconnecting ..................................................................................... 888 14.7.9 Locking the auxiliary hoist/releasing lock....................................................... 889 Auxiliary hoist safety valve........................................................................ 889 Locking............................................................................................. 890 Releasing the locking pin........................................................................... 890 Releasing the locking pin........................................................................... 891 Releasing the locking pin........................................................................... 891 14.7.10 Checking that the auxiliary hoist is functioning properly....................................... 892 With the manual control............................................................................. 892 In the crane cab.................................................................................... 893 14.7.11 Secure the upper hook block in the catcher...................................................... 893 14.7.12 Permissable utilization options for the auxiliary hoist......................................... 894 Replacement for the main hoist...................................................................... 894 Alternating operation with the main and auxiliary hoists............................................ 895 14.8 Rigging work on the main boom.......................................................................... 897 14.8.1 Hook block on the bumper......................................................................... 897 Picking up the hook block from the bumper........................................................... 897 Attach the hook block to the bumper................................................................. 898 14.8.2 Hook block on a separate vehicle................................................................. 899 Picking up the hook block from the separate vehicle................................................ 899 Place the hook block on a separate vehicle.......................................................... 900 14.8.3 Reeving and unreeving the hoist rope............................................................. 901 Rope end fitting.................................................................................... 901 Positioning hoist cable........................................................................... 903 14.8.4 Possible reeving on the main boom for standard design with9sheaves............................. 907 14.8.5 Possible reeving on the main boom for additional equipment with 11 sheaves...................... 912 14.8.6 Possible reeving on the main boom for additional equipment with 13 sheaves...................... 918 14.8.7 Installing/removing lifting limit switch......................................................... 925 Installing the lifting limit switch................................................................. 925 Removing the lifting limit switch................................................................... 928 14.8.8 Locking lifting limit switch/releasing lock...................................................... 930 Locking............................................................................................. 930 Release lock....................................................................................... 931 14.8.9 Installing/removing the anemometer............................................................... 931 Installing the anemometer.......................................................................... 932 Remove the anemometer.............................................................................. 933 14.8.10 Installing/removing the holding rod............................................................. 934 Installing.......................................................................................... 934 Removal............................................................................................. 935 14.8.11 Installing/removing the air traffic control light............................................... 935 Installing.......................................................................................... 935 Removal............................................................................................. 936 14.8.12 Rope end clamp.................................................................................. 937 14.8.13 Rigging heavy duty equipment.................................................................... 939 Heavy duty equipment parts.......................................................................... 939 Equipment required................................................................................. 939 Rigging heavy duty equipment........................................................................ 940 Unrigging heavy duty equipment...................................................................... 943 Reevings with heavy duty equipment.................................................................. 945 15 Crane operation malfunctions................................................................................. 947 15.1 Superstructure emergency stop device................................................................... 949 Reset the emergency stop switch......................................................................... 950 15.2 What to do in the event of a malfunction when working with the crane................................. 951 If Lower load is possible............................................................................... 951 If Lower load is not possible........................................................................... 952 15.3 Electrical system...................................................................................... 953 15.3.1 Inserts.......................................................................................... 954 15.3.2 Fuses............................................................................................ 956 Fuses on turntable.................................................................................. 956 Fuses in the crane cab.............................................................................. 958 Fuses in battery box................................................................................ 960 Fuses on the crane cab bracket...................................................................... 961 Fuses on I/O circuit boards......................................................................... 962 15.3.3 SLI fuses........................................................................................ 963 15.4 Trouble shooting and rectification at the power units.................................................. 965 15.4.1 Crane engine malfunctions........................................................................ 965 15.4.2 Malfunctions with operation with hand-held control............................................... 967 15.4.3 Malfunctions with movements of the crane cab..................................................... 967 15.4.4 Main hoist malfunctions.......................................................................... 968 15.4.5 Auxiliary hoist malfunctions..................................................................... 970 15.4.6 Derricking gear malfunctions..................................................................... 972 15.4.7 Slewing gear malfunctions........................................................................ 974 15.4.8 Hydraulic system/hydraulic oil cooler malfunctions............................................... 975 15.4.9 Malfunctions at the counterweight hoist unit..................................................... 976 15.4.10 Malfunctions on the turntable locking........................................................... 977 15.4.11 Telescoping gear malfunctions................................................................... 977 Error messages telescoping gear..................................................................... 980 15.5 Trouble shooting and rectification on the SLI.......................................................... 983 Program version of safe load indicator.................................................................. 983 15.5.1 General malfunctions............................................................................. 983 15.5.2 Error messages on the SLI display................................................................ 984 Table for the Error group 1........................................................................ 985 Table for the Error group 2........................................................................ 991 Table for the Error group 3........................................................................ 993 Table for the Error group 5........................................................................ 995 Table for the Error group 6........................................................................ 997 Table for the Error group 7........................................................................ 998 Table for the Error group 8........................................................................ 998 15.5.3 Checking SLI lines and connections............................................................... 999 On truck crane......................................................................................1000 On lattice extension (additional equipment).........................................................1001 15.6 Trouble shooting and rectification on the crane control................................................1003 Program version of crane control........................................................................1003 15.6.1 General malfunctions.............................................................................1003 15.6.2 Error messages on Crane control display..........................................................1004 Symbols for Devices................................................................................1005 Symbols for Groups.................................................................................1007 Symbols for Types of errors........................................................................1009 Index displays allocation..........................................................................1010 Control lever error table...........................................................................1021 Locking system error table..........................................................................1022 Error messages via Can-Bus..........................................................................1025 Error messages about hoisting gears.................................................................1027 Error messages system monitoring group..............................................................1028 Error messages group carrier........................................................................1030 15.6.3 Connections for the crane control's control units................................................1031 Control units connections position..................................................................1031 Layout of connections..............................................................................1032 15.6.4 Unrig truck crane when control units are defective...............................................1034 Prerequisites.......................................................................................1034 Example for unrigging with three control units......................................................1034 Replacing control units.............................................................................1036 15.7 Emergency operations and emergency programs............................................................1039 15.7.1 Emergency retract operation......................................................................1040 Check prior Emergency operation emergency operation.................................................1040 Procedure for intermediate length...................................................................1041 Mechanical emergency operation......................................................................1042 Hydraulic emergency operation.......................................................................1044 Length data for the locking points..................................................................1055 15.7.2 Sub-menu emergency program telescoping...........................................................1056 Starting emergency program..........................................................................1056 Emergency program display and operating elements....................................................1057 Retracting with an error on the length indicator....................................................1059 Retracting with an error on the proximity switch....................................................1063 Emergency program end..............................................................................1065 Table for approaching the locking points............................................................1065 15.7.3 Enter telescope status after emergency operation.................................................1067 15.7.4 Emergency operation in case of failure of the operating instruments in the crane cab.............1071 Prerequisites.......................................................................................1071 Connecting the hand-held control....................................................................1072 Starting the crane engine with the hand-held control................................................1072 Preselect power unit...............................................................................1073 Operating power unit................................................................................1073 Movements stopping.................................................................................1075 Stopping the movement in case of an emergency.......................................................1075 16 Technical information for superstructure.....................................................................1077 16.1 Technical description of the superstructure............................................................1079 16.1.1 Turntable........................................................................................1079 16.1.2 Crane cab........................................................................................1079 16.1.3 Crane engine and hydraulic system................................................................1080 16.1.4 Control system...................................................................................1081 16.1.5 Main boom........................................................................................1081 16.1.6 Telescoping gear.................................................................................1081 16.1.7 Hoists...........................................................................................1082 16.1.8 Slewing gear.....................................................................................1083 16.1.9 Houselock........................................................................................1083 16.1.10 Derricking cylinder.............................................................................1083 16.1.11 Electrical system..............................................................................1084 16.1.12 Counterweight...................................................................................1084 16.1.13 Safety devices..................................................................................1085 16.1.14 Hand-held control...............................................................................1085 16.2 Technical data.........................................................................................1087 16.2.1 Maximum load bearing capacity (DIN/ISO/EN).......................................................1087 16.2.2 Maximum load bearing capacity (ANSI B 30.5)......................................................1087 16.2.3 Dimensions, weights and axle loads...............................................................1088 Dimensions when driving on public roads.............................................................1089 16.2.4 Dimensions and weights of removable parts........................................................1090 Hook blocks and hook tackle.........................................................................1090 Auxiliary hoist.....................................................................................1091 Main boom...........................................................................................1091 Heavy dutyequipment................................................................................1091 Counterweightparts.................................................................................1091 Counterweight versions..............................................................................1092 16.2.5 Technical data for superstructure................................................................1094 Crane engine........................................................................................1094 Slewing gear........................................................................................1094 Derricking gear.....................................................................................1094 Main boom...........................................................................................1094 Main hoist..........................................................................................1095 Auxiliary hoist (additional equipment)..............................................................1095 Working speed and times without load................................................................1096 17 Index........................................................................................................1097 A...........................................................................................................1101 B...........................................................................................................1102 C...........................................................................................................1103 D...........................................................................................................1105 E...........................................................................................................1106 F...........................................................................................................1106 G...........................................................................................................1107 H...........................................................................................................1107 I...........................................................................................................1108 K...........................................................................................................1108 L...........................................................................................................1108 M...........................................................................................................1108 O...........................................................................................................1109 P...........................................................................................................1110 R...........................................................................................................1110 S...........................................................................................................1111 T...........................................................................................................1113 V...........................................................................................................1115 W...........................................................................................................1115
IMAGES PREVIEW OF THE MANUAL:
Questions? Email us: [email protected]
https://vimeo.com/864741103?share=copy
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V
