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Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 3302526 – PDF DOWNLOAD
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Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 3302526 – PDF DOWNLOAD
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Description
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 3302526 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 3302526 – PDF DOWNLOAD
Language : English
Pages : 974
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 3302526 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
The GMK 7450 is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 7450 truck crane may only be used in a perfect technical condition as intended and with due
attention paid to safe operation and possible haz- ards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 7450 truck crane may only be operated without the corresponding special equipment within
the permitted temperature range; à Technical
data, p. 1 – 5. - The GMK 7450 truck crane is designed solely for lifting loads which are within the permitted GMK
7450 lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes
– Observing the entire crane documentation, consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual.
TABLE OF CONTENTS:
Grove Crane GMK 7450 Driving & Crane operation Operating Instruction Manual 3302526 – PDF DOWNLOAD
Part 1 - Driving.................................................................................... 1 Additional Pages................................................................................ 3 SLI override................................................................................ 3 New outrigger control units................................................................. 15 1 Overview...................................................................................... 25 1.1 Accidents............................................................................... 25 1.2 Branch offices.......................................................................... 25 1.2.1 Manitowoc Crane Care.............................................................. 25 1.2.2 Dealer list....................................................................... 25 1.3 Warranty specifications................................................................. 25 1.4 Terms used.............................................................................. 26 1.5 Technical data.......................................................................... 29 1.5.1 Maximum lifting capacity (DIN / ISO / EN)......................................... 29 1.5.2 Dimensions and weights of the truck crane, axle loads............................. 30 Dimensions.......................................................................... 31 Weight and axle loads............................................................... 31 1.5.3 Dimensions and weights of removable parts......................................... 32 Spare wheel......................................................................... 32 Outriggers.......................................................................... 32 Lighting carrier................................................................... 32 Additional axle..................................................................... 33 Derricking cylinder support......................................................... 33 Main boom........................................................................... 33 Hook blocks and hook tackle......................................................... 34 Auxiliary hoist..................................................................... 34 Heavy duty equipment............................................................... 34 Counterweight parts................................................................ 35 counterweight versions.............................................................. 35 1.5.4 Carrier........................................................................... 36 Engine.............................................................................. 36 Transmission........................................................................ 36 Transfer case....................................................................... 36 Axle lines.......................................................................... 36 Steering............................................................................ 37 Tyres............................................................................... 37 Electrical system................................................................... 37 Tools............................................................................... 37 Towing coupling.................................................................... 37 Outriggers.......................................................................... 38 Driving speeds...................................................................... 39 Climbing ability.................................................................... 39 Turning circle radiuses............................................................ 39 1.5.5 Superstructure.................................................................... 40 Engine.............................................................................. 40 Slewing gears....................................................................... 40 Derricking gear..................................................................... 40 Main boom........................................................................... 40 Main hoist.......................................................................... 41 Auxiliary hoist..................................................................... 41 Lattice extension................................................................... 41 Operating speeds and times without a load........................................... 42 1.6 Documentation supplied.................................................................. 43 1.6.1 Questions on documentation........................................................ 44 1.7 Information about the operating instructions............................................ 45 1.7.1 What do the symbols used mean?.................................................... 45 1.7.2 How are the operating instructions structured?.................................... 47 Division............................................................................ 47 Structure of the chapters........................................................... 47 Structure of the pages.............................................................. 48 1.7.3 How do I find the information I need?............................................. 49 Cross-references example............................................................ 50 1.7.4 What information is available for operations planning?............................ 52 1.8 Conversion table for US measurements.................................................... 53 1.9 Training – Information.................................................................. 55 1.10 Identification......................................................................... 56 1.11 EC Declaration of Conformity........................................................... 59 2 Basic safety instructions..................................................................... 63 2.1 Intended use............................................................................ 63 2.1.1 Improper use...................................................................... 64 2.2 Organisational measures................................................................. 65 2.3 Qualifications of the personnel......................................................... 67 2.4 Safety instructions for driving the truck crane......................................... 68 2.5 Safety instructions for crane operation................................................. 69 2.6 Information on transporting persons..................................................... 71 Equipment for lifting persons........................................................... 71 Personnel............................................................................... 71 operation............................................................................... 72 Truck crane............................................................................. 73 3 Operating elements for driving................................................................ 77 3.1 Overview of the operating elements...................................................... 77 3.1.1 On the outside of the truck crane................................................. 78 3.1.2 Driver's cab...................................................................... 80 Overview............................................................................ 80 Below in the driver's cab........................................................... 82 Overhead in the driver's cab........................................................ 83 Behind the cover................................................................... 84 3.1.3 Instrument panel.................................................................. 86 Left................................................................................ 86 Middle.............................................................................. 88 Right............................................................................... 90 Page................................................................................ 92 Gearbox control unit............................................................... 94 3.1.4 Steering wheel.................................................................... 95 3.1.5 Tachograph........................................................................ 96 3.1.6 Heating / Air-conditioning system................................................. 97 Standard heating system............................................................. 97 Auxiliary water heating system..................................................... 98 Auxiliary air heater................................................................ 99 3.1.7 Outrigger control units...........................................................100 3.1.8 Control unit for lock, carrier....................................................101 3.2 Short description of the operating elements.............................................103 3.2.1 Definition of information relating to directions of movement......................103 Basic rule..........................................................................103 Switches and buttons...............................................................104 3.2.2 General information on the operating elements.....................................104 3.2.3 Engine............................................................................104 Steering column.....................................................................104 Multipurpose switch.................................................................105 Instrument panel....................................................................105 3.2.4 Electrical system.................................................................106 Electrical system...................................................................106 Electronics.........................................................................106 3.2.5 Transmission......................................................................108 Transmission display...............................................................108 Instrument panel....................................................................110 3.2.6 Transfer case.....................................................................111 3.2.7 Final drive.......................................................................112 Transverse differential locks.......................................................112 Longitudinal differential lock.....................................................112 3.2.8 Brakes............................................................................113 Service brake.......................................................................113 Parking brake.......................................................................113 Additional brakes...................................................................114 3.2.9 Steering / separate steering......................................................115 Instrument panels...................................................................115 In the driver's door................................................................115 3.2.10 Suspension.......................................................................116 3.2.11 Hydraulic system.................................................................117 Control unit for lock, carrier......................................................117 3.2.12 Lighting / windscreen wipers / horn..............................................118 Steering column.....................................................................118 Instrument panel....................................................................118 Overhead in the driver's cab........................................................120 3.2.13 Level adjustment system..........................................................121 Instrument panel....................................................................121 3.2.14 Tachograph / speedometer.........................................................123 Tachograph..........................................................................123 Speedometer........................................................................123 3.2.15 Other operating elements.........................................................124 Diagnostics.........................................................................124 Boom not set down indicator.........................................................124 3.2.16 Windows, doors, keys.............................................................125 Windows.............................................................................125 Doors...............................................................................126 Keys................................................................................127 3.2.17 Front flap.......................................................................127 4 Starting / turning off the engine for driving.................................................131 4.1 Start the engine........................................................................131 4.1.1 CHECKLIST: Starting the engine....................................................131 4.1.2 CHECKLIST: At low temperatures....................................................134 4.1.3 Ladders and access ladders........................................................135 Access ladders......................................................................135 Ladders.............................................................................135 4.1.4 Refuelling........................................................................138 4.1.5 Checks before starting the engine.................................................139 On the hydraulic tank...............................................................139 Battery master switch...............................................................139 4.1.6 Switch on the ignition............................................................140 4.1.7 Lamp test / equalisation of the switching states..................................140 Lamp test...........................................................................140 Equalisation of the switching states................................................141 4.1.8 Start the engine..................................................................141 Without flame start system..........................................................142 With flame start system............................................................142 4.1.9 Checks after starting the engine..................................................144 4.1.10 Control elements.................................................................145 4.1.11 Setting the idling speed.........................................................146 4.2 Turning off the engine..................................................................147 4.2.1 Stopping the engine from the driver's cab.........................................147 After parking......................................................................147 4.2.2 Stopping the engine with the emergency stop switches..............................148 Resetting the emergency stop switch.................................................148 4.3 Air intake inhibitor....................................................................149 Releasing the air intake inhibitor......................................................149 5 Driving.......................................................................................153 5.1 Before driving..........................................................................153 5.1.1 CHECKLIST: Inspections before on-road driving.....................................153 5.1.2 Checking the condition of the truck crane.........................................158 Windscreen, washing system..........................................................158 Electrical system...................................................................158 Adjusting the mirrors..............................................................159 Warning plates for vehicle width....................................................160 Boom not set down indicator.........................................................160 Supply pressure.....................................................................161 Parking brake.......................................................................162 5.1.3 Adjusting the seat and the steering column........................................163 Driver's seat.......................................................................163 Passenger's seat....................................................................164 Adjusting the steering column......................................................165 5.1.4 Switching the suspension on / off.................................................166 Switching on the suspension.........................................................166 Switching off the suspension.......................................................166 5.1.5 Adjusting the tachograph..........................................................167 Prerequisites.......................................................................167 In the event of malfunctions........................................................167 Adjusting the tachograph...........................................................168 5.2 Operating the transmission..............................................................173 5.2.1 Switching on......................................................................173 5.2.2 Switching the transmission to neutral position....................................174 While driving.......................................................................174 5.2.3 Changing the driving mode.........................................................175 5.2.4 Selecting the driving direction...................................................175 5.2.5 Changing highest gear / starting gear.............................................176 5.2.6 Starting..........................................................................177 5.2.7 Driving and changing gears........................................................178 5.2.8 Changing the driving direction....................................................179 5.2.9 Stopping..........................................................................179 Stopping for a long period of time.................................................179 5.2.10 On the roller type dynamometer...................................................179 5.2.11 Oil level gauge..................................................................180 5.3 Driving and turning off the truck crane.................................................183 5.3.1 Checks while driving..............................................................183 Immediately after you start to move.................................................183 While driving.......................................................................184 5.3.2 Tempomat..........................................................................185 Switching on.......................................................................185 Driving with the Tempomat..........................................................185 Switching off.......................................................................186 5.3.3 Temposet..........................................................................187 Switching on........................................................................187 Switching off.......................................................................187 5.3.4 Driving downhill..................................................................188 Starting............................................................................188 Checks when driving downhill.......................................................188 Shifting down from the highest gear.................................................189 Additional brakes...................................................................190 5.3.5 Driving uphill....................................................................191 Starting............................................................................191 Driving.............................................................................191 5.3.6 Warning messages in driving mode..................................................192 Meaning of the lamps................................................................192 5.3.7 Turning off the truck crane.......................................................195 Securing the truck crane against moving unintentionally.............................196 When stationary for more than 8hours...............................................197 5.3.8 Fold-up berth.....................................................................198 5.4 Off-road driving........................................................................199 Adjustments to the transmission.........................................................199 Connections.............................................................................199 Changing the vehicle level..............................................................199 Rocking the vehicle free and towing.....................................................199 5.4.1 Key-operated switch...............................................................200 When switching on...................................................................200 When switching off..................................................................200 5.4.2 Transfer case – switching on off-road / on-road gears.............................201 Neutral position....................................................................201 5.4.3 Operation of the longitudinal differential lock...................................202 5.4.4 Operation of the transverse differential locks....................................203 5.4.5 Operation of the level adjustment system..........................................204 Before level adjustment............................................................205 Preselecting level lift / lower.....................................................205 Inclining the truck crane...........................................................206 Changing the overall level.........................................................206 After level adjustment..............................................................206 Setting the on-road level...........................................................207 5.4.6 Freeing the truck crane stuck in terrain..........................................209 Rocking the truck crane free.......................................................209 Towing free to the front............................................................210 Towing free to the rear.............................................................210 5.4.7 Separate steering.................................................................211 Switching to separate steering......................................................211 Steering............................................................................212 Switching to normal steering mode...................................................213 5.5 Heating and air-conditioning system.....................................................215 5.5.1 Standard heating system...........................................................215 Switching on........................................................................215 Heating.............................................................................215 Air distribution....................................................................216 Examples............................................................................217 Switching off.......................................................................217 5.5.2 Air-conditioning system...........................................................218 Warnings............................................................................218 Switching on........................................................................219 Cooling.............................................................................219 Drying..............................................................................220 Switching off.......................................................................220 5.5.3 Auxiliary heater..................................................................221 Preheating the engine...............................................................221 Preheating the driver's cab.........................................................221 Switching on........................................................................222 Switching off.......................................................................223 5.5.4 Auxiliary water heater............................................................223 Preheating the engine...............................................................223 Preheating the driver's cab........................................................224 Switching on the auxiliary heater...................................................224 Switching off the auxiliary heater..................................................225 Setting the day and time............................................................225 Storing the heating start..........................................................226 Setting the heating period.........................................................227 Switching the heating start on and off..............................................227 Setting remaining time.............................................................228 5.5.5 Auxiliary air heater with timer...................................................229 Switching on the auxiliary heater...................................................229 Setting the temperature.............................................................230 Switching off the auxiliary heater..................................................230 Other functions.....................................................................230 6 Driving modes and rigging for on-road driving.................................................233 6.1 Driving modes...........................................................................233 Information about the axle loads........................................................233 6.1.1 Driving modes for the maximum axle load of 12 t...................................234 6.1.2 Maximum permitted speeds with an axle load of over 12t...........................235 6.2 Rigging work for driving with a trailer.................................................237 6.2.1 Switching on the slewing gear freewheel...........................................237 6.2.2 Switching on boom floating position...............................................240 6.2.3 Switching on boom pre-tensioning..................................................241 Filling the pressure accumulators..................................................242 6.2.4 Switching the superstructure driving lights on / off..............................243 Switching off.......................................................................243 Switching on........................................................................243 6.3 Rig the outrigger span 7.78x8.90 / 1.22m.............................................245 Rigging.................................................................................245 Unrigging...............................................................................247 6.4 Installing / removing supports..........................................................249 6.4.1 CHECKLIST: Remove the outrigger beams.............................................250 6.4.2 CHECKLIST: Installing the outrigger beams.........................................252 6.4.3 Preparing the truck crane.........................................................254 Prerequisites.......................................................................254 For removal.........................................................................254 6.4.4 Removing / attaching outrigger pads...............................................255 Removing the outrigger pads........................................................255 Attaching the outrigger pads.......................................................256 6.4.5 Disconnecting / establishing the hydraulic connection.............................257 6.4.6 Establishing / disconnecting the electrical connection............................258 6.4.7 Holding angle position............................................................258 6.4.8 Unscrewing / screwing in the spacers..............................................259 6.4.9 Disconnecting / establishing the connections to the outrigger box.................260 6.4.10 Pulling out / Inserting the outrigger beam.......................................261 Information.........................................................................261 Pulling out.........................................................................261 Installing..........................................................................262 6.4.11 Transporting the outrigger beams.................................................264 6.5 Mounting / dismounting the rear outriggers..............................................265 Equipment required.....................................................................265 6.5.1 CHECKLIST: Dismount the rear outriggers...........................................266 6.5.2 CHECKLIST: Mounting the rear outriggers...........................................269 6.5.3 Crane movements during the installation and removal procedures....................271 Prerequisites.......................................................................271 Before the installation.............................................................271 After the removal..................................................................271 6.5.4 Slinging points of the rear outrigger.............................................272 6.5.5 Disconnecting / establishing the hydraulic connection.............................273 Establishing........................................................................273 Disconnecting.......................................................................273 6.5.6 Electrical connection, establishing / breaking....................................275 Establishing........................................................................275 Disconnecting.......................................................................276 6.5.7 Establishing / Disconnecting the pneumatic connection.............................277 Establishing........................................................................277 Disconnecting.......................................................................277 6.5.8 Lifting / hanging the outrigger box with the truck crane..........................278 Prerequisites:......................................................................278 Lifting.............................................................................279 Hanging.............................................................................280 6.5.9 Locking/releasing the supporting box lock.........................................281 Locking.............................................................................281 Locking pin released................................................................282 6.5.10 Transportation on a separate vehicle.............................................283 6.5.11 Installing / removing the lighting carrier.......................................284 Prerequisites.......................................................................284 Sling the lighting carrier ........................................................284 Mounting............................................................................285 Removing............................................................................286 6.5.12 Hook block in the lighting carrier...............................................288 Setting down the hook block........................................................288 Picking up the hook block..........................................................289 6.6 Rigging the main boom...................................................................291 Auxiliary equipment required............................................................291 6.6.1 CHECKLIST: Removing the main boom.................................................292 General prerequisites...............................................................292 Prerequisites in terms of the outriggers............................................292 6.6.2 CHECKLIST: Installing the main boom...............................................295 Prerequisites.......................................................................295 6.6.3 Main boom slinging points.........................................................298 6.6.4 Removing / attaching the clamp....................................................299 6.6.5 Switching the pressure relief on / off............................................300 6.6.6 Retracting / fitting the derricking cylinder head pin.............................301 Derricking cylinder support........................................................301 Operating the lifting device........................................................302 Retracting the derricking cylinder head axle........................................303 Fitting the derricking cylinder head axle...........................................304 6.6.7 Retracting / extending the boom pivot pin.........................................305 Securing / releasing the main boom pin..............................................305 Retracting / extending the pivot pin................................................306 6.6.8 Separating the hydraulic / electrical connection..................................307 Lifting in front of the turntable...................................................307 Disconnecting.......................................................................308 6.6.9 Establishing the hydraulic / electrical connection................................309 Lifting onto the turntable..........................................................309 Establishing........................................................................310 6.6.10 Aligning the connecting points...................................................311 6.6.11 Securing / releasing the derricking cylinder.....................................312 6.6.12 Transporting the main boom.......................................................313 6.6.13 Inspections after main boom mounting.............................................314 6.6.14 Slewing the superstructure with main boom removed................................315 6.7 Installing/removing the additional axle on the carrier..................................319 Additional equipment required..........................................................319 6.7.1 CHECKLIST: Installing the additional axle.........................................320 Prerequisites.......................................................................320 6.7.2 CHECKLIST: Removing the additional axle...........................................323 6.7.3 Slinging points on the additional axle............................................326 6.7.4 Crane movements during the installation and removal procedures....................327 Prerequisites.......................................................................327 Before the installation.............................................................327 After the removal..................................................................327 6.7.5 Establish/disconnect hydraulic connections for the lock...........................328 Establishing........................................................................328 Disconnecting.......................................................................328 6.7.6 Establish/disconnect hydraulic connections for the additional axle suspension.....329 Establishing........................................................................329 Disconnecting.......................................................................330 6.7.7 Establish/disconnect electrical connection for the lock...........................331 Establishing........................................................................331 Disconnecting.......................................................................331 6.7.8 Establish/disconnect the electrical connection for the additional axle/trailer....332 Establishing........................................................................332 Disconnecting.......................................................................332 6.7.9 Establish/disconnect the electrical connection for the rear carrier light.........333 Establishing........................................................................333 Disconnecting.......................................................................333 6.7.10 Establishing / Disconnecting the pneumatic connection............................335 Establishing........................................................................335 Disconnecting.......................................................................335 6.7.11 Attaching / removing the additional axle with the truck crane....................336 Prerequisites.......................................................................336 Hanging.............................................................................337 Lifting.............................................................................338 6.7.12 Locking/releasing the additional axle lock.......................................339 Locking.............................................................................339 Releasing...........................................................................340 6.7.13 Locking / enabling the suspension on the additional axle.........................341 Locking.............................................................................341 Enabling............................................................................342 6.7.14 Unlocking/locking the steering of the additional axle............................343 6.7.15 Raising / lowering 3rd and 6th axle lines........................................345 Raising.............................................................................345 Lowering............................................................................346 6.8 Installing/removing additional axle on the rear outrigger...............................347 Additional equipment required..........................................................347 6.8.1 CHECKLIST: Installing the additional axle.........................................347 Prerequisites.......................................................................347 6.8.2 CHECKLIST: Removing the additional axle...........................................350 Prerequisites.......................................................................350 6.8.3 Slinging points on the additional axle............................................353 6.8.4 Establish/disconnect hydraulic connections for the lock...........................354 Establishing........................................................................354 Disconnecting.......................................................................354 Establishing........................................................................355 Disconnecting.......................................................................356 6.8.6 Establish/disconnect electrical connection for the lock...........................357 Establishing........................................................................357 Disconnecting.......................................................................357 6.8.7 Establish/disconnect the electrical connection for the additional axle/trailer....358 Establishing........................................................................358 Disconnecting.......................................................................358 6.8.8 Establishing/Disconnecting the pneumatic connection of the additional axle........359 Establishing........................................................................359 Disconnecting.......................................................................359 6.8.9 Attaching/removing the additional axle with the truck crane.......................360 Prerequisites.......................................................................360 Attaching...........................................................................360 Lifting.............................................................................361 6.8.10 Locking/releasing the additional axle lock.......................................363 Establishing........................................................................363 Releasing...........................................................................364 6.8.11 Locking/enabling the suspension on the additional axle...........................365 Locking.............................................................................365 Enabling............................................................................366 6.8.12 Unlocking/locking the steering of the additional axle............................367 6.8.13 Raising/lowering 3rd and 6th axle lines..........................................368 Raising.............................................................................368 Lowering............................................................................369 7 Malfunctions in driving mode..................................................................373 7.1 Emergency stop switch...................................................................373 7.2 What to do when a malfunction occurs in road traffic....................................375 7.3 Towing the truck crane..................................................................377 7.3.1 Towing in the event of engine or transmission damage..............................378 Compressed-air supply...............................................................378 Electric power supply...............................................................378 On the transmission.................................................................379 Transmission........................................................................379 Axle drives.........................................................................379 Transfer case.......................................................................379 Parking brake.......................................................................380 Towing the truck crane out of the danger area.......................................380 7.3.2 Tow starting......................................................................381 7.4 Wheels and tyres........................................................................383 7.4.1 Wheel change......................................................................383 Removing a damaged wheel...........................................................384 Lift the wheel......................................................................384 Mounting a wheel....................................................................385 7.4.2 Filling the tyres yourself........................................................386 Connecting the filling hose.........................................................386 Filling the tyres...................................................................387 Removing the filling hose...........................................................387 7.5 Fuses...................................................................................389 Information on replacing fuses........................................................389 7.5.1 Fuses in the driver's cab.........................................................390 7.5.2 Fuses in the battery box..........................................................394 7.5.3 Fuses on circuit boards...........................................................395 7.6 Troubleshooting and correction..........................................................397 7.6.1 Malfunctions on the engine........................................................397 7.6.2 Malfunctions to the transmission..................................................399 7.6.3 Malfunctions of the service brake.................................................400 7.6.4 Steering malfunctions.............................................................401 7.6.5 Transfer case malfunctions........................................................401 7.6.6 Differential lock malfunctions....................................................402 7.6.7 Malfunctions on the suspension....................................................402 7.6.8 Malfunctions in the hydraulic system / hydraulic oil cooler.......................403 7.6.9 Malfunctions of the level adjustment system.......................................403 7.6.10 Malfunctions to the carrier electronic system....................................404 7.7 Procedure in the event of malfunctions..................................................407 7.7.1 Switching on emergency operation in coolant circuit...............................407 On hydraulic cooler.................................................................407 At the engine.......................................................................408 7.7.2 Procedure in the event of transmission malfunctions...............................409 General malfunctions................................................................409 Serious malfunction.................................................................409 Shift lock, transmission............................................................410 Reading out error codes............................................................410 7.7.3 Separate steering emergency operation.............................................411 Bringing the steering into a condition for On-road driving..........................411 Locking the steering...............................................................412 8 Index.........................................................................................417 A...........................................................................................419 B...........................................................................................419 C...........................................................................................420 D...........................................................................................421 E...........................................................................................422 F...........................................................................................424 H...........................................................................................424 I...........................................................................................426 K...........................................................................................426 L...........................................................................................426 M...........................................................................................427 O...........................................................................................428 P...........................................................................................428 R...........................................................................................429 S...........................................................................................431 T...........................................................................................432 V...........................................................................................434 W...........................................................................................434 Part2 -Crane peration...............................................................................439 Additional Pages................................................................................441 SLI override................................................................................441 New outrigger control units.................................................................453 9 Operating elements for crane operation........................................................463 9.1 Overview of the operating elements......................................................463 9.1.1 On the outside of the truck crane.................................................464 9.1.2 Crane cab.........................................................................468 9.1.3 Front panel.......................................................................470 9.1.4 Side panel........................................................................471 Bottom..............................................................................471 Top.................................................................................472 Standard heating system.............................................................475 Auxiliary water heater.............................................................476 Auxiliary air heater...............................................................477 9.1.5 Control panels....................................................................478 Left................................................................................478 Right...............................................................................479 9.1.6 Control lever assignment..........................................................480 Version 1...........................................................................480 Version 2...........................................................................481 9.1.7 ECOS control unit.................................................................482 9.1.8 ECOS display – main menu..........................................................484 9.1.9 ECOS display – submenus...........................................................486 Superstructure lock submenu........................................................486 Outriggers submenu.................................................................487 Telescoping submenu................................................................488 Power unit speeds submenu.........................................................489 Monitoring submenu.................................................................490 Settings submenu...................................................................491 Operating hours submenu............................................................492 Warning submenu....................................................................492 Error submenu.......................................................................493 Working range limitation submenu..................................................494 9.1.10 SLI control unit.................................................................496 9.1.11 SLI display – main menu..........................................................497 9.1.12 SLI display – submenus...........................................................499 Enter rigging mode submenu........................................................499 Monitoring submenu.................................................................500 Rigging mode monitoring submenu...................................................502 Lifting capacity table submenu....................................................503 Working rang submenu...............................................................504 Error submenu.......................................................................505 Settings submenu....................................................................506 9.1.13 Hand-held control................................................................507 9.1.14 Outrigger control units..........................................................508 Outriggers..........................................................................509 Outrigger pressure display.........................................................509 Inclination display.................................................................509 9.2 Short description of the operating elements.............................................511 9.2.1 Definition of information relating to directions of movement......................511 Basic rule..........................................................................511 Switch..............................................................................511 9.2.2 General rules for buttons and symbols on the display..............................512 9.2.3 Engine for crane operation........................................................513 Side panel.........................................................................513 ECOS display........................................................................513 9.2.4 Seat contact switch and dead man's switch.........................................514 9.2.5 ECOS crane control................................................................515 9.2.6 Outriggers........................................................................518 In the Outriggers submenu..........................................................518 On the Outrigger control units......................................................518 9.2.7 Inclination displays..............................................................520 9.2.8 Outrigger pressure displays.......................................................521 Outriggers submenu.................................................................521 Outrigger control units............................................................521 9.2.9 Anemometer display................................................................521 9.2.10 Superstructure lock submenu......................................................522 Turntable locking..................................................................522 Houselock...........................................................................523 9.2.11 Main hoist.......................................................................524 9.2.12 Auxiliary hoist..................................................................525 9.2.13 Slewing gear.....................................................................526 9.2.14 Derricking gear..................................................................527 9.2.15 Telescoping mechanism............................................................528 Control panels......................................................................528 Submenu.............................................................................529 In the settings submenu.............................................................533 9.2.16 Hydraulic system.................................................................534 9.2.17 Safe load indicator (SLI)........................................................535 Control unit........................................................................535 Main menu...........................................................................537 Enter rigging mode submenu..........................................................538 Monitoring submenu..................................................................540 Lifting capacity table submenu......................................................544 Working range submenu..............................................................544 Other...............................................................................545 9.2.18 Electrical system................................................................546 9.2.19 Lighting, windscreen wiper / washing system......................................546 Lighting............................................................................546 Windscreen wiper/ Washing system..................................................548 9.2.20 Hand-held control................................................................549 Sockets for hand- held control......................................................549 Engine control panel................................................................550 Pre-select emergency operation.....................................................551 Function buttons....................................................................551 Pre-select rigging..................................................................552 Operation...........................................................................552 9.2.21 Diagnostics......................................................................556 9.2.22 Windows, doors, keys.............................................................557 Windows.............................................................................557 Crane cab door......................................................................558 Keys................................................................................559 10 Starting / turning off the engine – for crane operation.....................................563 10.1 Starting the engine – from the crane cab...............................................563 10.1.1 CHECKLIST: Starting the engine...................................................563 10.1.2 CHECKLIST: At low temperatures...................................................566 10.1.3 Refuelling.......................................................................567 10.1.4 Checks before starting the engine................................................568 On the hydraulic tank...............................................................568 Battery master switch...............................................................569 Checking the hand-held control......................................................569 10.1.5 Switch on the ignition...........................................................570 10.1.6 Lamp test........................................................................570 Lamp test...........................................................................570 10.1.7 Setting the display brightness...................................................572 10.1.8 Starting the engine..............................................................573 Without flame start system..........................................................573 With flame start system............................................................574 10.1.9 Checks after starting the engine.................................................575 10.1.10 Monitoring submenu..............................................................576 10.1.11 Setting the idling speed........................................................577 10.2 Starting the engine – with the hand-held control.......................................579 Prerequisites...........................................................................579 Starting the engine.....................................................................579 10.3 Turning off the engine.................................................................581 10.3.1 During normal operation, with the ignition lock / with the handheld control.....581 After parking......................................................................581 10.3.2 In emergencies, with the emergency-stop switches.................................582 Resetting the emergency stop switch.................................................582 10.4 Air intake inhibitor...................................................................583 Releasing the air intake inhibitor......................................................583 11 Crane operation .............................................................................587 11.1 Before crane operation.................................................................587 11.1.1 CHECKLIST: Inspections prior to crane operation..................................587 11.1.2 Checking the condition of the truck crane........................................591 Tank for windscreen washing system..................................................591 Visual inspection...................................................................591 Checking the position of the hoist ropes............................................592 Checking the electrical system......................................................592 11.1.3 Adjusting the front panel and crane cab seat.....................................593 Front panel.........................................................................593 Adjusting the crane cab seat........................................................593 11.1.4 Checking the safety devices......................................................594 Safe load indicator................................................................594 Lifting limit switch...............................................................594 Emergency stop switch...............................................................595 Seat contact switch and dead man's switch...........................................596 11.1.5 Load, earthing...................................................................597 11.1.6 Preheating the hydraulic oil.....................................................598 For oil temperature of between –15 C and 0 C......................................598 For oil temperatures below –15 C...................................................598 11.1.7 Locking / unlocking the superstructure...........................................599 Locking points......................................................................599 Lock the superstructure............................................................600 Unlock the superstructure..........................................................600 11.1.8 Switching the houselock on / off.................................................601 Switching on the houselock.........................................................601 Switching off the houselock........................................................603 11.2 Operation of the safe load indicator...................................................605 11.2.1 Switching on the SLI.............................................................606 Switching on........................................................................606 Brightness of the displays..........................................................608 11.2.2 Entering the rigging mode........................................................609 Entering individual components......................................................610 Entering the SLIcode..............................................................613 Entering the reeving...............................................................614 Accepting the rigging mode.........................................................614 11.2.3 Inspections prior to crane operation.............................................616 Open the Monitoring submenu.......................................................616 Inspections.........................................................................617 11.2.4 Displays during crane operation..................................................619 11.2.5 SLI early warning................................................................622 11.2.6 SLI shutdown.....................................................................622 Shutdown due to overload............................................................622 11.2.7 Display in the event of errors...................................................624 11.2.8 SLI override.....................................................................625 11.2.9 Displaying the lifting capacity tables...........................................626 11.2.10 Entering the time / date........................................................628 11.3 Crane operation with main boom.........................................................629 11.3.1 Checks during crane operation....................................................629 Horizontal alignment...............................................................629 Safe distances.....................................................................629 Checking the wind speed.............................................................630 Checking wind surface..............................................................632 Measures to be taken when this is exceeded..........................................633 11.3.2 Permissible slewing ranges and working positions.................................634 360 slewing range..................................................................634 Slewing range ±15 ..................................................................634 Working position 0 / 180 ..........................................................634 11.3.3 Main hoist.......................................................................635 Switching on the main hoist.........................................................636 Lifting and lowering...............................................................636 Switching off the main hoist.......................................................637 11.3.4 Auxiliary hoist..................................................................638 Switching on the auxiliary hoist...................................................638 Lifting and lowering...............................................................639 Switching off the auxiliary hoist..................................................640 11.3.5 Lifting limit switch and lowering limit switch...................................641 Lifting limit switch................................................................641 Lowering limit switch...............................................................643 11.3.6 Derricking gear..................................................................644 Switching on the derricking gear...................................................644 raising and lowering the boom.......................................................645 Switching off the derricking gear...................................................646 Lowering the main boom to a horizontal position.....................................646 11.3.7 Telescoping mechanism............................................................647 Overview............................................................................648 Telescoping process................................................................648 Assignment for display..............................................................650 Fixed length, intermediate length, telescoping length..............................652 Telescoping.........................................................................653 Telescoping sequence...............................................................653 Inspections prior to starting operations...........................................654 Switching on the telescoping mechanism..............................................655 Function of the control lever.......................................................655 Switching off the telescoping mechanism.............................................657 Manual telescoping.................................................................658 Checking the initial position......................................................658 Unlocking the telescoping cylinder..................................................661 Extending / retracting the telescoping cylinder.....................................663 Lock telescoping cylinder...........................................................664 Unlocking the telescopic section...................................................665 Telescoping the telescopic section.................................................667 Locking the telescopic section.....................................................668 Locking the telescopic section for on-road driving.................................669 Telescopic extension with teleautomation............................................669 Telescoping the main boom in horizontal position..................................674 11.3.8 High-speed mode..................................................................675 Derricking gear / Telescoping mechanism.............................................675 Hoists..............................................................................676 11.3.9 Slewing gear.....................................................................677 Switching on the slewing gear......................................................677 Slewing.............................................................................677 Braking the slewing movement........................................................679 Slewing gear freewheel..............................................................680 Switching off the slewing gear......................................................680 11.3.10 Possible movement combinations..................................................681 11.3.11 Hydraulic oil cooling...........................................................681 11.4 Settings and displays for crane operation..............................................683 11.4.1 Inclining the crane cab..........................................................683 11.4.2 Setting the idling speed.........................................................684 11.4.3 Limiting the power unit speeds...................................................684 11.4.4 Setting the characteristic curve for the control levers..........................686 11.4.5 Critical load control............................................................687 Function............................................................................687 Switching on and off...............................................................687 11.4.6 Directional spotlights...........................................................688 11.4.7 Displaying the operating hours...................................................689 11.4.8 Warning submenu..................................................................690 Meaning of the symbols..............................................................690 Exiting the submenu................................................................693 11.4.9 Error submenu....................................................................693 11.5 Working range limiter..................................................................695 11.5.1 Opening the Working range limiter submenu........................................696 11.5.2 Viewing current settings.........................................................696 11.5.3 Entering limit values............................................................698 Overall height / Working radius....................................................698 Slewing angle.......................................................................699 Entering objects....................................................................701 11.5.4 Entering limit values / objects manually.........................................704 Limit values........................................................................704 Objects.............................................................................705 11.5.5 Switching monitoring functions on / off..........................................706 11.5.6 Shutdown by working range limiter................................................707 11.6 Work breaks............................................................................709 11.6.1 Short work breaks................................................................709 11.6.2 Work breaks of more than 8 hours.................................................710 Securing the truck crane............................................................710 11.7 Heating and air-conditioning system....................................................711 11.7.1 Standard heating system..........................................................711 Switching on........................................................................711 Heating.............................................................................711 Air distribution....................................................................712 Switching off.......................................................................713 11.7.2 Auxiliary water heater...........................................................713 Preheating the engine..............................................................713 Preheating the crane cab...........................................................714 Switching on........................................................................715 Switching off.......................................................................716 Setting time and weekday...........................................................716 Saving automatic heating start.....................................................717 Setting the heating period.........................................................718 Switching the automatic heating start on and off....................................718 Setting remaining time.............................................................719 11.7.3 Air-conditioning system..........................................................720 Warnings............................................................................720 Switching on / off..................................................................720 Cooling.............................................................................721 Drying the air......................................................................721 12 Rigging work.................................................................................725 12.1 Rigging work checklists for crane operation with the main boom.........................725 12.1.1 CHECKLIST: Rigging...............................................................725 12.1.2 CHECKLIST: Unrigging.............................................................730 12.2 Choosing a suitable site...............................................................735 12.2.1 Determining the required ground bearing area.....................................735 Outrigger pressure..................................................................735 Load bearing capacity of the ground.................................................736 Ground bearing area.................................................................737 12.2.2 Safe distance from slopes and pits...............................................737 12.2.3 Earthing the truck crane.........................................................738 12.2.4 Safe distance from electrical lines..............................................739 12.3 Connecting / disconnecting the hand-held control.......................................741 12.4 Rigging for crane operation / driving..................................................743 12.4.1 Slewing the crane cab............................................................743 Crane operation position...........................................................743 Driving position...................................................................744 12.4.2 Tread grid, ladder, railings.....................................................746 Access ladder.......................................................................746 Crane operation position............................................................747 Driving position....................................................................748 12.4.3 Mirrors..........................................................................749 12.5 Rigging work after driving with a trailer..............................................751 12.5.1 Switching off the slewing gear freewheel.........................................751 Before slewing......................................................................752 12.5.2 Switching off the boom floating position.........................................753 12.5.3 Switching off boom pre-tensioning................................................754 12.6 Rigging / unrigging the outriggers.....................................................755 12.6.1 CHECKLIST: Extending the outriggers..............................................755 12.6.2 CHECKLIST: Retracting the outriggers.............................................757 12.6.3 Permissible outrigger spans......................................................758 12.6.4 Preparing the truck crane........................................................759 In the driver's cab.................................................................759 12.6.5 Setting the spans................................................................759 For on-road driving................................................................760 12.6.6 Extending / retracting outriggers................................................761 12.6.7 Moving the outrigger pads into working / driving position........................763 12.6.8 Enlarging the ground bearing area................................................764 12.6.9 Extending / retracting supporting cylinders......................................765 12.6.10 Levelling the truck crane.......................................................768 Inclination displays................................................................768 Prerequisite........................................................................769 Alignment..........................................................................770 12.6.11 Outrigger pressure display......................................................771 12.7 Counterweight..........................................................................773 12.7.1 Counterweight sections and identification........................................773 Counterweight parts................................................................773 Identification......................................................................774 12.7.2 Slinging points on the counterweight sections....................................775 12.7.3 Counterweight combinations.......................................................776 12.7.4 CHECKLIST: Rigging the counterweight.............................................779 12.7.5 CHECKLIST: Unrigging the counterweight...........................................781 Prerequisites.......................................................................781 12.7.6 Assembling the counterweight version.............................................784 Setting down the 20t base plate....................................................784 Placing the 10t plates / blocks...................................................785 12.7.7 Securing / releasing 10 t counterweight blocks...................................787 Securing 10t counterweight blocks.................................................787 Releasing 10t counterweight blocks................................................788 12.7.8 Establishing / disconnecting the hydraulic connection............................789 Establishing a connection.........................................................789 Disconnecting.......................................................................789 12.7.9 Electrical connection, establishing / breaking...................................790 Establishing a connection.........................................................790 Disconnecting......................................................................790 12.7.10 Rigging the counterweight.......................................................791 Hand-held control...................................................................791 Rigging the counterweight..........................................................792 Unrigging counterweight.............................................................793 Counterweight safety valve..........................................................795 12.7.11 Hoisting and setting down counterweight parts with mounted auxiliary hoist.....796 12.7.12 Slewing with rigged counterweight...............................................797 12.8 Auxiliary hoist........................................................................799 12.8.1 Identification...................................................................799 12.8.2 Slinging points and transport....................................................800 Slinging points.....................................................................800 Transportation......................................................................801 12.8.3 CHECKLIST: Mounting the auxiliary hoist..........................................802 Prerequisites.......................................................................802 12.8.4 CHECKLIST: Removing the auxiliary hoist..........................................804 Prerequisites.......................................................................804 12.8.5 Hoisting the auxiliary hoist onto the 20 t base plate............................806 12.8.6 Raising / setting down the catcher...............................................807 Raising.............................................................................807 Setting down........................................................................807 12.8.7 Establishing / disconnecting the hydraulic connection............................808 Establishing.......................................................................808 Disconnecting......................................................................808 12.8.8 Electrical connection, establishing / disconnecting..............................809 Establishing.......................................................................809 Disconnecting......................................................................809 12.8.9 Locking / Unlocking the auxiliary hoist..........................................810 Auxiliary hoist safety valve........................................................810 Locking.............................................................................811 Locking pin released................................................................812 Locking pin released................................................................812 12.8.10 Checking the auxiliary hoist for correct functioning............................813 With the hand- held control.........................................................813 In the crane cab....................................................................813 12.8.11 Securing the upper hook block in the catcher....................................814 12.8.12 Permissible applications for the auxiliary hoist................................815 Replacement for the main hoist......................................................815 Alternating operation with the main and the auxiliary hoist.........................816 12.9 Rigging work on the main boom..........................................................817 12.9.1 Hook block on the bumper.........................................................817 Picking up the hook block from the bumper...........................................817 Attaching the hook block to the bumper..............................................818 12.9.2 Hook block on a separate vehicle.................................................819 Picking up the hook block...........................................................820 Setting down the hook block.........................................................820 12.9.3 Reeving and unreeving the hoist rope.............................................822 Rope end fitting....................................................................822 Reeving.............................................................................823 Unreeving...........................................................................826 12.9.4 Possible reeving methods on the main boom........................................827 With 9 head sheaves.................................................................827 With 11 head sheaves................................................................832 With 13 head sheaves................................................................838 12.9.5 Installing / removing the lifting limit switch...................................845 Installing lifting limit switch.....................................................845 Removing the lifting limit switch...................................................848 12.9.6 Locking / Unlocking the lifting limit switch.....................................849 Locking.............................................................................849 Unlocking...........................................................................850 12.9.7 Anemometer and air traffic control light.........................................851 Information.........................................................................851 Version 1...........................................................................851 Version 2...........................................................................852 Version 3...........................................................................854 12.9.8 Rigging heavy duty equipment.....................................................855 Additional equipment required.......................................................855 Equipment required.................................................................855 Mounting............................................................................856 Maximum reeving.....................................................................858 Removing............................................................................859 13 Rigged truck crane, driving..................................................................863 13.1 Permissible rigging modes and axle loads...............................................865 Axle load table........................................................................866 13.2 Route..................................................................................867 13.3 Before driving.........................................................................867 13.3.1 Checking the tyre pressure and the wind speed....................................867 13.3.2 Securing the superstructure against slewing......................................868 13.3.3 Putting the truck crane on the wheels............................................869 13.3.4 Preparing to drive...............................................................871 Transmission........................................................................871 Switching on separate steering.....................................................871 Connections.........................................................................871 13.4 While driving..........................................................................873 13.5 After driving..........................................................................875 14 Malfunctions during crane operation..........................................................879 14.1 Emergency stop switch..................................................................879 14.2 What to do when a malfunction occurs during crane operation............................881 Load can be lowered....................................................................881 Load cannot be lowered..................................................................881 14.3 Fuses..................................................................................883 Information on replacing fuses........................................................883 14.3.1 Fuses on the turntable...........................................................884 14.3.2 Fuses in the crane cab...........................................................886 14.3.3 Fuses in the battery box.........................................................888 14.3.4 Fuses on the crane cab bracket...................................................889 14.3.5 Fuses on I/O circuit boards......................................................890 14.3.6 SLI fuses........................................................................891 14.4 Troubleshooting and correction.........................................................893 14.4.1 Malfunctions on the engine.......................................................893 14.4.2 Malfunctions of the hoists.......................................................895 14.4.3 Malfunctions on the derricking gear..............................................897 14.4.4 Malfunctions in the telescoping mechanism........................................898 Telescoping mechanism error messages................................................900 14.4.5 Malfunctions on the slewing gear.................................................901 14.4.6 Malfunctions on the counterweight hoist unit.....................................902 14.4.7 Malfunctions in the hydraulic system / hydraulic oil cooler......................903 14.4.8 Malfunctions with movements of the crane cab.....................................904 14.4.9 Malfunctions when operating with the hand-held control...........................904 14.4.10 Malfunctions of the superstructure lock.........................................905 14.4.11 Malfunctions on the outriggers..................................................905 14.4.12 Troubleshooting the SLI.........................................................906 General malfunctions...............................................................906 Error messages in the monitoring submenu............................................907 Displays in the error submenu.......................................................909 Table of error codes................................................................911 Switching off the sensor / tachogenerator..........................................914 14.4.13 ECOS malfunctions...............................................................915 ECOS program version................................................................915 General malfunctions...............................................................915 Error messages......................................................................916 Exiting the submenu................................................................917 14.5 Emergency operations and programs......................................................919 14.5.1 Emergency operation for retraction of the telescoping............................920 Prior to the emergency operation, check.............................................920 Procedure...........................................................................920 Mechanical emergency operation......................................................921 14.5.2 Telescoping emergency program....................................................923 Starting the emergency program......................................................923 Determining the type of error......................................................924 If there is an error on the length indicator........................................925 If there is an error at a proximity switch..........................................929 Terminating the emergency program..................................................930 Tables for approaching the locking points...........................................931 14.5.3 Entering the current telescoping.................................................933 14.5.4 Emergency operation with the hand-held control...................................935 Operating a power unit..............................................................936 Stopping movements.................................................................938 Stopping movements in emergencies...................................................938 Turning off the engine..............................................................938 14.6 Hydraulic emergency operation..........................................................939 14.6.1 Operating principle..............................................................939 14.6.2 Connecting/Disconnecting hoses...................................................941 Establishing connections...........................................................941 Disconnecting.......................................................................942 14.6.3 Switching emergency operation on/off.............................................943 14.6.4 Establishing the hydraulic circuits required.....................................944 Switching over valves...............................................................944 14.6.5 Carrying out emergency operation.................................................946 Lifting/Lowering in emergency operation............................................946 Slewing in emergency operation......................................................947 Raising/Lowering the boom in emergency operation....................................948 14.6.6 After emergency operation........................................................949 Switch off emergency operation......................................................949 Switch over to crane operation......................................................949 Disconnect the hoses................................................................949 14.6.7 Emergency supply of another crane................................................950 For emergency supply................................................................950 After emergency supply..............................................................950 15 Index........................................................................................953 A...........................................................................................955 B...........................................................................................955 C...........................................................................................956 D...........................................................................................957 E...........................................................................................958 F...........................................................................................960 H...........................................................................................960 I...........................................................................................962 K...........................................................................................962 L...........................................................................................962 M...........................................................................................963 O...........................................................................................964 P...........................................................................................964 R...........................................................................................965 S...........................................................................................967 T...........................................................................................968 V...........................................................................................970 W...........................................................................................970
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