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Grove Crane GMK 7450 Driving & Crane Operation Operating instructions Manual 3112248 – PDF DOWNLOAD
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Description
Grove Crane GMK 7450 Driving & Crane Operation Operating instructions Manual 3112248 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 7450 Driving & Crane Operation Operating instructions Manual 3112248 – PDF DOWNLOAD
Language : English
Pages : 1120
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 7450 Driving & Crane Operation Operating instructions Manual 3112248 – PDF DOWNLOAD
Operating instructions for driving and crane operation:
- These instructions contain the information required to operate the truck crane.
The operating instructions are divided into two parts. Part 1, comprising Chapters 1 to 10,
describes how the truck crane is driven. Part 2, comprising Chapters 11 to 17, describes how to
operate the crane. - In Chapter 2 you will find Basic safety instructions. Please read and observe these instructions,
even if you are familiar with the safety manual. The Basic safety instructions are only contained
in this chapter. Special safety instruc- tions that relate to specific hazards are described in the
section containing the operation with which the hazard is associated.
Chapter 3 contains Information for applications engineering. It is intended primarily for the truck
crane operator and those responsible for applications engineering. This chapter contains the
following:
– The qualifications required for those involved in operations planning for the truck crane
– Special safety instructions
– Information that is relevant to operations planning
- In Chapter 4 to Chapter 6 you will find information which is necessary for Driving the truck crane:
a description of all structural and operational compo- nents, clearly defined check lists for
rigging modes and rigging work and the operating instructions for road and off-road driving. - Chapter 7 gives information on Rigging for road driving.
- In Chapter 8 you will find information on Troubleshooting when driving.
- Chapter 9 contains the Technical description of the individual parts and func-
tional elements of the carrier as well as the Technical data.
TABLE OF CONTENTS:
Grove Crane GMK 7450 Driving & Crane Operation Operating instructions Manual 3112248 – PDF DOWNLOAD
2 084 965 en........................................................................................................ 3 Operating instructions Part 1 - Driving............................................................................. 1 1 Overview...................................................................................................... 9 1.1 Vehicle identification.................................................................................. 9 1.2 EC Conformity Declaration............................................................................... 13 1.3 Overview and contents of truck crane user information................................................... 15 1.3.1 Operating instructions for driving and crane operation............................................ 15 1.3.2 Operating instructions for the lattice extension (additionalequipment)........................... 16 1.3.3 Maintenance manual................................................................................ 16 1.3.4 Lifting capacity tables........................................................................... 17 1.3.5 Outrigger pressure tables......................................................................... 17 1.3.6 Safety manual..................................................................................... 17 1.3.7 Circuit diagrams.................................................................................. 17 1.3.8 Spare parts list.................................................................................. 18 1.4 Instructions for using this documentation............................................................... 18 1.4.1 How are the operating instructions laid out?...................................................... 18 1.4.2 How are the pages of the operating instructions formatted?........................................ 19 1.4.3 How can I find the necessary information quickly and easily?...................................... 20 Example of cross- reference usage................................................................... 21 How to use the index ............................................................................. 26 1.4.4 Definition of stated directions................................................................... 26 Basic rule.......................................................................................... 26 Buttons and switches............................................................................... 26 1.4.5 Conversion table for US measurements.............................................................. 27 2 Basic safety instructions for crane operators................................................................. 31 2.1 Warnings and symbols.................................................................................... 31 2.2 Intended use............................................................................................ 32 2.3 Organizational measures................................................................................. 34 2.4 Personnel qualifications................................................................................ 36 2.5 Safety instructions that apply to truck crane driving................................................... 37 2.6 Safety instructions for truck crane work................................................................ 37 3 Information for operations planning........................................................................... 43 3.1 Safety instructions..................................................................................... 43 3.1.1 Intended use...................................................................................... 43 3.1.2 Organisational measures........................................................................... 43 3.1.3 Personnel qualifications.......................................................................... 44 3.2 Operations planning..................................................................................... 45 3.2.1 Prerequisites for operations planning............................................................. 45 3.2.2 Information for operations planning contained in the information for use ........................ 46 4 Description of the truck crane vehicle section................................................................ 49 4.1 Overview of the operating and display elements.......................................................... 49 4.1.1 Overview of the vehicle........................................................................... 49 4.1.2 Overview of the driver's cab...................................................................... 52 Top view of driver's cab............................................................................ 52 Overhead in the driver's cab........................................................................ 54 Below the front instrument panel.................................................................... 55 4.1.3 Front instrument panel............................................................................ 56 Left-hand insert.................................................................................... 56 Tachograph insert................................................................................... 58 Speedometer insert................................................................................. 60 Right-hand insert................................................................................... 62 Heating insert...................................................................................... 64 4.1.4 Side instrument panel............................................................................. 66 Insert 1............................................................................................ 66 Insert 2............................................................................................ 68 Control unit for automatic transmission............................................................. 70 4.1.5 Switch boxes for the outrigger/electronic level/outrigger pressure indicator..................... 71 4.1.6 Operating elements on the steering column......................................................... 72 4.1.7 Control box for the locking pin of the rear housing/ additionalaxis.............................. 73 4.2 Functional description of the display and operating elements........................................... 75 4.2.1 On the instrument panels.......................................................................... 75 Vehicle engine...................................................................................... 75 Automatic transmission ........................................................................... 77 Transfer case....................................................................................... 81 Axle drive.......................................................................................... 82 Brakes.............................................................................................. 83 Steering............................................................................................ 84 Suspension.......................................................................................... 86 Hydraulic system.................................................................................... 87 Electrics........................................................................................... 88 Level adjustment system............................................................................ 90 Tachograph.......................................................................................... 92 Speedometer insert................................................................................. 92 Auxiliary heater.................................................................................... 93 Heating in the driver's cab........................................................................ 94 Auxiliary heater with timer (additional equipment)................................................. 95 Other operating elements........................................................................... 96 4.2.2 On the steering column............................................................................ 97 Ignition lock....................................................................................... 97 Multipurpose switch, right.......................................................................... 97 Multipurpose switch, left........................................................................... 99 4.2.3 Overhead in the driver's cab...................................................................... 100 Air-conditioning system (additional equipment)...................................................... 100 Cab lighting........................................................................................ 100 Cab lighting........................................................................................ 101 4.3 Other operating elements on the carrier................................................................. 103 Keys.................................................................................................... 103 Doors................................................................................................... 103 Windows................................................................................................. 105 Access ladders.......................................................................................... 106 Ladders................................................................................................. 106 Diagnostics for engine/ transmission/ electronics..................................................... 108 Front flap.............................................................................................. 108 Fire extinguisher (additional equipment)............................................................... 109 Folding berth (additional equipment).................................................................... 109 5 Vehicle engine................................................................................................ 113 5.1 Starting/turning off the vehicle engine................................................................. 113 5.1.1 CHECKLIST: Starting the vehicle engine............................................................ 113 5.1.2 CHECKLIST: In winter.............................................................................. 116 5.1.3 Checks prior to starting vehicle engine........................................................... 117 Checking the shut- off valves in the hydraulic system.............................................. 117 Switching on the battery master switch............................................................. 117 Pre-checking the oil level in the automatic transmission............................................ 118 Checking coolant level.............................................................................. 119 Checking the hydraulic oil level.................................................................... 120 Checking the engine oil level...................................................................... 120 Topping up motor oil................................................................................ 121 5.1.4 Refuelling........................................................................................ 122 5.1.5 Starting the vehicle engine....................................................................... 123 Switching on the ignition.......................................................................... 123 Starting the vehicle engine........................................................................ 125 Setting the idling speed............................................................................ 127 5.1.6 Checks after the engine has been started.......................................................... 129 Checking instruments............................................................................... 129 Checking the oil level in the automatic transmission.............................................. 131 5.2 Turning off the vehicle engine.......................................................................... 137 5.2.1 In a normal situation: ignition lock.............................................................. 137 5.2.2 In an emergency situation: vehicle engine emergency stopswitch................................... 138 5.2.3 In an emergency situation: using the air intake inhibitor (additional equipment).................. 139 Switching on the air intake inhibitor............................................................... 139 Releasing the air intake inhibitor manually........................................................ 140 6 Driving the truck crane....................................................................................... 143 6.1 Checks and adjustments before driving................................................................... 143 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving....................................... 143 6.1.2 Driving mode table............................................................................... 148 Axle loads in driving mode.......................................................................... 148 6.1.3 Checking the condition of the truck crane......................................................... 151 Checking the reservoir of the windscreen washing system............................................. 151 Warning plates for vehicle width.................................................................... 151 Checking the tyres................................................................................. 152 Checking the electrical system...................................................................... 152 Checking the mirror settings........................................................................ 153 Checking the compressed-air system................................................................. 153 Checking the suspension............................................................................ 154 Checking on-road level............................................................................ 154 Checking the transverse differential locks.......................................................... 155 Checking the longitudinal differential locks....................................................... 155 Checking the transfer case.......................................................................... 155 Checking the steering locks....................................................................... 155 Checking the Boom not set down warning lamp......................................................... 156 6.1.4 Adjusting the seat and the steering column........................................................ 157 Adjusting the driver's seat........................................................................ 157 Adjusting the passenger seat....................................................................... 158 Adjusting the steering column....................................................................... 159 6.1.5 Tachograph........................................................................................ 161 6.2 General operation....................................................................................... 167 6.2.1 Operating the automatic transmission.............................................................. 167 Switching on........................................................................................ 167 Changing the driving modes.......................................................................... 168 Selecting the driving direction.................................................................... 168 Selecting highest gear/starting gear................................................................ 169 Starting............................................................................................ 170 Driving and changing gears.......................................................................... 170 Switching the transmission to neutral position...................................................... 172 Changing the driving direction..................................................................... 173 Stopping the truck crane............................................................................ 173 On the roller type dynamometer...................................................................... 173 Driving in difficult terrain........................................................................ 174 Cold start program................................................................................. 174 6.2.2 Monitoring the control instruments while driving.................................................. 175 6.2.3 Driving downhill.................................................................................. 178 Starting on a downward slope....................................................................... 178 Driving downhill.................................................................................... 179 Preselecting transmissions.......................................................................... 179 Engine brake........................................................................................ 180 Transmission retarder............................................................................... 181 6.2.4 Driving uphill.................................................................................... 182 Starting............................................................................................ 182 Driving............................................................................................. 182 6.2.5 Cruise control.................................................................................... 183 Activating the cruise control...................................................................... 183 Driving with the cruise control.................................................................... 183 Switching off the cruise control................................................................... 184 6.2.6 Temposet (max. speed selector).................................................................... 185 Switching on temposet.............................................................................. 185 Driving with the temposet.......................................................................... 185 Temposet switching off.............................................................................. 186 6.2.7 Parking the truck crane........................................................................... 186 Applying the holding brake.......................................................................... 186 Activating neutral position........................................................................ 186 Turning off the vehicle engine..................................................................... 186 Securing the truck crane against rolling............................................................ 187 Extended standstill................................................................................. 187 6.3 Off-road driving........................................................................................ 189 6.3.1 Off-road transmission............................................................................. 190 Engaging the off- road transmission................................................................ 190 Deactivating the off-road transmission............................................................. 190 6.3.2 Longitudinal differential locks................................................................... 191 Switching on the longitudinal differential locks.................................................... 191 Switching off the longitudinal differential locks................................................... 192 6.3.3 Transverse differential locks in all driven axle lines............................................ 193 Activating the transverse differential locks........................................................ 193 Deactivating the transverse differential locks...................................................... 194 6.3.4 Level adjustment system........................................................................... 195 Checks before level adjustment...................................................................... 195 Activating the level adjustment system.............................................................. 196 Raising or lowering the entire truck crane.......................................................... 196 Tilting the truck crane lengthwise or crosswise..................................................... 197 Bring the truck crane into On- road level........................................................... 198 Deactivating the level adjustment system............................................................ 198 6.3.5 Freeing an immobilized truck crane................................................................ 199 Freeing the truck crane by its own power.......................................................... 199 Towing free to the front........................................................................... 200 Towing free to the rear............................................................................ 200 6.4 Separate steering....................................................................................... 201 6.4.1 Switching on separate steering.................................................................... 203 6.4.2 Steering axle lines with separate steering........................................................ 204 All-wheel steering.................................................................................. 204 Crab travel mode.................................................................................... 204 6.4.3 Switching off separate steering and locking the steering.......................................... 205 Locking the steering in "straight ahead" position................................................... 205 Locking the steering in other positions............................................................. 206 6.5 Heating system and fan for driver's cab................................................................. 207 6.5.1 Heating in the driver's cab....................................................................... 207 Heating the driver's cab............................................................................ 207 Ventilating the driver's cab........................................................................ 209 6.5.2 Auxiliary water heating system.................................................................... 210 Preheating the vehicle engine....................................................................... 210 Switching on the auxiliary heating system........................................................... 210 Switching off the auxiliary heating system.......................................................... 212 6.5.3 Auxiliary heater with timer (additional equipment)................................................ 212 Preheating the diesel engine....................................................................... 212 Preheating the driver's cab........................................................................ 212 Switching on the auxiliary heating system........................................................... 213 Displaying and setting the current time............................................................. 214 Switching on and saving the automatic heating start................................................. 214 Switching on and saving the automatic heating start................................................. 215 6.6 Air-conditioning system (additional equipment).......................................................... 217 6.6.1 To switch on...................................................................................... 217 6.6.2 To switch off..................................................................................... 217 6.6.3 Air conditioning.................................................................................. 219 How to use the air conditioning effectively......................................................... 219 Dry air in the driver's cab......................................................................... 220 7 Rigging for on-road driving................................................................................... 223 7.1 Rigging work for driving with a trailer................................................................. 225 7.1.1 Switching on the slewing gear freewheel........................................................... 226 7.1.2 Switching on the boom floating position........................................................... 228 Placing the main boom on a trailer.................................................................. 228 7.1.3 Switching on boom pretensioning................................................................... 229 7.2 Rigging the front outrigger beams....................................................................... 231 Equipment............................................................................................... 231 7.2.1 CHECKLIST: Removing the outrigger beams........................................................... 232 7.2.2 CHECKLIST: Mounting of outrigger beams............................................................ 233 7.2.3 Preparing the truck crane for removal/installation................................................ 235 Prerequisites for installation/ removal............................................................. 235 Preparing the truck crane.......................................................................... 235 7.2.4 Removing/attaching outrigger pads................................................................. 237 Removing outrigger pads............................................................................. 237 Attaching the outrigger pads....................................................................... 238 7.2.5 Breaking/establishing the hydraulic connection.................................................... 238 Position of the valve blocks....................................................................... 239 Breaking the hydraulic connection................................................................... 240 Establishing the hydraulic connection............................................................... 241 7.2.6 Establishing/disconnecting the electrical connection for theoutrigger pressure indicator......... 242 7.2.7 Transport position/operating position of the holding angle........................................ 243 7.2.8 Locking/releasing the extension cylinder locking pin.............................................. 244 Releasing the lock.................................................................................. 244 Locking the extension cylinder...................................................................... 245 7.2.9 Extending/reinserting outrigger beams............................................................. 246 Turning down and adjusting the wear pads............................................................ 246 Extending the outrigger............................................................................ 246 Reinserting the outrigger beams.................................................................... 249 7.2.10 Transporting the outriggers/outrigger pads....................................................... 251 7.3 Rigging the rear outrigger housing...................................................................... 253 Required equipment...................................................................................... 253 7.3.1 CHECKLIST: Removal of the outrigger housing....................................................... 254 7.3.2 CHECKLIST: Installation of outrigger housing...................................................... 257 7.3.3 Rig the outrigger span 7.78x8.90/1.22m (25.5x29.2/4.0ft).................................... 259 Preparations for installation....................................................................... 259 Preparations for removal............................................................................ 259 Supporting the truck crane with the jack stands.................................................... 260 Removing the jack stands............................................................................ 262 7.3.4 Crane movements when installing and removing...................................................... 262 Prerequisites....................................................................................... 262 Before installation................................................................................. 262 After removal...................................................................................... 263 7.3.5 Attachment points on the rear outrigger housing................................................... 263 7.3.6 Breaking/establishing the hydraulic connection.................................................... 264 Depressurizing the connections...................................................................... 264 Establishing the hydraulic connection............................................................. 265 Breaking the hydraulic connection................................................................... 265 7.3.7 Establishing/disconnecting electrical connection.................................................. 266 Establishing the electrical connection............................................................ 266 Breaking the electrical connection.................................................................. 267 7.3.8 Establishing/disconnecting pneumatic connection................................................... 268 7.3.9 Attaching/removing the outrigger housing with the truck crane..................................... 269 Raising the outrigger housing...................................................................... 270 Attaching the outrigger housing..................................................................... 270 7.3.10 Locking the outrigger housing to the carrier, unlocking.......................................... 271 Locking the outrigger housing....................................................................... 271 Releasing the lock.................................................................................. 271 Extending and retracting pins....................................................................... 272 7.3.11 Setting the outrigger box onto the support....................................................... 273 7.3.12 Transportation on a separate vehicle............................................................. 275 7.3.13 Installing/removing the rear bumper.............................................................. 276 Prerequisites....................................................................................... 276 Slinging the rear bumper............................................................................ 276 Installing the rear bumper.......................................................................... 277 Removing the rear bumper............................................................................ 278 7.3.14 Hook block in the rear bumper.................................................................... 280 Setting down the hook block........................................................................ 280 Picking up the hook block.......................................................................... 281 7.4 Rigging the main boom................................................................................... 283 Additional equipment required........................................................................... 283 7.4.1 CHECKLIST: Removing the main boom................................................................. 284 General prerequisites:.............................................................................. 284 Prerequisites in terms of the outriggers............................................................ 284 Removing main boom................................................................................. 285 7.4.2 CHECKLIST: Installing the main boom............................................................... 288 Prerequisites:...................................................................................... 288 7.4.3 Pushing the railings on the access ladder out/in................................................. 292 Pushing out the railings........................................................................... 292 Pushing in the railing............................................................................. 293 7.4.4 Rigging work with auxiliary crane................................................................. 293 Slinging points..................................................................................... 293 Lifting the main boom from the turntable........................................................... 294 Lifting the main boom onto the turntable........................................................... 295 7.4.5 Connecting and removing the hand-held control..................................................... 296 Connections on the superstructure................................................................... 296 Connecting/ removing the hand-held control.......................................................... 296 Connecting/ removing the hand-held control.......................................................... 297 7.4.6 Electrical connections on the main boom........................................................... 299 Breaking the electrical connections................................................................ 299 Establishing electrical connections................................................................. 300 7.4.7 Derricking the main boom with the hand-held control............................................... 300 Preparing the hand-held control..................................................................... 300 Derricking the main boom............................................................................ 301 7.4.8 Hydraulic connections on the main boom............................................................ 302 Removing/replacing guide plates..................................................................... 302 Connections for the telescoping mechanism........................................................... 303 Connections for the pulling devices................................................................. 304 7.4.9 Pulling device on the boom pivot pin.............................................................. 305 Removing/inserting the locking pin.................................................................. 305 Preparing the hand-held control..................................................................... 306 Retract/extend the boom pivot pin.................................................................. 307 7.4.10 Pulling devices on the head pins of the derricking cylinders..................................... 308 Attaching the derricking cylinder support........................................................... 308 Operating the lifting device....................................................................... 310 Releasing/ tightening the mechanical locks......................................................... 311 Preparing the hand-held control..................................................................... 312 Retracting the derricking cylinder head pin........................................................ 313 Extending the derricking cylinder head pin......................................................... 314 7.4.11 Checks after main boom installation.............................................................. 315 Checks at the Crane control display................................................................ 315 Hydraulic system check............................................................................. 316 7.4.12 Slewing the superstructure with main boom removed................................................ 317 Slewing to the front............................................................................... 317 Slewing to the rear................................................................................ 319 7.4.13 Before road driving.............................................................................. 322 Transport protection for the derricking cylinder.................................................... 322 Transporting the main boom.......................................................................... 323 7.4.14 Derricking cylinder pressure relief.............................................................. 324 Activating pressure relief.......................................................................... 324 Deactivating pressure relief........................................................................ 325 7.5 Installing/removing the additional axle................................................................. 327 Auxiliary equipment required............................................................................ 327 7.5.1 CHECKLIST: Installing the additional axle......................................................... 328 7.5.2 CHECKLIST: Removing the additional axle........................................................... 331 7.5.3 Outrigger span 7.78x8.90/1.22m (25.5x29.2/4.0ft) for rigging the additional axle............ 335 Supporting the truck crane with the connection pieces.............................................. 335 Removing the jack supports.......................................................................... 337 7.5.4 Slinging points on the additional axle............................................................ 337 7.5.5 Crane movements when installing and removing...................................................... 339 Prerequisites....................................................................................... 339 Before installation................................................................................. 339 After removal...................................................................................... 339 7.5.6 Breaking/establishing the hydraulic connections................................................... 340 Establishing the hydraulic connection............................................................. 340 Breaking the hydraulic connection................................................................... 341 7.5.7 Establishing/disconnecting electrical connection.................................................. 343 Establishing the electrical connection............................................................ 343 Breaking the electrical connection.................................................................. 344 7.5.8 Establishing/disconnecting the pneumatic connection............................................... 345 7.5.9 Attaching/removing the additional axle with the truck crane....................................... 346 Attaching the additional axle...................................................................... 347 Raising the additional axle........................................................................ 347 7.5.10 Locking the additional axle to the carrier, unlocking............................................ 348 Locking the additional axle........................................................................ 348 Releasing the lock.................................................................................. 348 Extending and retracting pins....................................................................... 349 7.5.11 Setting down the additional axle after removal................................................... 350 7.5.12 Locking/enabling the suspension on the additional axle........................................... 352 Locking the suspension............................................................................. 352 Enabling the suspension............................................................................ 353 7.5.13 Raising/lowering axle line....................................................................... 354 Raising the axle lines............................................................................. 354 Lowering the axle lines............................................................................ 355 8 Malfunctions in driving mode.................................................................................. 359 8.1 Emergency stop device on carrier........................................................................ 359 8.1.1 Emergency stop switch, vehicle engine............................................................. 359 8.2 Breakdown in road traffic............................................................................... 361 8.3 Towing the truck crane.................................................................................. 363 8.3.1 Towing in the case of engine or transmission damage............................................... 363 Towing the truck crane out of the danger area....................................................... 364 Longer distances.................................................................................... 364 Compressed-air supply in the event of engine failure................................................ 365 Power supply........................................................................................ 366 Axle drives......................................................................................... 366 Parking brake....................................................................................... 366 Mechanically releasing the parking brake............................................................ 367 Towing procedure.................................................................................... 367 Removing mechanical locking from all spring- loaded brake cylinders................................. 368 Tow starting........................................................................................ 368 8.4 Wheels and tyres........................................................................................ 369 8.4.1 Wheel change...................................................................................... 369 Removing a damaged wheel............................................................................ 369 Lifting/setting down wheel.......................................................................... 370 Mounting the spare wheel........................................................................... 371 8.4.2 Filling the tyres yourself at tyre inflator connection............................................ 372 Connecting the filling hose......................................................................... 372 Filling the tyres................................................................................... 373 Removing the tyre inflator hose..................................................................... 373 8.5 Electrical system....................................................................................... 375 8.5.1 Inserts........................................................................................... 376 8.5.2 Fuses............................................................................................. 378 Fuses in the driver's cab........................................................................... 378 Fuses in battery box................................................................................ 382 Fuses on I/O circuit boards......................................................................... 383 8.6 Troubleshooting and remedy.............................................................................. 385 8.6.1 Vehicle engine malfunctions....................................................................... 385 8.6.2 Automatic transmission malfunctions............................................................... 387 8.6.3 Transfer case malfunctions........................................................................ 388 8.6.4 Differential lock malfunctions.................................................................... 388 8.6.5 Steering malfunctions............................................................................. 389 8.6.6 Service brake malfunctions........................................................................ 390 8.6.7 Outrigger malfunctions............................................................................ 390 8.6.8 Tachograph malfunctions........................................................................... 391 8.6.9 Suspension locking system malfunctions............................................................ 392 8.6.10 Level adjustment system malfunctions............................................................. 392 8.6.11 Malfunctions in the carrier electronic system.................................................... 393 Reading error messages on carrier................................................................... 393 8.7 Procedure in the event of malfunctions.................................................................. 395 8.7.1 Switching on emergency operation in cooling water circuit......................................... 395 On hydraulic cooler................................................................................. 395 On the vehicle engine.............................................................................. 396 8.7.2 Procedure in the event of malfunctions in the automatic transmission.............................. 397 Troubleshooting..................................................................................... 397 Effect oferror..................................................................................... 397 Reading off errorcodes............................................................................ 398 8.7.3 Emergency operation of the solenoid valves for the outriggers..................................... 400 Position and allocation of the solenoid valves...................................................... 402 8.7.4 Separate steering emergency operation............................................................. 404 Moving the steering into on-road driving............................................................ 404 9 Technical Information on Carrier.............................................................................. 409 9.1 Technical description of the carrier.................................................................... 409 9.1.1 Crane carrier..................................................................................... 409 9.1.2 Driver's cab...................................................................................... 409 9.1.3 Drive units....................................................................................... 410 9.1.4 Engine cooling system............................................................................. 410 9.1.5 Hydraulic system.................................................................................. 410 9.1.6 Steering.......................................................................................... 411 9.1.7 Suspension system................................................................................. 411 9.1.8 Outrigger......................................................................................... 412 9.1.9 Compressed air system............................................................................. 412 9.1.10 Service brake.................................................................................... 413 9.1.11 Parking brake.................................................................................... 413 9.1.12 Retarder......................................................................................... 413 9.1.13 Secondary consumers.............................................................................. 414 9.1.14 Towing the crane................................................................................. 414 9.1.15 Towing a trailer (trailer operation)............................................................. 414 9.1.16 Electrical system................................................................................ 414 9.1.17 Rotary transmission.............................................................................. 414 9.2 Technical data.......................................................................................... 415 9.2.1 Dimensions and weights of the truck crane......................................................... 416 Dimensions for driving on public roads.............................................................. 417 9.2.2 Dimensions and weights of removable parts......................................................... 418 Spare wheel (additional equipment).................................................................. 418 Main boom........................................................................................... 418 Outrigger........................................................................................... 419 Rear bumper......................................................................................... 419 Additional axle..................................................................................... 419 Derricking cylinder support......................................................................... 419 9.2.3 Carrier........................................................................................... 420 Vehicle engine...................................................................................... 420 On-load shift transmission.......................................................................... 420 Transfer case....................................................................................... 420 Axle lines.......................................................................................... 420 Steering............................................................................................ 421 Tyres............................................................................................... 421 Vehicle's electrical system......................................................................... 421 Tools............................................................................................... 421 Outrigger........................................................................................... 422 Driving speeds...................................................................................... 423 Climbing ability.................................................................................... 423 Turning circle radiuses............................................................................ 424 10 Index........................................................................................................ 427 A........................................................................................................... 429 B........................................................................................................... 430 C........................................................................................................... 431 D........................................................................................................... 433 E........................................................................................................... 434 F........................................................................................................... 435 G........................................................................................................... 435 H........................................................................................................... 435 I........................................................................................................... 436 K........................................................................................................... 436 L........................................................................................................... 436 M........................................................................................................... 437 O........................................................................................................... 437 P........................................................................................................... 438 R........................................................................................................... 438 S........................................................................................................... 439 T........................................................................................................... 441 V........................................................................................................... 443 W........................................................................................................... 443 Operating instructions Part 2 Crane Operation....................................................................... 447 11 Description of the crane section of the truckcrane.......................................................... 453 11.1 Overview of the operating and display instruments...................................................... 453 11.1.1 Overview of the crane section.................................................................... 453 11.1.2 Overview of crane cab............................................................................ 456 11.1.3 Operating elements on the front panel............................................................ 458 11.1.4 Operating elements on the front panel............................................................ 459 Left side of the side panel........................................................................ 459 Top of the side panel.............................................................................. 460 Heating system/ air-conditioning system............................................................ 462 Crane cab additional heating....................................................................... 463 11.1.5 Control consoles................................................................................. 464 Left-hand control console........................................................................... 464 Right-hand control console.......................................................................... 465 11.1.6 Control lever configuration...................................................................... 466 Version 1 (standard)................................................................................ 466 Version 2 (additional equipment).................................................................... 467 11.1.7 Crane control plug-in module..................................................................... 468 11.1.8 Main menu – crane control display................................................................ 470 11.1.9 Crane control display – submenus................................................................. 472 Submenu for Electronic level/ outrigger pressure indicator......................................... 472 Submenu for superstructure lock.................................................................. 473 Submenu for semi-automatic telescoping.............................................................. 474 Submenu for fully automatic telescoping............................................................. 475 Driving transmission speed submenu................................................................. 476 Submenu for settings/displays..................................................................... 477 Control instruments submenu......................................................................... 479 Error menu.......................................................................................... 481 Working area limitation submenu.................................................................... 482 11.1.10 SLI plug-in module.............................................................................. 484 11.1.11 Main menu – SLI display......................................................................... 487 11.1.12 Submenus – SLI display.......................................................................... 488 Submenu for entering rigging mode................................................................. 488 Submenu for SLI monitoring......................................................................... 490 Service submenu.................................................................................... 492 Submenu for error messages......................................................................... 493 11.1.13 Switch boxes for outrigger/electronic level/outrigger pressure display.......................... 494 Operating instruments for the outriggers............................................................ 495 Display elements for the outrigger pressure indicator............................................... 495 Operating and display elements for the electronic level............................................ 495 11.1.14 Hand-held control............................................................................... 496 11.2 Functional description of the display and operating elements.......................................... 497 11.2.1 Crane engine..................................................................................... 497 On the side panel.................................................................................. 497 On the crane control display........................................................................ 498 11.2.2 Crane control.................................................................................... 498 Crane control plug-in module........................................................................ 498 Crane control display............................................................................... 501 Display elements in main menu....................................................................... 502 11.2.3 Outriggers, electronic level, outrigger pressure indicator....................................... 503 On the display fields of the carrier................................................................ 503 Electronic level/ outrigger pressure indicator submenu............................................. 505 11.2.4 Submenu for superstructure lock.................................................................. 506 Turntable lock..................................................................................... 507 Houselock........................................................................................... 508 11.2.5 Hoists........................................................................................... 509 Main hoist.......................................................................................... 509 Auxiliary hoist (additional equipment).............................................................. 511 11.2.6 Slewing gear..................................................................................... 512 11.2.7 Derricking gear.................................................................................. 513 11.2.8 Telescoping gear................................................................................. 515 Control consoles.................................................................................... 515 Control lever for telescoping....................................................................... 515 Telescoping submenu................................................................................. 517 11.2.9 Safe load indicator (SLI)........................................................................ 525 SLI plug-in module.................................................................................. 525 SLI display......................................................................................... 526 Display elements in the main menu................................................................... 527 Enter rigging mode submenu.......................................................................... 528 In the SLI monitoring submenu...................................................................... 533 In the Servicing submenu............................................................................ 539 On the front console............................................................................... 539 11.2.10 Hydraulic system................................................................................ 541 Control consoles.................................................................................... 541 In submenu Settings/displays....................................................................... 541 In the submenu for control instruments.............................................................. 542 In the submenu for warning messages................................................................. 542 11.2.11 Electricity, lighting, windscreen wiper/washing system.......................................... 543 Electricity......................................................................................... 543 Lighting............................................................................................ 543 Windscreen wiper/ washing system................................................................... 544 11.2.12 Crane cab heating system........................................................................ 546 Crane cab heating.................................................................................. 546 Crane cab auxiliary heater......................................................................... 547 Air-conditioning system............................................................................. 548 11.2.13 On the hand-held control........................................................................ 549 Connections on the superstructure................................................................... 549 Crane engine operating field....................................................................... 550 Pre-selection button for emergency operation........................................................ 550 Pre-selection button for rigging................................................................... 551 Two-hand operatingfield............................................................................ 553 11.2.14 Other operating instruments in the crane cab.................................................... 556 Keys................................................................................................ 556 Crane cab door...................................................................................... 556 Windows............................................................................................. 557 Cab lighting........................................................................................ 558 Diagnostics plug.................................................................................... 559 Fire extinguisher (additional equipment)........................................................... 559 Railing by step..................................................................................... 560 11.3 Functional description of the safety devices........................................................... 561 11.3.1 Safe load indicator (SLI)........................................................................ 561 11.3.2 Lowering limit switch............................................................................ 563 11.3.3 Lifting limit switch............................................................................. 564 Overriding lifting limit switch shutdown............................................................ 564 11.3.4 Dead man's and seat contact switches............................................................. 566 12 Crane engine................................................................................................. 569 12.1 Starting the crane engine.............................................................................. 569 12.1.1 CHECKLIST: Starting the crane engine............................................................. 569 12.1.2 CHECKLIST: in winter............................................................................. 571 12.1.3 Inspections before starting the crane engine..................................................... 572 Check shut-off valves on the hydraulic system....................................................... 572 Switching on the battery master switch............................................................. 572 Checking coolant level.............................................................................. 573 Checking the hydraulic oil level.................................................................... 574 Checking the oil level in the crane engine.......................................................... 575 Topping up motor oil............................................................................... 576 Refuelling.......................................................................................... 576 12.1.4 Starting the crane engine........................................................................ 578 Switching on the ignition.......................................................................... 578 Starting the crane engine........................................................................... 580 12.1.5 Inspections after starting the crane engine...................................................... 582 Checks on the side panel............................................................................ 582 Checks on the Crane control display................................................................. 583 Warning messages.................................................................................... 584 12.2 Switching off the crane engine......................................................................... 585 12.2.1 Usually with the ignition lock/hand-held control................................................. 585 12.2.2 In an emergency, with the emergency stop switches................................................ 586 12.2.3 In an emergency, using the air intake inhibitor.................................................. 587 Switching on the air intake inhibitor............................................................... 587 Releasing the air intake inhibitor manually......................................................... 587 13 Crane operation.............................................................................................. 591 13.1 Checks and adjustments before crane operation.......................................................... 591 13.1.1 CHECKLIST: When truck crane is rigged............................................................ 591 13.1.2 Adjusting the front console and the crane cab seat............................................... 597 Adjusting the front console........................................................................ 597 Adjusting the crane cab............................................................................. 598 13.1.3 Checking the condition of the hoist rope......................................................... 599 Checking the reservoir of the windscreen washing system............................................. 599 Visual inspection of the entire crane............................................................... 599 Checking theposition of the hoist ropes............................................................ 600 Checking the electrical system...................................................................... 600 13.1.4 Checking the safety devices...................................................................... 601 Checking the safe load indicator.................................................................... 601 Checking the lifting limit switch.................................................................. 602 Checking the seat contact switch and dead man's switch system....................................... 602 Emergency stop switch for the crane control......................................................... 603 13.1.5 Preheating the hydraulic oil..................................................................... 604 When the oil temperatureis between –15 C and 0 C (5 F and 32 F):............................... 604 For oil temperatures below–15 C (5 F):......................................................... 604 13.1.6 Locking/unlocking the turntable.................................................................. 605 Superstructure lock submenu....................................................................... 606 Locking the turntable.............................................................................. 606 Unlocking the turntable............................................................................ 607 Display of errors related to the turntable lock.................................................... 608 13.1.7 Switching the houselock on/off................................................................... 609 Superstructure lock submenu....................................................................... 609 Switching on thehouselock......................................................................... 610 Switching off the houselock........................................................................ 611 13.2 Operating the safe load indicator (SLI)................................................................ 613 13.2.1 Switching on the SLI............................................................................. 613 Switching on........................................................................................ 613 Setting the brightness of the displays.............................................................. 615 Lamp test on theSLI................................................................................ 615 13.2.2 Entering the rigging mode........................................................................ 617 Entering new counterweight versions................................................................. 619 Entering a new outrigger span....................................................................... 622 Entering a new slewing range....................................................................... 623 Entering components for the lattice extension...................................................... 624 Entering a new reeving.............................................................................. 628 Entering the rigging mode using an SLI code......................................................... 629 13.2.3 Checks and displays in the SLI monitoring submenu................................................ 630 Submenu for SLI monitoring.......................................................................... 630 Checks to be carried out before starting........................................................... 630 Current displays during crane operation............................................................. 633 13.2.4 SLI pre-warning and SLI shutdown................................................................. 636 SLI early warning................................................................................... 636 SLI shutdown........................................................................................ 636 Error message....................................................................................... 639 Submenu for error messages.......................................................................... 640 SLI override....................................................................................... 642 13.3 Crane work with main boom.............................................................................. 643 13.3.1 External influences during crane operation....................................................... 643 Horizontal alignment................................................................................ 643 Safe distances..................................................................................... 643 Checking the wind speed............................................................................. 644 If the maximum permitted wind speed has been exceeded............................................... 645 Permissible wind load.............................................................................. 646 Earthing the load................................................................................... 647 13.3.2 Permissible slewing ranges and working positions for crane work.................................. 648 Slewing range 360 .................................................................................. 648 Limited slewing range ±15 .......................................................................... 648 Working position 0 to the rear..................................................................... 649 Working position 180 to the front.................................................................. 649 13.3.3 Main hoist....................................................................................... 651 Switching on the main hoist......................................................................... 651 Lifting and lowering............................................................................... 652 Switching off themain hoist....................................................................... 655 13.3.4 Auxiliary hoist (additional equipment)........................................................... 656 Switching on the auxiliary hoist................................................................... 656 Lifting and lowering............................................................................... 657 Switching off the auxiliary hoist.................................................................. 657 13.3.5 Derricking gear.................................................................................. 658 Switching on the derricking gear.................................................................... 658 Raising and lowering................................................................................ 659 Switching off the derricking gear.................................................................. 660 Maximum permissible derricking speed............................................................... 660 13.3.6 Slewing gear..................................................................................... 661 Switching on the slewing gear...................................................................... 661 Slewing............................................................................................. 662 Slewing speed and braking.......................................................................... 664 Tracking the slewing gear.......................................................................... 664 Switching off the slewing gear..................................................................... 665 Maximum permissible slewing speed.................................................................. 665 13.3.7 Telescoping gear................................................................................. 667 Structure of the chapter............................................................................ 667 Description offunctioning.......................................................................... 668 Main boom fixed length, intermediate length, telescoping length..................................... 669 Telescope status.................................................................................... 671 Notes on the telescoping sequence................................................................... 673 Checks before the first telescoping................................................................. 673 Switching on telescoping gear....................................................................... 674 Function of the control lever....................................................................... 674 Switching off telescoping gear...................................................................... 676 Example of the procedure for telescoping........................................................... 677 Checking the initial position....................................................................... 678 Unlocking the telescoping cylinder.................................................................. 683 Extend/retract telescoping cylinder................................................................. 686 Locking the telescoping cylinder.................................................................... 687 Unlocking the telescopic section.................................................................... 691 Telescoping the telescopic section................................................................. 693 Locking the telescopic section..................................................................... 695 Telescoping the telescopic section to an intermediate length........................................ 699 Lock telescopic section for on- road driving....................................................... 699 Telescoping with fully automatic control............................................................ 700 Lowering the main boom for maintenance............................................................. 705 Telescoping the main boom at anglesunder 10 ....................................................... 705 13.3.8 High-speed mode.................................................................................. 707 13.3.9 Special menus on the crane control display....................................................... 708 Operating hours meter submenu..................................................................... 708 Driving transmission speeds submenu.............................................................. 710 Warning message submenu............................................................................. 712 Error menu.......................................................................................... 714 Setting the brightnessof the displays.............................................................. 716 Control lever characteristic curve.................................................................. 717 13.3.10 Setting a constant engine speed................................................................. 719 13.3.11 Critical load control........................................................................... 720 Function............................................................................................ 720 Switching on and off.............................................................................. 720 13.3.12 Inclining the crane cab......................................................................... 722 13.3.13 Using the directional spotlight for the working area............................................ 723 Switching on/off.................................................................................... 723 Adjusting the direction............................................................................. 723 13.3.14 Cooling the hydraulic oil....................................................................... 724 Standard oil cooler................................................................................. 724 Additional oil cooler............................................................................... 724 13.3.15 Possible movement combinations.................................................................. 725 13.4 Driving with a rigged crane............................................................................ 727 13.4.1 Driving route.................................................................................... 727 13.4.2 Boom positions and axle loads.................................................................... 728 Table of axle loads................................................................................. 729 13.4.3 Driving the rigged crane......................................................................... 730 Locking the turntable and engaging the slewing gear holding brake.................................. 730 Retracting theoutrigger........................................................................... 730 Switching over the suspension locking system........................................................ 730 Switching on separate steering...................................................................... 731 Driving............................................................................................. 732 Extending the outrigger............................................................................ 732 13.5 Work breaks............................................................................................ 733 13.5.1 Short work breaks................................................................................ 733 13.5.2 Work breaks lasting more than 8 hours............................................................ 733 Securing the truck crane against unauthorized use................................................... 734 13.6 Crane cab heating and air-conditioning system.......................................................... 735 13.6.1 Engine-dependent crane cab heater................................................................ 735 Switching the heater on and off..................................................................... 735 Setting recirculated air/fresh air.................................................................. 736 Setting the air distribution....................................................................... 736 Adjusting the air vents............................................................................. 737 13.6.2 Engine-independent auxiliary crane cab heater.................................................... 738 Switching on the auxiliary heating system........................................................... 738 Regulating the temperature......................................................................... 739 Setting air distribution........................................................................... 739 Setting recirculated air/ fresh air operation....................................................... 739 Storing automatic heating start..................................................................... 739 Setting automatic heating duration.................................................................. 740 Switching automaticheating start on/off............................................................ 741 Setting remaining time.............................................................................. 741 Setting time and weekday............................................................................ 742 13.6.3 Air-conditioning system.......................................................................... 743 Switching on........................................................................................ 743 Setting the air distribution........................................................................ 744 To switch off....................................................................................... 744 How to use the airconditioning effectively......................................................... 744 Dehumidifying the crane cab air..................................................................... 745 13.7 Working range limiter.................................................................................. 747 13.7.1 Opening the working area limitation submenu...................................................... 748 13.7.2 Reading current settings......................................................................... 749 Display monitoring switched on/ off................................................................. 749 Reading the limit values entered................................................................... 749 13.7.3 Entering a limit value for a maximum overall height.............................................. 751 13.7.4 Entering a limit value for a maximum working radius.............................................. 752 13.7.5 Entering limit values for maximum slewing angles................................................. 753 Displays in the submenu Working area limitation..................................................... 753 Presentation of slewing angles...................................................................... 754 Entering the slewing angle.......................................................................... 755 13.7.6 Entering point data for objects.................................................................. 756 Presentation of defined objects.................................................................... 756 Selecting and deleting point data................................................................. 757 Entering point data................................................................................ 758 13.7.7 Entering limit values manually................................................................... 760 Limit values for overall height, working radius or slewing angle.................................... 760 Manual point data entry............................................................................. 761 13.7.8 Switching monitoring on and off.................................................................. 763 Switching monitoring on............................................................................. 763 Switching monitoringoff............................................................................ 764 13.8 Shutdown caused by working range limiter............................................................... 765 13.8.1 Crane movements which are switched off........................................................... 765 Bypassing shutdown................................................................................. 766 14 Rigging work................................................................................................. 769 14.1 Checklists for rigging work for crane operation with main boom......................................... 769 14.1.1 CHECKLIST: Rigging............................................................................... 769 14.1.2 CHECKLIST: Unrigging............................................................................. 773 14.2 Choosing a suitable site............................................................................... 777 14.2.1 Load bearing capacity of the ground and the outrigger............................................ 777 Enlarging the enlarge............................................................................... 779 14.2.2 Safe distance from banks and pits................................................................ 780 14.2.3 Earthing the truck crane......................................................................... 781 Earthing the truck crane............................................................................ 781 14.2.4 Safe distance from electrical lines.............................................................. 782 14.3 Rigging work after driving with trailer................................................................ 785 14.3.1 Switching off the boom floating position......................................................... 786 14.3.2 Switching off boom pre-tensioning................................................................ 786 14.3.3 Switching off slewing gear freewheel............................................................. 788 Before slewing...................................................................................... 789 14.4 Add-on parts in position for crane mode/driving mode................................................... 791 14.4.1 Swivelling the crane cab into position for crane mode/ drivingmode.............................. 792 Connecting/ removing the hand-held control......................................................... 792 Slewing into crane mode position.................................................................... 794 Slewing into the position driving mode............................................................. 796 14.4.2 Pushing the railings on the access ladder out/in................................................ 799 Pushing out the railings........................................................................... 799 Pushing in the railing............................................................................. 800 14.4.3 Folding the hoist mirror in/out.................................................................. 801 Folding the mirror out and adjusting it............................................................. 801 Folding in the mirror............................................................................. 801 14.4.4 Rigging work on the rear steps................................................................... 802 Before crane operation............................................................................ 802 After crane operation............................................................................. 803 14.5 Outriggers............................................................................................. 805 14.5.1 CHECKLIST: Extending the outrigger............................................................... 805 14.5.2 CHECKLIST: Retracting the outrigger.............................................................. 807 14.5.3 Permissible outrigger spans...................................................................... 809 Outrigger span 8.76 x 8.90 m (28.7x29.2ft)....................................................... 810 Outrigger span 8.76 x 6.10 m (28.7x20.0ft)....................................................... 810 Outrigger span 8.76 x 2.63 m (28.7x8.6ft)........................................................ 811 Outrigger span 7.78 x 8.90/1.22m 25.5x29.2/4.0ft................................................ 812 14.5.4 Preparing the truck crane........................................................................ 813 Align horizontally................................................................................. 813 Locking the suspension............................................................................. 813 14.5.5 Securing/releasing outrigger beam................................................................ 814 Securing the outrigger beams....................................................................... 814 Releasing the outrigger beams...................................................................... 815 14.5.6 Extending/retracting the outrigger beams......................................................... 816 Setting outrigger spans............................................................................. 818 14.5.7 Moving the outrigger pads into working/driving position.......................................... 822 Moving the outrigger pads into working position.................................................... 822 Moving the outrigger pads into driving position.................................................... 823 14.5.8 Extending/retracting the outrigger cylinder...................................................... 824 Allocation of the button units..................................................................... 824 Extending the outrigger cylinders................................................................... 825 Retracting theoutrigger cylinders................................................................. 827 14.5.9 Checking the alignment of the truck crane........................................................ 829 Electronic level on the carrier................................................................... 829 Electronic levels on crane control display......................................................... 831 14.5.10 Aligning the truck crane horizontally........................................................... 834 If the boom is in the boom support................................................................ 834 If the boom is raised............................................................................. 834 14.5.11 Outrigger pressure display...................................................................... 835 Outrigger pressure display on thecarrier........................................................... 835 Outrigger pressure display on superstructure....................................................... 836 14.6 Rigging/unrigging the counterweight.................................................................... 837 14.6.1 Counterweight parts and identification........................................................... 837 Counterweight parts................................................................................. 837 Identification...................................................................................... 838 14.6.2 Counterweight versions........................................................................... 839 14.6.3 Slinging points on the counterweight sections.................................................... 842 14.6.4 CHECKLIST: Rigging the counterweight............................................................. 844 Prerequisites....................................................................................... 844 14.6.5 CHECKLIST: Unrigging the counterweight........................................................... 848 Prerequisites....................................................................................... 848 14.6.6 Setting down/picking up the counterweight platform – counterweight sections...................... 852 Setting down the 20 t base plate................................................................... 852 Picking up counterweight parts..................................................................... 853 14.6.7 Assembling the counterweight version............................................................. 854 14.6.8 Securing/releasing 10 t counterweight blocks..................................................... 858 Securing the counterweight blocks................................................................... 858 Releasing counterweight blocks...................................................................... 859 14.6.9 Establishing/disconnecting the hydraulic connection.............................................. 860 Establishing thehydraulic connection............................................................. 860 Breaking the hydraulic connection................................................................... 861 14.6.10 Establishing/disconnecting the electrical connection............................................ 861 Establishing the electrical connection............................................................ 862 Breaking the electrical connection.................................................................. 862 14.6.11 Hand-held control............................................................................... 863 Connecting the hand-held control.................................................................... 863 Starting the crane engine with the hand-held control................................................ 864 Turning off crane engine with the hand-held control................................................. 864 14.6.12 Extending/retracting the lifting cylinder of the 20 t base plate or lifting/lowering coun....... 865 Lifting cylinders: extend........................................................................... 866 Lifting cylinders: retracting....................................................................... 867 14.6.13 Locking/unlocking the counterweight to the turntable............................................ 868 Counterweight safety valve.......................................................................... 869 Locking the counterweight........................................................................... 870 Counterweight; unlocking............................................................................ 871 14.6.14 Slewing with the rigged counterweight........................................................... 872 14.6.15 Hoisting and setting down counterweight sections with mounted auxiliary hoist................... 874 14.7 Auxiliary hoist........................................................................................ 875 Required components..................................................................................... 875 14.7.1 Components and identification.................................................................... 876 14.7.2 Slinging points and transport.................................................................... 877 Slinging points..................................................................................... 877 Transport........................................................................................... 878 14.7.3 CHECKLIST: Mounting the auxiliary hoist.......................................................... 879 Prerequisites....................................................................................... 879 14.7.4 CHECKLIST: Dismantling the auxiliary hoist....................................................... 882 Prerequisites....................................................................................... 882 14.7.5 Hoist the auxiliary hoist onto the 20 t base plate............................................... 885 14.7.6 Raising and setting down the catcher............................................................. 885 Catcher 1........................................................................................... 886 Catcher 2........................................................................................... 888 14.7.7 Establishing/disconnecting the hydraulic connection.............................................. 889 Establishing a connection.......................................................................... 889 Disconnecting ..................................................................................... 889 14.7.8 Establishing/disconnecting the electrical connection............................................. 890 Establishing a connection.......................................................................... 890 Disconnecting ..................................................................................... 890 14.7.9 Locking the auxiliary hoist/releasing lock....................................................... 891 Auxiliary hoist safety valve........................................................................ 891 Locking............................................................................................. 892 Releasing the locking pin........................................................................... 892 Releasing the locking pin........................................................................... 893 Releasing the locking pin........................................................................... 893 14.7.10 Checking that the auxiliary hoist is functioning properly....................................... 894 With the manual control............................................................................. 894 In the crane cab.................................................................................... 895 14.7.11 Secure the upper hook block in the catcher...................................................... 895 14.7.12 Permissable utilization options for the auxiliary hoist......................................... 896 Replacement for the main hoist...................................................................... 896 Alternating operation with the main and auxiliary hoists............................................ 897 14.8 Rigging work on the main boom.......................................................................... 899 14.8.1 Hook block on the bumper......................................................................... 899 Picking up the hook block from the bumper........................................................... 899 Attach the hook block to the bumper................................................................. 900 14.8.2 Hook block on a separate vehicle................................................................. 901 Picking up the hook block from the separate vehicle................................................ 901 Place the hook block on a separate vehicle.......................................................... 902 14.8.3 Reeving and unreeving the hoist rope............................................................. 903 Rope end fitting.................................................................................... 903 Positioning hoist cable........................................................................... 905 14.8.4 Possible reeving on the main boom for standard design with9sheaves............................. 909 14.8.5 Possible reeving on the main boom for additional equipment with 11 sheaves...................... 914 14.8.6 Possible reeving on the main boom for additional equipment with 13 sheaves...................... 920 14.8.7 Installing/removing lifting limit switch......................................................... 927 Installing the lifting limit switch................................................................. 927 Removing the lifting limit switch................................................................... 930 14.8.8 Locking lifting limit switch/releasing lock...................................................... 932 Locking............................................................................................. 932 Release lock....................................................................................... 933 14.8.9 Installing/removing the anemometer............................................................... 933 Installing the anemometer.......................................................................... 934 Remove the anemometer.............................................................................. 935 14.8.10 Installing/removing the holding rod............................................................. 936 Installing.......................................................................................... 936 Removal............................................................................................. 937 14.8.11 Installing/removing the air traffic control light............................................... 937 Installing.......................................................................................... 937 Removal............................................................................................. 938 14.8.12 Rope end clamp.................................................................................. 939 14.8.13 Rigging heavy duty equipment.................................................................... 941 Heavy duty equipment parts.......................................................................... 941 Equipment required................................................................................. 941 Rigging heavy duty equipment........................................................................ 942 Unrigging heavy duty equipment...................................................................... 945 Reevings with heavy duty equipment.................................................................. 947 15 Crane operation malfunctions................................................................................. 951 15.1 Superstructure emergency stop device................................................................... 951 Reset the emergency stop switch......................................................................... 952 15.2 What to do in the event of a malfunction when working with the crane................................. 953 If Lower load is possible............................................................................... 953 If Lower load is not possible........................................................................... 954 15.3 Electrical system...................................................................................... 955 15.3.1 Inserts.......................................................................................... 956 15.3.2 Fuses............................................................................................ 958 Fuses on turntable.................................................................................. 958 Fuses in the crane cab.............................................................................. 960 Fuses in battery box................................................................................ 962 Fuses on the crane cab bracket...................................................................... 963 Fuses on I/O circuit boards......................................................................... 964 15.3.3 SLI fuses........................................................................................ 965 15.4 Trouble shooting and rectification at the power units.................................................. 967 15.4.1 Crane engine malfunctions........................................................................ 967 15.4.2 Malfunctions with operation with hand-held control............................................... 969 15.4.3 Malfunctions with movements of the crane cab..................................................... 969 15.4.4 Main hoist malfunctions.......................................................................... 970 15.4.5 Auxiliary hoist malfunctions..................................................................... 972 15.4.6 Derricking gear malfunctions..................................................................... 974 15.4.7 Slewing gear malfunctions........................................................................ 976 15.4.8 Hydraulic system/hydraulic oil cooler malfunctions............................................... 977 15.4.9 Malfunctions at the counterweight hoist unit..................................................... 978 15.4.10 Malfunctions on the turntable locking........................................................... 979 15.4.11 Telescoping gear malfunctions................................................................... 979 Error messages telescoping gear..................................................................... 982 15.5 Trouble shooting and rectification on the SLI.......................................................... 985 Program version of safe load indicator.................................................................. 985 15.5.1 General malfunctions............................................................................. 985 15.5.2 Error messages on the SLI display................................................................ 986 Table for the Error group 1........................................................................ 987 Table for the Error group 2........................................................................ 993 Table for the Error group 3........................................................................ 995 Table for the Error group 5........................................................................ 997 Table for the Error group 6........................................................................ 999 Table for the Error group 7........................................................................1000 Table for the Error group 8........................................................................1000 15.5.3 Checking SLI lines and connections...............................................................1001 On truck crane......................................................................................1002 On lattice extension (additional equipment).........................................................1003 15.6 Trouble shooting and rectification on the crane control................................................1005 Program version of crane control........................................................................1005 15.6.1 General malfunctions.............................................................................1005 15.6.2 Error messages on Crane control display..........................................................1006 Symbols for Devices................................................................................1007 Symbols for Groups.................................................................................1009 Symbols for Types of errors........................................................................1011 Index displays allocation..........................................................................1012 Control lever error table...........................................................................1023 Locking system error table..........................................................................1024 Error messages via Can-Bus..........................................................................1027 Error messages about hoisting gears.................................................................1029 Error messages system monitoring group..............................................................1030 Error messages group carrier........................................................................1032 15.6.3 Connections for the crane control's control units................................................1033 Control units connections position..................................................................1033 Layout of connections..............................................................................1034 15.6.4 Unrig truck crane when control units are defective...............................................1036 Prerequisites.......................................................................................1036 Example for unrigging with three control units......................................................1036 Replacing control units.............................................................................1038 15.7 Emergency operations and emergency programs............................................................1041 15.7.1 Emergency retract operation......................................................................1042 Check prior Emergency operation emergency operation.................................................1042 Procedure for intermediate length...................................................................1043 Mechanical emergency operation......................................................................1044 Hydraulic emergency operation.......................................................................1046 Length data for the locking points..................................................................1057 15.7.2 Sub-menu emergency program telescoping...........................................................1058 Starting emergency program..........................................................................1058 Emergency program display and operating elements....................................................1059 Retracting with an error on the length indicator....................................................1061 Retracting with an error on the proximity switch....................................................1065 Emergency program end..............................................................................1067 Table for approaching the locking points............................................................1067 15.7.3 Enter telescope status after emergency operation.................................................1069 15.7.4 Emergency operation in case of failure of the operating instruments in the crane cab.............1073 Prerequisites.......................................................................................1073 Connecting the hand-held control....................................................................1074 Starting the crane engine with the hand-held control................................................1074 Preselect power unit...............................................................................1075 Operating power unit................................................................................1075 Movements stopping.................................................................................1077 Stopping the movement in case of an emergency.......................................................1077 16 Technical information for superstructure.....................................................................1081 16.1 Technical description of the superstructure............................................................1081 16.1.1 Turntable........................................................................................1081 16.1.2 Crane cab........................................................................................1081 16.1.3 Crane engine and hydraulic system................................................................1082 16.1.4 Control system...................................................................................1083 16.1.5 Main boom........................................................................................1083 16.1.6 Telescoping gear.................................................................................1083 16.1.7 Hoists...........................................................................................1084 16.1.8 Slewing gear.....................................................................................1085 16.1.9 Houselock........................................................................................1085 16.1.10 Derricking cylinder.............................................................................1085 16.1.11 Electrical system..............................................................................1086 16.1.12 Counterweight...................................................................................1086 16.1.13 Safety devices..................................................................................1087 16.1.14 Hand-held control...............................................................................1087 16.2 Technical data.........................................................................................1089 16.2.1 Maximum load bearing capacity (DIN/ISO/EN).......................................................1089 16.2.2 Maximum load bearing capacity (ANSI B 30.5)......................................................1089 16.2.3 Dimensions, weights and axle loads...............................................................1090 Dimensions when driving on public roads.............................................................1091 16.2.4 Dimensions and weights of removable parts........................................................1092 Hook blocks and hook tackle.........................................................................1092 Auxiliary hoist.....................................................................................1093 Main boom...........................................................................................1093 Heavy dutyequipment................................................................................1093 Counterweightparts.................................................................................1093 Counterweight versions..............................................................................1094 16.2.5 Technical data for superstructure................................................................1096 Crane engine........................................................................................1096 Slewing gear........................................................................................1096 Derricking gear.....................................................................................1096 Main boom...........................................................................................1096 Main hoist..........................................................................................1097 Auxiliary hoist (additional equipment)..............................................................1097 Working speed and times without load................................................................1098 17 Index........................................................................................................1101 A...........................................................................................................1103 B...........................................................................................................1104 C...........................................................................................................1105 D...........................................................................................................1107 E...........................................................................................................1108 F...........................................................................................................1109 G...........................................................................................................1109 H...........................................................................................................1109 I...........................................................................................................1110 K...........................................................................................................1110 L...........................................................................................................1110 M...........................................................................................................1111 O...........................................................................................................1111 P...........................................................................................................1112 R...........................................................................................................1112 S...........................................................................................................1113 T...........................................................................................................1115 V...........................................................................................................1117 W...........................................................................................................1117
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