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Grove Crane GMK 7450 Driving Operating Instruction Manual 2084734 – PDF DOWNLOAD
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Description
Grove Crane GMK 7450 Driving Operating Instruction Manual 2084734 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 7450 Driving Operating Instruction Manual 2084734 – PDF DOWNLOAD
Language : English
Pages : 1090
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 7450 Driving Operating Instruction Manual 2084734 – 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 instructions
that relate to specific hazards are described in the section containing
the operation with which the hazard is associated. - Chapter 3 contains Information for applications engineering. It is intended
primarily for the truck crane operator and those responsible for applications
engineering.
This chapter contains the 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 components,
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 functional
elements of the carrier as well as the Technical data.
TABLE OF CONTENTS:
Grove Crane GMK 7450 Driving Operating Instruction Manual 2084734 – PDF DOWNLOAD
Operating instructions Part 1 - Driving......................................................................... 1 1 Overview...................................................................................................... 7 1.1 Vehicle identification.................................................................................. 7 1.2 EC Conformity Declaration............................................................................... 11 1.3 Overview and contents of truck crane user information................................................... 13 1.3.1 Operating instructions for driving and crane operation............................................ 13 1.3.2 Operating instructions for the lattice extension (additionalequipment)........................... 14 1.3.3 Maintenance manual................................................................................ 14 1.3.4 Lifting capacity tables........................................................................... 15 1.3.5 Outrigger pressure tables......................................................................... 15 1.3.6 Safety manual..................................................................................... 15 1.3.7 Circuit diagrams.................................................................................. 15 1.3.8 Spare parts list.................................................................................. 16 1.4 Instructions for using this documentation............................................................... 16 1.4.1 How are the operating instructions laid out?...................................................... 16 1.4.2 How are the pages of the operating instructions formatted?........................................ 17 1.4.3 How can I find the necessary information quickly and easily?...................................... 18 Example of cross- reference usage................................................................... 19 How to use the index ............................................................................. 24 1.4.4 Definition of stated directions................................................................... 24 Basic rule.......................................................................................... 24 Buttons and switches............................................................................... 24 1.4.5 Conversion table for US measurements.............................................................. 25 2 Basic safety instructions for crane operators................................................................. 29 2.1 Warnings and symbols.................................................................................... 29 2.2 Intended use............................................................................................ 30 2.3 Organisational measures................................................................................. 32 2.4 Personnel qualifications................................................................................ 34 2.5 Safety instructions that apply to truck crane driving................................................... 35 2.6 Safety instructions for truck crane work................................................................ 35 3 Information for operations planning........................................................................... 41 3.1 Safety instructions..................................................................................... 41 3.1.1 Intended use...................................................................................... 41 3.1.2 Organisational measures........................................................................... 41 3.1.3 Personnel qualifications.......................................................................... 42 3.2 Operations planning..................................................................................... 43 3.2.1 Prerequisites for operations planning............................................................. 43 3.2.2 Information for operations planning contained in the information for use ........................ 44 4 Description of the truck crane vehicle section................................................................ 47 4.1 Overview of the operating and display elements.......................................................... 47 4.1.1 Overview of the vehicle........................................................................... 47 4.1.2 Overview of the driver's cab...................................................................... 50 Top view of driver's cab............................................................................ 50 Overhead in the driver's cab........................................................................ 52 Below the front instrument panel.................................................................... 53 4.1.3 Front instrument panel............................................................................ 54 Left-hand insert.................................................................................... 54 Tachograph insert................................................................................... 56 Speedometer insert................................................................................. 58 Right-hand insert................................................................................... 60 Heating insert...................................................................................... 62 4.1.4 Side instrument panel............................................................................. 64 Insert 1............................................................................................ 64 Insert 2............................................................................................ 66 Control unit for automatic transmission............................................................. 68 4.1.5 Switch boxes for the outrigger/electronic level/outrigger pressure indicator..................... 69 4.1.6 Operating elements on the steering column......................................................... 70 4.1.7 Control box for the locking pin of the rear housing/ additionalaxis.............................. 71 4.2 Functional description of the display and operating elements........................................... 73 4.2.1 On the instrument panels.......................................................................... 73 Vehicle engine...................................................................................... 73 Automatic transmission ........................................................................... 75 Transfer case....................................................................................... 77 Axle drive.......................................................................................... 78 Brakes.............................................................................................. 79 Steering............................................................................................ 80 Suspension.......................................................................................... 82 Hydraulic system.................................................................................... 83 Electrics........................................................................................... 84 Level adjustment system............................................................................ 86 Tachograph.......................................................................................... 88 Speedometer insert................................................................................. 88 Auxiliary heater.................................................................................... 89 Heating in the driver's cab........................................................................ 90 Auxiliary heater with timer (additional equipment)................................................. 91 Other operating elements........................................................................... 92 4.2.2 On the steering column............................................................................ 93 Ignition lock....................................................................................... 93 Multipurpose switch, right.......................................................................... 93 Multipurpose switch, left........................................................................... 95 4.2.3 Overhead in the driver's cab...................................................................... 96 Air-conditioning system (additional equipment)...................................................... 96 Cab lighting........................................................................................ 96 Cab lighting........................................................................................ 97 4.3 Other operating elements on the carrier................................................................. 99 Keys.................................................................................................... 99 Doors................................................................................................... 99 Windows................................................................................................. 101 Access ladders.......................................................................................... 102 Ladders................................................................................................. 102 Diagnostics for engine/ transmission/ electronics..................................................... 104 Front flap.............................................................................................. 104 Fire extinguisher (additional equipment)............................................................... 105 Folding berth (additional equipment).................................................................... 105 5 Vehicle engine................................................................................................ 109 5.1 Starting/turning off the vehicle engine................................................................. 109 5.1.1 CHECKLIST: Starting the vehicle engine............................................................ 109 5.1.2 CHECKLIST: In winter.............................................................................. 112 5.1.3 Checks prior to starting vehicle engine........................................................... 113 Checking the shut- off valves in the hydraulic system.............................................. 113 Switching on the battery master switch............................................................. 113 Pre-checking the oil level in the automatic transmission............................................ 114 Checking coolant level.............................................................................. 115 Checking the hydraulic oil level.................................................................... 116 Checking the engine oil level...................................................................... 116 Topping up motor oil................................................................................ 117 5.1.4 Refuelling........................................................................................ 118 5.1.5 Starting the vehicle engine....................................................................... 119 Switching on the ignition.......................................................................... 119 Starting the vehicle engine........................................................................ 121 Setting the idling speed............................................................................ 123 5.1.6 Checks after the engine has been started.......................................................... 125 Checking instruments............................................................................... 125 Checking the oil level in the automatic transmission.............................................. 127 5.2 Turning off the vehicle engine.......................................................................... 131 5.2.1 In a normal situation: ignition lock.............................................................. 131 5.2.2 In an emergency situation: vehicle engine emergency stopswitch................................... 132 5.2.3 In an emergency situation: using the air intake inhibitor (additional equipment).................. 133 Switching on the air intake inhibitor............................................................... 133 Releasing the air intake inhibitor manually........................................................ 134 6 Driving the truck crane....................................................................................... 137 6.1 Checks and adjustments before driving................................................................... 137 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving....................................... 137 6.1.2 Driving mode table............................................................................... 142 Axle loads in driving mode.......................................................................... 142 6.1.3 Checking the condition of the truck crane......................................................... 145 Checking the reservoir of the windscreen washing system............................................. 145 Warning plates for vehicle width.................................................................... 145 Checking the tyres................................................................................. 146 Checking the electrical system...................................................................... 146 Checking the mirror settings........................................................................ 147 Checking the compressed-air system................................................................. 147 Checking the suspension............................................................................ 148 Checking on-road level............................................................................ 148 Checking the transverse differential locks.......................................................... 149 Checking the longitudinal differential locks....................................................... 149 Checking the transfer case.......................................................................... 149 Checking the steering locks....................................................................... 149 Checking the Boom not set down warning lamp......................................................... 150 6.1.4 Adjusting the seat and the steering column........................................................ 151 Adjusting the driver's seat........................................................................ 151 Adjusting the passenger seat....................................................................... 152 Adjusting the steering column....................................................................... 153 6.1.5 Tachograph........................................................................................ 155 6.2 General operation....................................................................................... 161 6.2.1 Operating the automatic transmission.............................................................. 161 Switching on........................................................................................ 161 Automatic transmission box driving modes........................................................... 162 Selecting the driving direction.................................................................... 163 Starting............................................................................................ 164 Driving and changing transmissions.................................................................. 164 Switching the transmission to neutral position...................................................... 165 Changing the direction of travel.................................................................... 166 Stopping the truck crane............................................................................ 167 Cold start program................................................................................. 167 On the roller type dynamometer...................................................................... 167 6.2.2 Monitoring the control instruments while driving.................................................. 168 6.2.3 Driving downhill.................................................................................. 171 Starting on a downward slope....................................................................... 171 Driving downhill.................................................................................... 172 Preselecting transmissions.......................................................................... 172 Engine brake........................................................................................ 173 Transmission retarder............................................................................... 174 6.2.4 Driving uphill.................................................................................... 175 Starting............................................................................................ 175 Driving............................................................................................. 175 6.2.5 Cruise control.................................................................................... 176 Activating the cruise control...................................................................... 176 Driving with the cruise control.................................................................... 176 Switching off the cruise control................................................................... 177 6.2.6 Temposet (max. speed selector).................................................................... 178 Switching on temposet.............................................................................. 178 Driving with the temposet.......................................................................... 178 Temposet switching off.............................................................................. 179 6.2.7 Parking the truck crane........................................................................... 179 Applying the holding brake.......................................................................... 179 Activating neutral position........................................................................ 179 Turning off the vehicle engine..................................................................... 179 Securing the truck crane against rolling............................................................ 180 Extended standstill................................................................................. 180 6.3 Off-road driving........................................................................................ 181 6.3.1 Off-road transmission............................................................................. 182 Engaging the off- road transmission................................................................ 182 Deactivating the off-road transmission............................................................. 182 6.3.2 Longitudinal differential locks................................................................... 183 Switching on the longitudinal differential locks.................................................... 183 Switching off the longitudinal differential locks................................................... 184 6.3.3 Transverse differential locks in all driven axle lines............................................ 185 Activating the transverse differential locks........................................................ 185 Deactivating the transverse differential locks...................................................... 186 6.3.4 Level adjustment system........................................................................... 187 Checks before level adjustment...................................................................... 187 Activating the level adjustment system.............................................................. 188 Raising or lowering the entire truck crane.......................................................... 188 Tilting the truck crane lengthwise or crosswise..................................................... 189 Bring the truck crane into On- road level........................................................... 190 Deactivating the level adjustment system............................................................ 190 6.3.5 Freeing an immobilized truck crane................................................................ 191 Freeing the truck crane by its own power.......................................................... 191 Towing free to the front........................................................................... 192 Towing free to the rear............................................................................ 192 6.4 Separate steering....................................................................................... 193 6.4.1 Switching on separate steering.................................................................... 195 6.4.2 Steering axle lines with separate steering........................................................ 196 All-wheel steering.................................................................................. 196 Crab travel mode.................................................................................... 196 6.4.3 Switching off separate steering and locking the steering.......................................... 197 Locking the steering in "straight ahead" position................................................... 197 Locking the steering in other positions............................................................. 198 6.5 Heating system and fan for driver's cab................................................................. 199 6.5.1 Heating in the driver's cab....................................................................... 199 Heating the driver's cab............................................................................ 199 Ventilating the driver's cab........................................................................ 201 6.5.2 Auxiliary water heating system.................................................................... 202 Preheating the vehicle engine....................................................................... 202 Preheating the driver's cab........................................................................ 202 Switching off the auxiliary heating system.......................................................... 203 6.5.3 Auxiliary heater with timer (additional equipment)................................................ 204 Preheating the diesel engine....................................................................... 204 Preheating the driver's cab........................................................................ 204 Switching the auxiliary heater on/off............................................................... 204 Displaying and setting the current time............................................................. 205 Switching on and saving the automatic heating start................................................. 205 Switching on and saving the automatic heating start................................................. 206 6.6 Air-conditioning system (additional equipment).......................................................... 207 6.6.1 To switch on...................................................................................... 207 6.6.2 To switch off..................................................................................... 207 6.6.3 Air conditioning.................................................................................. 209 How to use the air conditioning effectively......................................................... 209 Dry air in the driver's cab......................................................................... 210 7 Rigging for on-road driving................................................................................... 213 7.1 Rigging work for driving with a trailer................................................................. 215 7.1.1 Switching on the slewing gear freewheel........................................................... 216 7.1.2 Switching on the boom floating position........................................................... 218 Placing the main boom on a trailer.................................................................. 218 7.1.3 Switching on boom pretensioning................................................................... 219 7.2 Rigging the front outrigger beams....................................................................... 221 Equipment............................................................................................... 221 7.2.1 CHECKLIST: Removing the outrigger beams........................................................... 222 7.2.2 CHECKLIST: Mounting of outrigger beams............................................................ 223 7.2.3 Preparing the truck crane for removal/installation................................................ 225 Prerequisites for installation/ removal............................................................. 225 Preparing the truck crane.......................................................................... 225 7.2.4 Removing/attaching outrigger pads................................................................. 227 Removing outrigger pads............................................................................. 227 Attaching the outrigger pads....................................................................... 228 7.2.5 Breaking/establishing the hydraulic connection.................................................... 228 Position of the valve blocks....................................................................... 229 Breaking the hydraulic connection................................................................... 230 Establishing the hydraulic connection............................................................... 231 7.2.6 Establishing/disconnecting the electrical connection for theoutrigger pressure indicator......... 232 7.2.7 Transport position/operating position of the holding angle........................................ 233 7.2.8 Locking/releasing the extension cylinder locking pin.............................................. 234 Releasing the lock.................................................................................. 234 Locking the extension cylinder...................................................................... 235 7.2.9 Extending/reinserting outrigger beams............................................................. 236 Turning down and adjusting the wear pads............................................................ 236 Extending the outrigger............................................................................ 236 Reinserting the outrigger beams.................................................................... 239 7.2.10 Transporting the outriggers/outrigger pads....................................................... 241 7.3 Rigging the rear outrigger housing...................................................................... 243 Required equipment...................................................................................... 243 7.3.1 CHECKLIST: Removal of the outrigger housing....................................................... 244 7.3.2 CHECKLIST: Installation of outrigger housing...................................................... 247 7.3.3 Rig the outrigger span 7.78x8.90/1.22m (25.5x29.2/4.0ft).................................... 249 Preparations for installation....................................................................... 249 Preparations for removal............................................................................ 249 Supporting the truck crane with the jack stands.................................................... 250 Removing the jack stands............................................................................ 252 7.3.4 Crane movements when installing and removing...................................................... 252 Prerequisites....................................................................................... 252 Before installation................................................................................. 252 After removal...................................................................................... 253 7.3.5 Attachment points on the rear outrigger housing................................................... 253 7.3.6 Breaking/establishing the hydraulic connection.................................................... 254 Depressurizing the connections...................................................................... 254 Establishing the hydraulic connection............................................................. 255 Breaking the hydraulic connection................................................................... 255 7.3.7 Establishing/disconnecting electrical connection.................................................. 256 Breaking the electrical connection.................................................................. 257 7.3.8 Establishing/disconnecting pneumatic connection................................................... 258 7.3.9 Attaching/removing the outrigger housing with the truck crane..................................... 259 Raising the outrigger housing...................................................................... 260 Attaching the outrigger housing..................................................................... 260 7.3.10 Locking the outrigger housing to the carrier, unlocking.......................................... 261 Locking the outrigger housing....................................................................... 261 Extending and retracting pins....................................................................... 262 7.3.11 Setting the outrigger box onto the support....................................................... 263 7.3.12 Transportation on a separate vehicle............................................................. 265 7.3.13 Installing/removing the rear bumper.............................................................. 266 Prerequisites....................................................................................... 266 Slinging the rear bumper............................................................................ 266 Installing the rear bumper.......................................................................... 267 Removing the rear bumper............................................................................ 268 7.3.14 Hook block in the rear bumper.................................................................... 270 Setting down the hook block........................................................................ 270 Picking up the hook block.......................................................................... 271 7.4 Rigging the main boom................................................................................... 273 Additional equipment required........................................................................... 273 7.4.1 CHECKLIST: Removing the main boom................................................................. 275 Prerequisites:...................................................................................... 275 Removing main boom................................................................................. 275 7.4.2 CHECKLIST: Installing the main boom............................................................... 278 Prerequisites:...................................................................................... 278 7.4.3 Pushing the railings on the access ladder out/in................................................. 282 Pushing out the railings........................................................................... 282 Pushing in the railing............................................................................. 283 7.4.4 Rigging work with auxiliary crane................................................................. 283 Slinging points..................................................................................... 283 Lifting the main boom onto the turntable........................................................... 285 7.4.5 Connecting and removing the hand-held control..................................................... 286 Connections on the superstructure................................................................... 286 Connecting/removing the hand- held control.......................................................... 287 7.4.6 Electrical connections on the main boom........................................................... 288 Breaking the electrical connections................................................................ 288 Establishing electrical connections................................................................. 289 7.4.7 Derricking the main boom with the hand-held control............................................... 289 Preparing the hand-held control..................................................................... 289 Derricking the main boom............................................................................ 290 7.4.8 Hydraulic connections on the main boom............................................................ 291 Removing/replacing guide plates..................................................................... 291 Connections for the telescoping mechanism........................................................... 292 Connections for the pulling devices................................................................. 293 7.4.9 Pulling device on the boom pivot pin.............................................................. 294 Removing/inserting the locking pin.................................................................. 294 Preparing the hand-held control..................................................................... 295 Retract/extend the boom pivot pin.................................................................. 296 7.4.10 Pulling devices on the head pins of the derricking cylinders..................................... 297 Operating the lifting device....................................................................... 298 Releasing/ tightening the mechanical locks......................................................... 299 Preparing the hand-held control..................................................................... 300 Retracting the derricking cylinder head pin........................................................ 301 Extending the derricking cylinder head pin......................................................... 302 7.4.11 Checks after main boom installation.............................................................. 303 Checks at the Crane control display................................................................ 303 Hydraulic system check............................................................................. 304 7.4.12 Before road driving.............................................................................. 305 Transport protection for the derricking cylinder................................................... 305 Transporting the main boom.......................................................................... 305 7.4.13 Derricking cylinder pressure relief.............................................................. 306 Activating pressure relief.......................................................................... 306 Deactivating pressure relief........................................................................ 307 7.5 Installing/removing the additional axle................................................................. 309 Auxiliary equipment required............................................................................ 309 7.5.1 CHECKLIST: Installing the additional axle......................................................... 310 7.5.2 CHECKLIST: Removing the additional axle........................................................... 313 7.5.3 Outrigger span 7.78x8.90/1.22m (25.5x29.2/4.0ft) for rigging the additional axle............ 317 Supporting the truck crane with the connection pieces.............................................. 317 Removing the jack supports.......................................................................... 319 7.5.4 Slinging points on the additional axle............................................................ 319 7.5.5 Crane movements when installing and removing...................................................... 321 Prerequisites....................................................................................... 321 Before installation................................................................................. 321 After removal...................................................................................... 321 7.5.6 Breaking/establishing the hydraulic connections................................................... 322 Establishing the hydraulic connection............................................................. 322 Breaking the hydraulic connection................................................................... 323 7.5.7 Establishing/disconnecting electrical connection.................................................. 325 Breaking the electrical connection.................................................................. 326 7.5.8 Establishing/disconnecting the pneumatic connection............................................... 327 7.5.9 Attaching/removing the additional axle with the truck crane....................................... 328 Attaching the additional axle...................................................................... 329 Raising the additional axle........................................................................ 329 7.5.10 Locking the additional axle to the carrier, unlocking............................................ 330 Locking the additional axle........................................................................ 330 Extending and retracting pins....................................................................... 331 7.5.11 Setting down the additional axle after removal................................................... 332 7.5.12 Locking/enabling the suspension on the additional axle........................................... 334 Locking the suspension............................................................................. 334 Enabling the suspension............................................................................ 335 7.5.13 Raising/lowering axle line....................................................................... 336 Raising the axle lines............................................................................. 336 Lowering the axle lines............................................................................ 337 8 Malfunctions in driving mode.................................................................................. 341 8.1 Emergency stop device on carrier........................................................................ 341 8.1.1 Emergency stop switch, vehicle engine............................................................. 341 8.2 Breakdown in road traffic............................................................................... 343 8.3 Towing the truck crane.................................................................................. 345 8.3.1 Towing in the case of engine or transmission damage............................................... 345 Towing the truck crane out of the danger area....................................................... 346 Longer distances.................................................................................... 346 Compressed-air supply in the event of engine failure................................................ 347 Power supply........................................................................................ 348 Axle drives......................................................................................... 348 Parking brake....................................................................................... 348 Mechanically releasing the parking brake............................................................ 349 Towing procedure.................................................................................... 349 Removing mechanical locking from all spring- loaded brake cylinders................................. 350 Tow starting........................................................................................ 350 8.4 Wheel change............................................................................................ 351 Removing a damaged wheel................................................................................ 351 Lifting/setting down wheel.............................................................................. 352 Mounting the spare wheel............................................................................... 353 8.5 Electrical system....................................................................................... 355 8.5.1 Inserts........................................................................................... 356 8.5.2 Fuses............................................................................................. 358 Fuses in the driver's cab........................................................................... 358 Fuses in battery box................................................................................ 362 Fuses on I/O circuit boards......................................................................... 363 8.6 Troubleshooting and remedy.............................................................................. 365 8.6.1 Vehicle engine malfunctions....................................................................... 365 8.6.2 Automatic transmission malfunctions............................................................... 367 8.6.3 Transfer case malfunctions........................................................................ 368 8.6.4 Differential lock malfunctions.................................................................... 368 8.6.5 Steering malfunctions............................................................................. 369 8.6.6 Service brake malfunctions........................................................................ 370 8.6.7 Outrigger malfunctions............................................................................ 370 8.6.8 Tachograph malfunctions........................................................................... 371 8.6.9 Suspension locking system malfunctions............................................................ 372 8.6.10 Level adjustment system malfunctions............................................................. 372 8.6.11 Malfunctions in the carrier electronic system.................................................... 373 Reading error messages on carrier................................................................... 373 8.7 Procedure in the event of malfunctions.................................................................. 375 8.7.1 Switching on emergency operation in cooling water circuit......................................... 375 On hydraulic cooler................................................................................. 375 On the vehicle engine.............................................................................. 376 8.7.2 Procedure in the event of malfunctions in the automatic transmission.............................. 377 Troubleshooting..................................................................................... 377 Effect oferror..................................................................................... 377 Reading off errorcodes............................................................................ 378 8.7.3 Emergency operation of the solenoid valves for the outriggers..................................... 380 Position and allocation of the solenoid valves...................................................... 382 8.7.4 Separate steering emergency operation............................................................. 384 Moving the steering into on-road driving............................................................ 384 9 Technical Information on Carrier.............................................................................. 389 9.1 Technical description of the carrier.................................................................... 389 9.1.1 Crane carrier..................................................................................... 389 9.1.2 Driver's cab...................................................................................... 389 9.1.3 Drive units....................................................................................... 390 9.1.4 Engine cooling system............................................................................. 390 9.1.5 Hydraulic system.................................................................................. 390 9.1.6 Steering.......................................................................................... 391 9.1.7 Suspension system................................................................................. 391 9.1.8 Outrigger......................................................................................... 392 9.1.9 Compressed air system............................................................................. 392 9.1.10 Service brake.................................................................................... 393 9.1.11 Parking brake.................................................................................... 393 9.1.12 Retarder......................................................................................... 393 9.1.13 Secondary consumers.............................................................................. 394 9.1.14 Towing the crane................................................................................. 394 9.1.15 Towing a trailer (trailer operation)............................................................. 394 9.1.16 Electrical system................................................................................ 394 9.1.17 Rotary transmission.............................................................................. 394 9.2 Technical data.......................................................................................... 395 9.2.1 Dimensions and weights of the truck crane......................................................... 396 Dimensions for driving on public roads.............................................................. 397 9.2.2 Dimensions and weights of removable parts......................................................... 398 Spare wheel (additional equipment).................................................................. 398 Main boom........................................................................................... 398 Outrigger........................................................................................... 399 Rear bumper......................................................................................... 399 Additional axle..................................................................................... 399 Derricking cylinder support......................................................................... 399 9.2.3 Carrier........................................................................................... 400 Vehicle engine...................................................................................... 400 On-load shift transmission.......................................................................... 400 Transfer case....................................................................................... 400 Axle lines.......................................................................................... 400 Steering............................................................................................ 401 Tyres............................................................................................... 401 Vehicle's electrical system......................................................................... 401 Tools............................................................................................... 401 Outrigger........................................................................................... 402 Driving speeds...................................................................................... 403 Climbing ability.................................................................................... 403 Turning circle radiuses............................................................................ 404 10 Index........................................................................................................ 407 A........................................................................................................... 409 B........................................................................................................... 410 C........................................................................................................... 411 D........................................................................................................... 413 E........................................................................................................... 414 F........................................................................................................... 414 G........................................................................................................... 415 H........................................................................................................... 415 I........................................................................................................... 416 K........................................................................................................... 416 L........................................................................................................... 416 M........................................................................................................... 416 O........................................................................................................... 417 P........................................................................................................... 418 R........................................................................................................... 418 S........................................................................................................... 419 T........................................................................................................... 421 V........................................................................................................... 423 W........................................................................................................... 423 Operating instructions Part 2 Crane Operation................................................................... 427 11 Description of the crane section of the truck crane.......................................................... 433 11.1 Overview of the operating and display instruments...................................................... 433 11.1.1 Overview of the crane section.................................................................... 433 11.1.2 Overview of crane cab............................................................................ 436 11.1.3 Operating elements on the front panel............................................................ 438 11.1.4 Operating elements on the front panel............................................................ 439 Left side of the side panel........................................................................ 439 Top of the side panel.............................................................................. 440 Heating system/ air-conditioning system............................................................ 442 Crane cab additional heating....................................................................... 443 11.1.5 Control consoles................................................................................. 444 Left-hand control console........................................................................... 444 Right-hand control console.......................................................................... 445 11.1.6 Control lever configuration...................................................................... 446 Version 1 (standard)................................................................................ 446 Version 2 (additional equipment).................................................................... 447 11.1.7 Crane control plug-in module..................................................................... 448 11.1.8 Main menu – crane control display................................................................ 450 11.1.9 Crane control display – submenus................................................................. 452 Submenu for Electronic level/ outrigger pressure indicator......................................... 452 Submenu for superstructure lock.................................................................. 453 Submenu for semi-automatic telescoping.............................................................. 454 Submenu for fully automatic telescoping............................................................. 455 Driving transmission speed submenu................................................................. 456 Submenu for settings/displays..................................................................... 457 Control instruments submenu......................................................................... 459 Error menu.......................................................................................... 461 Working area limitation submenu.................................................................... 462 11.1.10 SLI plug-in module.............................................................................. 464 11.1.11 Main menu – SLI display......................................................................... 467 11.1.12 Submenus – SLI display.......................................................................... 468 Submenu for entering rigging mode................................................................. 468 Submenu for SLI monitoring......................................................................... 470 Service submenu.................................................................................... 472 Submenu for error messages......................................................................... 473 11.1.13 Switch boxes for outrigger/electronic level/outrigger pressure display.......................... 474 Operating instruments for the outriggers............................................................ 475 Display elements for the outrigger pressure indicator............................................... 475 Operating and display elements for the electronic level............................................ 475 11.1.14 Hand-held control............................................................................... 476 11.2 Functional description of the display and operating elements.......................................... 477 11.2.1 Crane engine..................................................................................... 477 On the side panel.................................................................................. 477 On the crane control display........................................................................ 478 11.2.2 Crane control.................................................................................... 478 Crane control plug-in module........................................................................ 478 Crane control display............................................................................... 481 Display elements in main menu....................................................................... 482 11.2.3 Outriggers, electronic level, outrigger pressure indicator....................................... 483 On the display fields of the carrier................................................................ 483 Electronic level/ outrigger pressure indicator submenu............................................. 485 11.2.4 Submenu for superstructure lock.................................................................. 486 Turntable lock..................................................................................... 487 Houselock........................................................................................... 488 11.2.5 Hoists........................................................................................... 489 Main hoist.......................................................................................... 489 Auxiliary hoist (additional equipment).............................................................. 491 11.2.6 Slewing gear..................................................................................... 492 11.2.7 Derricking gear.................................................................................. 493 11.2.8 Telescoping gear................................................................................. 495 Control consoles.................................................................................... 495 Control lever for telescoping....................................................................... 495 Telescoping submenu................................................................................. 497 11.2.9 Safe load indicator (SLI)........................................................................ 505 SLI plug-in module.................................................................................. 505 SLI display......................................................................................... 506 Display elements in the main menu................................................................... 507 Enter rigging mode submenu.......................................................................... 508 In the SLI monitoring submenu...................................................................... 513 In the Servicing submenu............................................................................ 519 On the front console............................................................................... 519 11.2.10 Hydraulic system................................................................................ 521 Control consoles.................................................................................... 521 In submenu Settings/displays....................................................................... 521 In the submenu for control instruments.............................................................. 522 In the submenu for warning messages................................................................. 522 11.2.11 Electricity, lighting, windscreen wiper/washing system.......................................... 523 Electricity......................................................................................... 523 Lighting............................................................................................ 523 Windscreen wiper/ washing system................................................................... 524 11.2.12 Crane cab heating system........................................................................ 525 Crane cab heating.................................................................................. 525 Crane cab auxiliary heater......................................................................... 526 Air-conditioning system............................................................................. 527 11.2.13 On the hand-held control........................................................................ 528 Connections on the superstructure................................................................... 528 Crane engine operating field....................................................................... 529 Pre-selection button for emergency operation........................................................ 529 Pre-selection button for rigging................................................................... 530 Two-hand operatingfield............................................................................ 532 11.2.14 Other operating instruments in the crane cab.................................................... 535 Keys................................................................................................ 535 Crane cab door...................................................................................... 535 Windows............................................................................................. 536 Cab lighting........................................................................................ 537 Diagnostics plug.................................................................................... 538 Fire extinguisher (additional equipment)........................................................... 538 Railing by step..................................................................................... 539 11.3 Functional description of the safety devices........................................................... 541 11.3.1 Safe load indicator (SLI)........................................................................ 541 11.3.2 Lowering limit switch............................................................................ 543 11.3.3 Lifting limit switch............................................................................. 544 Overriding lifting limit switch shutdown............................................................ 544 11.3.4 Dead man's and seat contact switches............................................................. 546 12 Crane engine................................................................................................. 549 12.1 Starting the crane engine.............................................................................. 549 12.1.1 CHECKLIST: Starting the crane engine............................................................. 549 12.1.2 CHECKLIST: in winter............................................................................. 551 12.1.3 Inspections before starting the crane engine..................................................... 552 Check shut-off valves on the hydraulic system....................................................... 552 Switching on the battery master switch............................................................. 552 Checking coolant level.............................................................................. 553 Checking the hydraulic oil level.................................................................... 554 Checking the oil level in the crane engine.......................................................... 555 Topping up motor oil............................................................................... 556 Refuelling.......................................................................................... 556 12.1.4 Starting the crane engine........................................................................ 558 Switching on the ignition.......................................................................... 558 Starting the crane engine........................................................................... 560 12.1.5 Inspections after starting the crane engine...................................................... 562 Checks on the side panel............................................................................ 562 Checks on the Crane control display................................................................. 563 Warning messages.................................................................................... 564 12.2 Switching off the crane engine......................................................................... 565 12.2.1 Usually with the ignition lock/hand-held control................................................. 565 12.2.2 In an emergency, with the emergency stop switches................................................ 566 12.2.3 In an emergency, using the air intake inhibitor.................................................. 567 Switching on the air intake inhibitor............................................................... 567 Releasing the air intake inhibitor manually......................................................... 567 13 Crane operation.............................................................................................. 571 13.1 Checks and adjustments before crane operation.......................................................... 571 13.1.1 CHECKLIST: When truck crane is rigged............................................................ 571 13.1.2 Adjusting the front console and the crane cab seat............................................... 577 Adjusting the front console........................................................................ 577 Adjusting the crane cab............................................................................. 578 13.1.3 Checking the condition of the hoist rope......................................................... 579 Checking the reservoir of the windscreen washing system............................................. 579 Visual inspection of the entire crane............................................................... 579 Checking theposition of the hoist ropes............................................................ 580 Checking the electrical system...................................................................... 580 13.1.4 Checking the safety devices...................................................................... 581 Checking the safe load indicator.................................................................... 581 Checking the lifting limit switch.................................................................. 582 Checking the seat contact switch and dead man's switch system....................................... 582 Emergency stop switch for the crane control......................................................... 583 13.1.5 Preheating the hydraulic oil..................................................................... 584 When the oil temperatureis between –15 C and 0 C (5 F and 32 F):............................... 584 For oil temperatures below–15 C (5 F):......................................................... 584 13.1.6 Locking/unlocking the turntable.................................................................. 585 Superstructure lock submenu....................................................................... 586 Locking the turntable.............................................................................. 586 Unlocking the turntable............................................................................ 587 Display of errors related to the turntable lock.................................................... 588 13.1.7 Switching the houselock on/off................................................................... 589 Superstructure lock submenu....................................................................... 589 Switching on thehouselock......................................................................... 590 Switching off the houselock........................................................................ 591 13.2 Operating the safe load indicator (SLI)................................................................ 593 13.2.1 Switching on the SLI............................................................................. 593 Setting the brightness of the displays.............................................................. 595 Lamp test on theSLI................................................................................ 595 13.2.2 Entering the rigging mode........................................................................ 597 Entering new counterweight versions................................................................. 599 Entering a new outrigger span....................................................................... 602 Entering a new slewing range....................................................................... 603 Entering components for the lattice extension...................................................... 604 Entering a new reeving.............................................................................. 608 Entering the rigging mode using an SLI code......................................................... 609 13.2.3 Checks and displays in the SLI monitoring submenu................................................ 610 Submenu for SLI monitoring.......................................................................... 610 Checks to be carried out before starting........................................................... 610 Current displays during crane operation............................................................. 613 13.2.4 SLI pre-warning and SLI shutdown................................................................. 616 SLI early warning................................................................................... 616 SLI shutdown........................................................................................ 616 Error message....................................................................................... 619 Submenu for error messages.......................................................................... 620 SLI override....................................................................................... 622 13.3 Crane work with main boom.............................................................................. 623 13.3.1 External influences during crane operation....................................................... 623 Horizontal alignment................................................................................ 623 Safe distances..................................................................................... 623 Checking the wind speed............................................................................. 624 If the maximum permitted wind speed has been exceeded............................................... 625 Permissible wind load.............................................................................. 626 Earthing the load................................................................................... 627 13.3.2 Permissible slewing ranges and working positions for crane work.................................. 628 Slewing range 360 .................................................................................. 628 Limited slewing range ±15 .......................................................................... 628 Working position 0 to the rear..................................................................... 629 Working position 180 to the front.................................................................. 629 13.3.3 Main hoist....................................................................................... 631 Switching on the main hoist......................................................................... 631 Lifting and lowering............................................................................... 632 Switching off themain hoist....................................................................... 635 13.3.4 Auxiliary hoist (additional equipment)........................................................... 636 Switching on the auxiliary hoist................................................................... 636 Lifting and lowering............................................................................... 637 Switching off the auxiliary hoist.................................................................. 637 13.3.5 Derricking gear.................................................................................. 638 Switching on the derricking gear.................................................................... 638 Raising and lowering................................................................................ 639 Switching off the derricking gear.................................................................. 640 Maximum permissible derricking speed............................................................... 640 13.3.6 Slewing gear..................................................................................... 641 Switching on the slewing gear...................................................................... 641 Slewing............................................................................................. 642 Slewing speed and braking.......................................................................... 644 Tracking the slewing gear.......................................................................... 644 Switching off the slewing gear..................................................................... 645 Maximum permissible slewing speed.................................................................. 645 13.3.7 Telescoping gear................................................................................. 647 Structure of the chapter............................................................................ 647 Description offunctioning.......................................................................... 648 Main boom fixed length, intermediate length, telescoping length..................................... 649 Telescope status.................................................................................... 651 Notes on the telescoping sequence................................................................... 653 Checks before the first telescoping................................................................. 653 Switching on telescoping gear....................................................................... 654 Function of the control lever....................................................................... 654 Switching off telescoping gear...................................................................... 656 Example of the procedure for telescoping........................................................... 657 Checking the initial position....................................................................... 658 Unlocking the telescoping cylinder.................................................................. 663 Extend/retract telescoping cylinder................................................................. 666 Locking the telescoping cylinder.................................................................... 667 Unlocking the telescopic section.................................................................... 671 Telescoping the telescopic section................................................................. 673 Locking the telescopic section..................................................................... 675 Telescoping the telescopic section to an intermediate length........................................ 679 Lock telescopic section for on- road driving....................................................... 679 Telescoping with fully automatic control............................................................ 680 Lowering the main boom for maintenance............................................................. 685 Telescoping the main boom at anglesunder 10 ....................................................... 685 13.3.8 High-speed mode.................................................................................. 687 13.3.9 Special menus on the crane control display....................................................... 688 Operating hours meter submenu..................................................................... 688 Driving transmission speeds submenu.............................................................. 690 Warning message submenu............................................................................. 692 Error menu.......................................................................................... 694 Setting the brightnessof the displays.............................................................. 696 13.3.10 Setting a constant engine speed................................................................. 698 13.3.11 Critical load control........................................................................... 699 Function............................................................................................ 699 Switching on and off.............................................................................. 699 13.3.12 Inclining the crane cab......................................................................... 701 13.3.13 Cooling the hydraulic oil....................................................................... 702 Standard oil cooler................................................................................. 702 Additional oil cooler............................................................................... 702 13.3.14 Possible movement combinations.................................................................. 703 13.4 Driving with a rigged crane............................................................................ 705 13.4.1 Driving route.................................................................................... 705 13.4.2 Boom positions and axle loads.................................................................... 706 Table of axle loads................................................................................. 707 13.4.3 Driving the rigged crane......................................................................... 708 Locking the turntable and engaging the slewing gear holding brake.................................. 708 Retracting theoutrigger........................................................................... 708 Switching over the suspension locking system........................................................ 708 Switching on separate steering...................................................................... 709 Driving............................................................................................. 710 Extending theoutrigger............................................................................ 710 13.5 Work breaks............................................................................................ 711 13.5.1 Short work breaks................................................................................ 711 13.5.2 Work breaks lasting more than 8 hours............................................................ 711 Securing the truck crane against unauthorized use................................................... 712 13.6 Crane cab heating and air-conditioning system.......................................................... 713 13.6.1 Engine-dependent crane cab heater................................................................ 713 Switching the heater on and off..................................................................... 713 Setting recirculated air/fresh air.................................................................. 714 Setting the air distribution........................................................................ 714 Adjusting the air vents............................................................................. 715 13.6.2 Engine-independent auxiliary crane cab heater.................................................... 716 Switching the auxiliary heater on/off............................................................... 716 Regulating the temperature......................................................................... 717 Setting air distribution........................................................................... 717 Setting recirculated air/ fresh air operation....................................................... 717 Storing automatic heating start..................................................................... 717 Setting automatic heating duration.................................................................. 718 Switching automaticheating start on/off............................................................ 719 Setting remaining time.............................................................................. 719 Setting time and weekday............................................................................ 720 13.6.3 Air-conditioning system.......................................................................... 721 Switching on........................................................................................ 721 Setting the air distribution........................................................................ 722 To switch off....................................................................................... 722 How to use the airconditioning effectively......................................................... 722 Dehumidifying the crane cab air..................................................................... 723 13.7 Working range limiter.................................................................................. 725 13.7.1 Opening the working area limitation submenu...................................................... 726 13.7.2 Reading current settings......................................................................... 727 Display monitoring switched on/ off................................................................. 727 Reading the limit values entered................................................................... 727 13.7.3 Entering a limit value for a maximum overall height.............................................. 729 13.7.4 Entering a limit value for a maximum working radius.............................................. 730 13.7.5 Entering limit values for maximum slewing angles................................................. 731 Displays in the submenu Working area limitation..................................................... 731 Presentation of slewing angles...................................................................... 732 Entering the slewing angle.......................................................................... 733 13.7.6 Entering point data for objects.................................................................. 734 Presentation of defined objects.................................................................... 734 Selecting and deleting point data................................................................. 735 Entering point data................................................................................ 736 13.7.7 Entering limit values manually................................................................... 738 Limit values for overall height, working radius or slewing angle.................................... 738 Manual point data entry............................................................................. 739 13.7.8 Switching monitoring on and off.................................................................. 741 Switching monitoring on............................................................................. 741 Switching monitoringoff............................................................................ 742 13.8 Shutdown caused by working range limiter............................................................... 743 13.8.1 Crane movements which are switched off........................................................... 743 Bypassing shutdown................................................................................. 744 14 Rigging work................................................................................................. 747 14.1 Checklists for rigging work for crane operation with main boom......................................... 747 14.1.1 CHECKLIST: Rigging............................................................................... 747 14.1.2 CHECKLIST: Unrigging............................................................................. 751 14.2 Choosing a suitable site............................................................................... 755 14.2.1 Load bearing capacity of the ground and the outrigger............................................ 755 Enlarging the enlarge............................................................................... 757 14.2.2 Safe distance from banks and pits................................................................ 758 14.2.3 Earthing the truck crane......................................................................... 759 Earthing the truck crane............................................................................ 759 14.2.4 Safe distance from electrical lines.............................................................. 760 14.3 Rigging work after driving with trailer................................................................ 763 14.3.1 Switching off the boom floating position......................................................... 764 14.3.2 Switching off boom pre-tensioning................................................................ 764 14.3.3 Switching off slewing gear freewheel............................................................. 766 Before slewing...................................................................................... 767 14.4 Add-on parts in position for crane mode/driving mode................................................... 769 14.4.1 Swivelling the crane cab into position for crane mode/ drivingmode.............................. 770 Connecting/ removing the hand-held control......................................................... 770 Slewing into crane mode position.................................................................... 772 Slewing into th position driving mode.............................................................. 774 14.4.2 Pushing the railings on the access ladder out/in................................................ 776 Pushing out the railings........................................................................... 776 Pushing in the railing............................................................................. 777 14.4.3 Folding the hoist mirror in/out.................................................................. 778 Folding the mirror out and adjusting it............................................................. 778 Folding in the mirror............................................................................. 778 14.4.4 Rigging work on the rear steps................................................................... 779 Before crane operation............................................................................ 779 After crane operation............................................................................. 780 14.5 Outriggers............................................................................................. 781 14.5.1 CHECKLIST: Extending the outrigger............................................................... 781 14.5.2 CHECKLIST: Retracting the outrigger.............................................................. 783 14.5.3 Permissible outrigger spans...................................................................... 785 Outrigger span 8.76 x 8.90 m (28.7x29.2ft)....................................................... 786 Outrigger span 8.76 x 6.10 m (28.7x20.0ft)....................................................... 786 Outrigger span 8.76 x 2.63 m (28.7x8.6ft)........................................................ 787 Outrigger span 7.78 x 8.90/1.22m 25.5x29.2/4.0ft................................................ 788 14.5.4 Preparing the truck crane........................................................................ 789 Align horizontally................................................................................. 789 Locking the suspension............................................................................. 789 14.5.5 Securing/releasing outrigger beam................................................................ 790 Securing the outrigger beams....................................................................... 790 Releasing the outrigger beams...................................................................... 791 14.5.6 Extending/retracting the outrigger beams......................................................... 792 Setting outrigger spans............................................................................. 794 14.5.7 Moving the outrigger pads into working/driving position.......................................... 798 Moving the outrigger pads into working position.................................................... 798 Moving the outrigger pads into driving position.................................................... 799 14.5.8 Extending/retracting the outrigger cylinder...................................................... 800 Allocation of the button units..................................................................... 800 Extending the outrigger cylinders................................................................... 801 Retracting theoutrigger cylinders................................................................. 803 14.5.9 Checking the alignment of the truck crane........................................................ 805 Electronic level on the carrier................................................................... 805 Electronic levels on crane control display......................................................... 807 14.5.10 Aligning the truck crane horizontally........................................................... 810 If the boom is in the boom support................................................................ 810 If the boom is raised............................................................................. 810 14.5.11 Outrigger pressure display...................................................................... 811 Outrigger pressure display on thecarrier........................................................... 811 Outrigger pressure display on superstructure....................................................... 812 14.6 Rigging/unrigging the counterweight.................................................................... 813 14.6.1 Counterweight parts and identification........................................................... 813 Counterweight parts................................................................................. 813 Identification...................................................................................... 814 14.6.2 Counterweight versions........................................................................... 815 14.6.3 Slinging points on the counterweight sections.................................................... 818 14.6.4 CHECKLIST: Rigging the counterweight............................................................. 820 Prerequisites....................................................................................... 820 14.6.5 CHECKLIST: Unrigging the counterweight........................................................... 824 Prerequisites....................................................................................... 824 14.6.6 Setting down/picking up the counterweight platform – counterweight sections...................... 828 Setting down the 20 t base plate................................................................... 828 Picking up counterweight parts..................................................................... 829 14.6.7 Assembling the counterweight version............................................................. 830 14.6.8 Securing/releasing 10-t counterweight blocks..................................................... 834 Securing the counterweight blocks................................................................... 834 Releasing counterweight blocks...................................................................... 835 14.6.9 Establishing/disconnecting the hydraulic connection.............................................. 836 Establishing thehydraulic connection............................................................. 836 Breaking the hydraulic connection................................................................... 837 14.6.10 Establishing/disconnecting the electrical connection............................................ 837 Establishing the electrical connection............................................................ 838 Breaking the electrical connection.................................................................. 838 14.6.11 Hand-held control............................................................................... 839 Connecting the hand-held control.................................................................... 839 Starting the crane engine with the hand-held control................................................ 840 Turning off crane engine with the hand-held control................................................. 840 14.6.12 Extending/retracting the lifting cylinder of the 20 t base plate or lifting/lowering coun....... 841 Lifting cylinders: extend........................................................................... 842 Lifting cylinders: retracting....................................................................... 843 14.6.13 Locking/unlocking the counterweight to the turntable............................................ 844 Safety hand valve................................................................................... 845 Locking the counterweight........................................................................... 846 Counterweight; unlocking............................................................................ 847 14.6.14 Slewing with the rigged counterweight........................................................... 848 14.6.15 Hoisting and setting down counterweight sections with mounted auxiliary hoist................... 850 14.7 Auxiliary hoist........................................................................................ 851 Required components..................................................................................... 851 14.7.1 Components and identification.................................................................... 852 14.7.2 Slinging points and transport.................................................................... 853 Slinging points..................................................................................... 853 Transport........................................................................................... 854 14.7.3 CHECKLIST: Mounting the auxiliary hoist.......................................................... 855 Prerequisites....................................................................................... 855 14.7.4 CHECKLIST: Dismantling the auxiliary hoist....................................................... 858 Prerequisites....................................................................................... 858 14.7.5 Hoist the auxiliary hoist onto the 20 t base plate............................................... 861 14.7.6 Raising and setting down the catcher............................................................. 861 Raising thecatcher................................................................................. 862 Set down the catcher................................................................................ 863 14.7.7 Establishing/disconnecting the hydraulic connection.............................................. 864 Establishing a connection.......................................................................... 864 Disconnecting ..................................................................................... 864 14.7.8 Establishing/disconnecting the electrical connection............................................. 865 Establishing a connection.......................................................................... 865 Disconnecting ..................................................................................... 865 14.7.9 Locking the auxiliary hoist / releasing lock..................................................... 866 Safety valve........................................................................................ 866 Locking............................................................................................. 867 Releasing the locking pin........................................................................... 867 Releasing the locking pin........................................................................... 868 Releasing the locking pin........................................................................... 868 14.7.10 Checking that the auxiliary hoist is functioning properly....................................... 869 With the manual control............................................................................. 869 In the crane cab.................................................................................... 870 14.7.11 Secure the upper hook block in the catcher...................................................... 870 14.7.12 Permissable utilization options for the auxiliary hoist......................................... 871 Replacement for the main hoist...................................................................... 871 Alternating operation with the main and auxiliary hoists............................................ 872 14.8 Rigging work on the main boom.......................................................................... 873 14.8.1 Hook block on the bumper......................................................................... 873 Picking up the hook block from the bumper........................................................... 873 Attach the hook block to the bumper................................................................. 874 14.8.2 Hook block on a separate vehicle................................................................. 875 Picking up the hook block from the separate vehicle................................................ 875 Place the hook block on a separate vehicle.......................................................... 876 14.8.3 Reeving and unreeving the hoist rope............................................................. 877 Rope end fitting.................................................................................... 877 Reeve the hoist rope............................................................................... 879 Lifting limit switch on the main boom............................................................... 882 Rope end clamp...................................................................................... 886 14.8.4 Possible reeving on the main boom for standard design with9sheaves............................. 888 14.8.5 Possible reeving on the main boom for additional equipment with 11 sheaves...................... 893 14.8.6 Possible reeving on the main boom for additional equipment with 13 sheaves...................... 899 14.8.7 Anemometer....................................................................................... 906 Installing the anemometer......................................................................... 906 Remove the anemometer............................................................................. 907 14.8.8 Stay bar for anemometer and air traffic control lights........................................... 908 14.8.9 Mounting and connecting the air traffic control lights........................................... 909 14.8.10 Rigging heavy duty equipment.................................................................... 911 Heavy duty equipment parts.......................................................................... 911 Equipment required................................................................................. 911 Rigging heavy duty equipment........................................................................ 912 Unrigging heavy duty equipment...................................................................... 915 Reevings with heavy duty equipment.................................................................. 917 15 Crane operation malfunctions................................................................................. 921 15.1 Superstructure emergency stop device................................................................... 921 Reset the emergency stop switch......................................................................... 922 15.2 What to do in the event of a malfunction when working with the crane................................. 923 If Lower load is not possible........................................................................... 924 15.3 Electrical system...................................................................................... 925 15.3.1 Inserts.......................................................................................... 926 15.3.2 Fuses............................................................................................ 928 Fuses on turntable.................................................................................. 928 Fuses in the crane cab.............................................................................. 930 Fuses in battery box................................................................................ 932 Fuses on the crane cab bracket...................................................................... 933 Fuses on I/O circuit boards......................................................................... 934 15.3.3 SLI fuses........................................................................................ 935 15.4 Trouble shooting and rectification at the power units.................................................. 937 15.4.1 Crane engine malfunctions........................................................................ 937 15.4.2 Malfunctions with operation with hand-held control............................................... 939 15.4.3 Malfunctions with movements of the crane cab..................................................... 939 15.4.4 Main hoist malfunctions.......................................................................... 940 15.4.5 Auxiliary hoist malfunctions..................................................................... 942 15.4.6 Derricking gear malfunctions..................................................................... 944 15.4.7 Slewing gear malfunctions........................................................................ 946 15.4.8 Hydraulic system/hydraulic oil cooler malfunctions............................................... 947 15.4.9 Malfunctions at the counterweight hoist unit..................................................... 948 15.4.10 Malfunctions on the turntable locking........................................................... 949 15.4.11 Telescoping gear malfunctions................................................................... 949 Error messages telescoping gear..................................................................... 952 15.5 Trouble shooting and rectification on the SLI.......................................................... 955 Program version of safe load indicator.................................................................. 955 15.5.1 General malfunctions............................................................................. 955 15.5.2 Error messages on the SLI display................................................................ 956 Table for the Error group 1........................................................................ 957 Table for the Error group 2........................................................................ 963 Table for the Error group 3........................................................................ 965 Table for the Error group 5........................................................................ 967 Table for the Error group 6........................................................................ 969 Table for the Error group 7........................................................................ 970 Table for the Error group 8........................................................................ 970 15.5.3 Checking SLI lines and connections............................................................... 971 On truck crane...................................................................................... 972 On lattice extension (additional equipment)......................................................... 973 15.6 Trouble shooting and rectification on the crane control................................................ 975 15.6.1 General malfunctions............................................................................. 975 15.6.2 Error messages on Crane control display.......................................................... 976 Symbols for Devices................................................................................ 977 Symbols for Groups................................................................................. 979 Symbols for Types of errors........................................................................ 981 Index displays allocation.......................................................................... 982 Control lever error table........................................................................... 993 Locking system error table.......................................................................... 994 Error messages via Can-Bus.......................................................................... 997 Error messages about hoisting gears................................................................. 999 Error messages system monitoring group.............................................................. 999 Error messages group carrier........................................................................1001 15.6.3 Connections for the crane control's control units................................................1003 Control units connections position..................................................................1003 Layout of connections..............................................................................1004 15.6.4 Unrig truck crane when control units are defective...............................................1006 Prerequisites.......................................................................................1006 Replacing control units.............................................................................1008 15.7 Emergency operations and emergency programs............................................................1011 15.7.1 Emergency retract operation......................................................................1012 Check prior Emergency operation emergency operation.................................................1012 Procedure for intermediate length...................................................................1013 Mechanical emergency operation......................................................................1014 Hydraulic emergency operation.......................................................................1016 Length data for the locking points..................................................................1027 15.7.2 Sub-menu emergency program telescoping...........................................................1028 Starting emergency program..........................................................................1028 Emergency program display and operating elements....................................................1029 Retracting with an error on the length indicator....................................................1031 Retracting with an error on the proximity switch....................................................1035 Emergency program end..............................................................................1037 Table for approaching the locking points............................................................1037 15.7.3 Enter telescope status after emergency operation.................................................1039 15.7.4 Emergency operation in case of failure of the operating instruments in the crane cab.............1043 Prerequisites.......................................................................................1043 Connecting the hand-held control....................................................................1044 Starting the crane engine with the hand-held control................................................1044 Preselect power unit...............................................................................1045 Operating power unit................................................................................1045 Movements stopping.................................................................................1047 Stopping the movement in case of an emergency.......................................................1047 16 Technical information for superstructure.....................................................................1051 16.1 Technical description of the superstructure............................................................1051 16.1.1 Turntable........................................................................................1051 16.1.2 Crane cab........................................................................................1051 16.1.3 Crane engine and hydraulic system................................................................1052 16.1.4 Control system...................................................................................1053 16.1.5 Main boom........................................................................................1053 16.1.6 Telescoping gear.................................................................................1053 16.1.7 Hoists...........................................................................................1054 16.1.8 Slewing gear.....................................................................................1055 16.1.9 Houselock........................................................................................1055 16.1.10 Derricking cylinder.............................................................................1055 16.1.11 Electrical system..............................................................................1056 16.1.12 Counterweight...................................................................................1056 16.1.13 Safety devices..................................................................................1057 16.1.14 Hand-held control...............................................................................1057 16.2 Technical data.........................................................................................1059 16.2.1 Maximum load bearing capacity (DIN/ISO/EN).......................................................1059 16.2.2 Maximum load bearing capacity (ANSI B 30.5)......................................................1059 16.2.3 Dimensions, weights and axle loads...............................................................1060 Dimensions when driving on public roads.............................................................1061 16.2.4 Dimensions and weights of removable parts........................................................1062 Hook blocks and hook tackle.........................................................................1062 Auxiliary hoist.....................................................................................1063 Main boom...........................................................................................1063 Heavy dutyequipment................................................................................1063 Counterweightparts.................................................................................1063 Counterweight versions..............................................................................1064 16.2.5 Technical data for superstructure................................................................1066 Vehicle engine......................................................................................1066 Slewing gear........................................................................................1066 Derricking gear.....................................................................................1066 Main boom...........................................................................................1066 Main hoist..........................................................................................1067 Auxiliary hoist (additional equipment)..............................................................1067 Working speed and times without load................................................................1068 17 Index........................................................................................................1071 A...........................................................................................................1073 B...........................................................................................................1074 C...........................................................................................................1075 D...........................................................................................................1077 E...........................................................................................................1078 F...........................................................................................................1078 G...........................................................................................................1079 H...........................................................................................................1079 I...........................................................................................................1080 K...........................................................................................................1080 L...........................................................................................................1080 M...........................................................................................................1080 O...........................................................................................................1081 P...........................................................................................................1082 R...........................................................................................................1082 S...........................................................................................................1083 T...........................................................................................................1085 V...........................................................................................................1087 W...........................................................................................................1087
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