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Grove Crane GMK4075 Operating Instructions Part 1 Carrier 2084640 – PDF DOWNLOAD
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Grove Crane GMK4075 Operating Instructions Part 1 Carrier 2084640 – PDF DOWNLOAD
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Grove Crane GMK4075 Operating Instructions Part 1 Carrier 2084640 – PDF DOWNLOAD
Language : English
Pages : 906
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Grove Crane GMK4075 Operating Instructions Part 1 Carrier 2084640 – PDF DOWNLOAD
GMK 4075 .................................................................................................................. 1 Operating instructions Part 1 Carrier.................................................................................. 1 Additional pages: Holding brake operation from the crane cab....................................................... 3 Validity....................................................................................................... 3 Reasons for this additional information........................................................................ 3 Checking the crane type........................................................................................ 3 Supplement to the operating instructions....................................................................... 4 Operation with the toggle switch............................................................................... 4 Correction sheet: Operating the hand pump for emergency activation Correction for counterweight rigging............ 5 Validity....................................................................................................... 5 Reason for the correction..................................................................................... 5 Correction Handpump........................................................................................... 5 Correction for counterweight rigging.......................................................................... 6 Additional pages .................................................................................................. 7 Validity....................................................................................................... 7 Reasons for this additional information........................................................................ 7 Driving from the crane cab..................................................................................... 8 Mounting counterweight sections on the 1.3 t counterweight section............................................ 9 Information.................................................................................................... 9 Additional page: Guaranteed value specifications .................................................................. 13 Validity....................................................................................................... 13 Supplement to the technical data for the superstructure....................................................... 13 Information.................................................................................................... 13 Correction sheets: Telescoping emergency program submenu .......................................................... 15 Validity....................................................................................................... 15 Reason for the correction...................................................................................... 15 Contents of the Correction sheets.............................................................................. 15 Correcting..................................................................................................... 15 Starting emergency program..................................................................................... 16 Starting emergency program..................................................................................... 19 Additional pages: Continuous switching for the crane's hydraulic system............................................ 25 Validity....................................................................................................... 25 Reasons for this additional information........................................................................ 25 Changes........................................................................................................ 25 Additional pages: Emergency operation/Emergency program telescoping ............................................... 27 Validity....................................................................................................... 27 Reasons for the additional information......................................................................... 27 Additional information......................................................................................... 27 1 Overview......................................................................................................... 33 1.1 Vehicle identification..................................................................................... 33 1.2 EC Declaration of Conformity............................................................................... 37 1.3 Overview and contents of truck crane user information...................................................... 39 1.3.1 Carrier and superstructure operating manual.......................................................... 39 1.3.2 Lattice extension operating manual (additional equipment)............................................ 40 1.3.3 Maintenance manual................................................................................... 40 1.3.4 Lifting capacity table............................................................................... 40 1.3.5 Outrigger pressure table............................................................................. 41 1.3.6 Safety manual........................................................................................ 41 1.3.7 Spare parts list..................................................................................... 41 1.3.8 Circuit diagrams..................................................................................... 41 1.4 Instructions for use of this document...................................................................... 42 1.4.1 How are the operating instructions laid out?......................................................... 42 1.4.2 How are the pages of the operating instructions formatted?........................................... 43 1.4.3 How can I find the necessary information quickly and easily?......................................... 44 Example of cross- reference usage...................................................................... 45 Explanations of how to use the index................................................................... 50 1.4.4 Definitions of stated directions..................................................................... 50 Basic rule............................................................................................. 50 Buttons and switches.................................................................................. 50 1.4.5 Conversion table for metric measurements............................................................. 51 2 Fundamental safety instructions for crane operators.............................................................. 55 2.1 Warnings and symbols....................................................................................... 55 2.2 Proper use................................................................................................. 56 2.3 Organizational measures.................................................................................... 58 2.4 Personnel qualifications................................................................................... 60 2.5 Safety instructions that apply to truck crane driving...................................................... 61 2.6 Safety instructions for truck crane work................................................................... 61 3 Information for the operating schedule........................................................................... 65 3.1 Safety instructions........................................................................................ 65 3.1.1 Proper use........................................................................................... 65 3.1.2 Organizational measures.............................................................................. 65 3.1.3 Personnel qualifications............................................................................. 66 3.2 Operating schedule......................................................................................... 67 3.2.1 Prerequisites for operations scheduling.............................................................. 67 3.2.2 Details about operations scheduling contained in the user information................................ 68 4 Description of the truck crane vehicle section................................................................... 71 4.1 Overview of the operating and display instruments.......................................................... 71 4.1.1 Overview of the vehicle.............................................................................. 71 4.1.2 Overview of the driver's cab......................................................................... 74 Top view of driver's cab............................................................................... 74 In the driver's cab, at the top........................................................................ 76 Below the front instrument panel....................................................................... 77 4.1.3 Front instrument panel............................................................................... 78 Left-hand insert....................................................................................... 78 Tachograph insert...................................................................................... 80 Speedometer insert..................................................................................... 81 Right-hand insert...................................................................................... 82 Heating and gearbox display insert..................................................................... 84 4.1.4 Side instrument panel................................................................................ 86 Insert 1............................................................................................... 86 Insert 2............................................................................................... 88 Gearbox operating instruments.......................................................................... 90 4.1.5 Switch boxes for outrigger/electronic level/outrigger pressure display (additional equipment)........ 91 4.1.6 Operating instruments on the steering column......................................................... 92 4.2 Functional description of the display and operating instruments........................................... 93 4.2.1 On the instrument panels............................................................................. 93 Diesel engine.......................................................................................... 93 Gearbox with automatic gear change..................................................................... 95 Axle drive............................................................................................. 98 Brakes................................................................................................. 99 Steering...............................................................................................100 Suspension.............................................................................................101 Hydraulic system.......................................................................................102 Electrics..............................................................................................102 Leveladjustment.......................................................................................105 Tachograph.............................................................................................106 Speedometer insert....................................................................................107 Heating in the driver's cab............................................................................108 Auxiliary heater with timer (additional equipment)....................................................109 Other operating instruments...........................................................................111 4.2.2 On the steering column...............................................................................113 Ignition lock..........................................................................................113 Multipurpose switch, right.............................................................................113 Multipurpose switch, left..............................................................................115 4.2.3 Other operating instruments in the vehicle section...................................................116 Cab lighting...........................................................................................116 Keys...................................................................................................116 Doors..................................................................................................117 Window.................................................................................................118 Ladders................................................................................................119 Access ladders.........................................................................................120 Diesel engine/ gearbox/ electronics diagnostic system..................................................120 Front flap.............................................................................................121 Fire extinguisher (additional equipment)..............................................................121 5 Diesel engine....................................................................................................125 5.1 Starting/turning off the diesel engine.....................................................................125 5.1.1 CHECKLIST: Starting the diesel engine................................................................125 5.1.2 CHECKLIST: In winter.................................................................................127 5.1.3 Inspections before starting the diesel engine........................................................128 Check diesel engine oil level..........................................................................128 Topping up motor oil...................................................................................129 Checking coolant level.................................................................................130 Switching on the battery master switch.................................................................131 Checking hydraulic oil level...........................................................................131 Checking the stop cocks in the hydraulic system........................................................132 5.1.4 Starting the diesel engine...........................................................................133 Switching on ignition..................................................................................133 Starting the diesel engine.............................................................................134 Setting the idling speed...............................................................................136 5.1.5 Inspections before starting the diesel engine........................................................137 Checkinstruments......................................................................................137 5.2 Switching off the diesel engine............................................................................139 5.2.1 Usually via the ignition lock........................................................................139 5.2.2 In an emergency situation, with the emergency stop switch............................................140 5.2.3 In an emergency via the air intake lock (additional equipment).......................................141 Switching on the air intake lock.......................................................................141 Manually releasing the air intake lock.................................................................142 6 Driving the truck crane..........................................................................................145 6.1 Checking the truck crane before driving....................................................................145 6.1.1 CHECKLISTE: Condition of the truck crane for on-road driving.........................................145 6.1.2 Driving mode table..................................................................................148 6.1.3 Checking the condition of the hoist rope.............................................................151 Checking the reservoir of the windscreen washing system................................................151 Warning plates for vehicle width.......................................................................151 Checking the tyres.....................................................................................152 Checking the mirror settings...........................................................................153 Adjusting the steering column..........................................................................153 Checking the electrical system.........................................................................154 Switching between driving mode/crane operation.........................................................154 Check the compressed air and brake systems.............................................................154 Checking the suspension................................................................................155 Checking on-the- road level............................................................................155 Checking the transverse differential locks.............................................................156 Checking longitudinal differential locks/drive of 2nd axle line........................................156 Checking the steering locks...........................................................................156 Checking the Boom not set down warning lamp............................................................157 6.1.4 Adjusting the driver's and the passenger's seat......................................................158 Adjust the driver's seat...............................................................................158 Adjusting the driver's seat............................................................................159 6.1.5 Refuelling...........................................................................................160 6.1.6 Switching on the boom floating position..............................................................161 6.1.7 Switching on boom pretensioning......................................................................162 6.1.8 Switching on the slewing gear freewheel..............................................................164 6.1.9 Tachograph...........................................................................................165 6.2 General operation..........................................................................................171 6.2.1 Operating the transmission with automatic gear change................................................171 To switch on...........................................................................................171 Selecting the driving direction........................................................................172 Starting...............................................................................................173 Select gearbox operating mode..........................................................................174 Driving and changing gears.............................................................................175 Changing the direction of travel.......................................................................177 Stopping...............................................................................................177 Switch gearbox to neutral position.....................................................................177 Manoeuvring mode.......................................................................................178 On the roller type dynamometer.........................................................................178 Starting at extremely low temperatures................................................................179 6.2.2 Monitoring the control instruments while driving.....................................................179 6.2.3 Driving on downhill slopes...........................................................................183 Starting on a slope....................................................................................183 Monitoring the maximum permissible engine speed........................................................184 Preselecting gears.....................................................................................184 Retarder...............................................................................................185 Eddy currentretarder (additional equipment)...........................................................186 6.2.4 Driving on uphill slopes.............................................................................187 Starting...............................................................................................187 Driving................................................................................................187 6.2.5 Tempomat.............................................................................................188 Activating the tempomat...............................................................................188 Driving with tempomat..................................................................................188 Switching off tempomat.................................................................................189 6.2.6 Temposet.............................................................................................190 Switching on temposet..................................................................................190 Driving with the temposet..............................................................................190 Switching off Temposet.................................................................................191 6.2.7 Parking the truck crane..............................................................................191 Locking the parking brake..............................................................................191 Gearbox in neutral position...........................................................................191 Turning off the vehicle engine.........................................................................191 Securing the truck crane against rolling...............................................................192 After long periods of standstill.......................................................................192 Securing the truck crane against un- authorized use....................................................192 6.3 Off-the-road driving.......................................................................................193 6.3.1 Longitudinal differential locks/drive of 2nd axle line...............................................194 Switching on drive/longitudinal differential locks.....................................................194 Switching off drive/longitudinal differential locks....................................................195 6.3.2 Deactivating transverse differential locks...........................................................196 Activating transverse differential locks...............................................................196 Deactivating transverse differential locks.............................................................196 6.3.3 Level adjustment.....................................................................................197 Activating the level adjustment system.................................................................198 Raising or lower- ing the entire truck crane...........................................................198 Tilting the truck crane lengthwise or crosswise........................................................199 Bring the truck crane into position On-the-road level..................................................199 Deactivating the level adjustment system...............................................................200 6.3.4 Freeing an immobilized truck crane...................................................................200 Freeing the truck crane by onself ...................................................................200 Towing free forward....................................................................................201 Towing free in reverse.................................................................................201 6.4 Separate steering..........................................................................................203 6.4.1 Unlocking the 3rd axle line steering, connecting 3rd and 4thaxle lines..............................204 6.4.2 Steering the 3rd and 4th axle lines..................................................................204 6.4.3 Separate 4th axle line, lock steering of 3rd axle line...............................................205 6.5 Heating system and fan for driver's cab....................................................................207 6.5.1 Driver's cab heating system..........................................................................207 Heating the driver's cab...............................................................................207 Ventilating the driver's cab...........................................................................208 Air vents..............................................................................................209 6.5.2 Roof fan (additional equipment)......................................................................209 6.5.3 Additional heating system with timer (additional equipment)..........................................210 Preheating the diesel engine...........................................................................210 Preheating the driver's cab............................................................................210 Switching the additional heating system on/off.........................................................210 Displaying and setting the current time................................................................211 Automatic heating start switch on and save.............................................................211 Automatic heating start switching off..................................................................212 6.6 Air-conditioning system (additional equipment).............................................................213 6.6.1 Switching on/off.....................................................................................213 To switch on...........................................................................................213 To switch off..........................................................................................213 6.6.2 Air conditioning.....................................................................................214 How to ensure pleasant air- conditioning...............................................................214 Dry air in the driver's cab............................................................................215 6.7 Towing a trailer (additional equipment)....................................................................217 Effects on the axleloads..................................................................................217 Coupling the trailer.......................................................................................218 Connecting the supply lines...............................................................................219 Removing supplylines......................................................................................220 Uncoupling the trailer.....................................................................................220 Test position of the parking brake when towing a trailer...................................................221 7 Malfunctions on the carrier.....................................................................................225 7.1 Emergency stop device on carrier...........................................................................225 7.1.1 Diesel engine emergency stop switch..................................................................225 7.2 Breakdown in road traffic..................................................................................227 7.3 Towing the truck crane.....................................................................................229 7.3.1 Towing in the case of engine or gearbox damage.......................................................229 Towing the truck crane out of the danger area..........................................................230 Longer distances.......................................................................................230 Compressed-air supply for diesel engine failure........................................................231 Power supply...........................................................................................232 Axle drives............................................................................................232 Parking brake..........................................................................................232 Mechanically releasing the parking brake...............................................................233 Towing procedure.......................................................................................233 Removing the mechanical locking from all spring- loaded brake cylinders................................234 Tow starting...........................................................................................234 7.4 Wheel change...............................................................................................235 Removing a damaged wheel...................................................................................235 Removing the wheel from the spare wheel holder.............................................................236 Mounting a damaged wheel on the spare wheel holder.........................................................237 Mounting the spare wheel...................................................................................237 7.5 Tilt driver's cab forward..................................................................................239 Prerequisites and information on tilting...................................................................239 Unlocking/locking the driver's cab.........................................................................240 Driver's cab tilting.......................................................................................240 Lowering the driver's cab.................................................................................242 7.6 Emergency operation for lifting the main boom..............................................................243 7.6.1 Connecting/disconnecting the hose....................................................................244 Connecting the hose....................................................................................244 Disconnecting the hose.................................................................................244 7.6.2 Connecting hydraulic circuits........................................................................245 7.6.3 Switching continuous operation on or off.............................................................246 7.6.4 Performing emergency operation.......................................................................247 7.6.5 After emergency operation...........................................................................248 7.7 Electrical system..........................................................................................249 7.7.1 Inserts..............................................................................................249 Front insert...........................................................................................249 Side insert............................................................................................250 7.7.2 Fuses................................................................................................251 Fuses in the driver's cab..............................................................................251 Fuses in battery box...................................................................................254 Fuses on input-output pcb's............................................................................255 7.8 Troubleshooting and remedy.................................................................................257 7.8.1 Malfunctions on the diesel engine....................................................................257 7.8.2 Malfunctions of the gearbox with automatic gear change...............................................259 7.8.3 Differential lock malfunctions.......................................................................260 7.8.4 Service brake malfunctions...........................................................................261 7.8.5 Steering system malfunctions.........................................................................262 7.8.6 Tachograph malfunctions..............................................................................263 7.8.7 Outrigger malfunctions...............................................................................264 7.8.8 Suspension locking system malfunctions...............................................................264 7.8.9 Level adjustment system malfunctions.................................................................264 7.8.10 Malfunctions on the carrier electronic system.......................................................265 7.9 Procedure in the event of malfunctions.....................................................................267 7.9.1 Switching the fan thermostat to emergency operation..................................................267 7.9.2 What to do if there is a gearbox malfunction.........................................................268 Error messages on the Gearbox display..................................................................268 Calling up error codes................................................................................269 7.9.3 Emergency operation of the solenoid valves for the outriggers........................................271 Pressure build-up valve................................................................................271 Position and allocation of the solenoid valves.........................................................272 8 Technical information Carrier....................................................................................277 8.1 Technical description of the carrier.......................................................................277 8.1.1 Crane carrier........................................................................................277 8.1.2 Driver's cab.........................................................................................277 8.1.3 Drive units..........................................................................................278 8.1.4 Engine cooling system................................................................................278 8.1.5 Hydraulic system.....................................................................................278 8.1.6 Steering.............................................................................................279 8.1.7 Suspension system....................................................................................279 8.1.8 Outrigger............................................................................................280 8.1.9 Compressed air system................................................................................280 8.1.10 Service brake.......................................................................................281 8.1.11 Parking brake.......................................................................................281 8.1.12 Retarder............................................................................................281 8.1.13 Secondary consumers.................................................................................282 8.1.14 Towing the crane....................................................................................282 8.1.15 Towing a trailer....................................................................................282 8.1.16 Electrical system...................................................................................282 8.2 Technical data.............................................................................................283 8.2.1 Measurements and weights of the truck crane..........................................................284 Dimensions for driving on public roads.................................................................284 Total weight and axle load.............................................................................285 8.2.2 Dimensions and weights of removable parts............................................................285 Spare wheel (additional equipment).....................................................................285 Outrigger..............................................................................................285 8.2.3 Carrier..............................................................................................286 Vehicle engine.........................................................................................286 Power shift gear.......................................................................................286 Distributor gearbox....................................................................................286 Axle lines.............................................................................................286 Steering...............................................................................................286 Tyres..................................................................................................287 Outrigger..............................................................................................287 Vehicle's electrical system............................................................................288 Tools..................................................................................................288 Driving speeds.........................................................................................288 Climbing ability.......................................................................................288 Turning circle radii...................................................................................289 9 Alphabetical index...............................................................................................293 A..............................................................................................................295 B..............................................................................................................295 C..............................................................................................................296 D..............................................................................................................298 E..............................................................................................................300 F..............................................................................................................300 G..............................................................................................................301 H..............................................................................................................301 I..............................................................................................................302 K..............................................................................................................302 L..............................................................................................................302 M..............................................................................................................302 O..............................................................................................................303 P..............................................................................................................304 R..............................................................................................................305 S..............................................................................................................305 T..............................................................................................................307 V..............................................................................................................308 W..............................................................................................................308 Operating instructions Part 2 Superstructure...........................................................................311 Additional pages: Holding brake operation from the crane cab.......................................................313 Validity....................................................................................................... 3 Reasons for this additional information........................................................................ 3 Checking the crane type........................................................................................ 3 Supplement to the operating instructions....................................................................... 4 Operation with the toggle switch............................................................................... 4 Correction sheet: Operating the hand pump for emergency activation Correction for counterweight rigging............315 Validity....................................................................................................... 5 Reason for the correction..................................................................................... 5 Correction Handpump........................................................................................... 5 Correction for counterweight rigging.......................................................................... 6 Additional pages ..................................................................................................317 Validity....................................................................................................... 7 Reasons for this additional information........................................................................ 7 Driving from the crane cab..................................................................................... 8 Mounting counterweight sections on the 1.3 t counterweight section............................................ 9 Information.................................................................................................... 9 Additional page: Guaranteed value specifications ..................................................................323 Validity....................................................................................................... 13 Supplement to the technical data for the superstructure....................................................... 13 Information.................................................................................................... 13 Correction sheets: Telescoping emergency program submenu ..........................................................325 Validity....................................................................................................... 15 Reason for the correction...................................................................................... 15 Contents of the Correction sheets.............................................................................. 15 Correcting..................................................................................................... 15 Starting emergency program..................................................................................... 16 Starting emergency program..................................................................................... 19 Additional pages: Continuous switching for the crane's hydraulic system............................................ 25 Validity....................................................................................................... 25 Reasons for this additional information........................................................................ 25 Changes........................................................................................................ 25 Additional pages: Emergency operation/Emergency program telescoping ...............................................337 Validity....................................................................................................... 27 Reasons for the additional information......................................................................... 27 Additional information......................................................................................... 27 10 Description of the crane section of the truckcrane.............................................................343 10.1 Overview of the operating and display instruments.........................................................343 10.1.1 Overview of the crane section.......................................................................343 10.1.2 Overview of crane cab...............................................................................346 10.1.3 Front instrument panel..............................................................................348 Left-hand insert.......................................................................................348 Centre plug-in module.................................................................................350 Right-hand insert......................................................................................352 SLI plug-in module....................................................................................354 Side plug-in module...................................................................................360 10.1.4 Control consoles....................................................................................362 Left-hand control console..............................................................................362 Right-hand control console.............................................................................363 10.1.5 Control lever configuration.........................................................................364 Version 1 (standard)...................................................................................364 Version 2 (additional equipment)......................................................................365 10.1.6 Crane control plug-in module........................................................................366 Main menu – crane control display......................................................................368 Submenu for counterweight..............................................................................370 Submenu for outrigger/ electronic level/ outrigger pressure indicator..................................372 Submenu for semi-automatic telescoping.................................................................374 Submenu for fully automatic telescoping................................................................375 Submenu for Settings/status display....................................................................376 10.1.7 Behind crane driver´s seat..........................................................................378 10.1.8 Control box for emergency operation without crane control...........................................379 10.1.9 Switch boxes for outrigger/electronic level/outriggerpressure display (additional equipment).......381 Operating instruments for the outrigger................................................................382 Operating instruments for outrigger pressure indicator (additional equipment)..........................382 Operating instruments for electronic level.............................................................382 10.2 Functional description of the display and operating instruments for crane work...........................384 10.2.1 Diesel engine.......................................................................................384 On the instrument panels...............................................................................384 Crane control display..................................................................................385 10.2.2 Crane control.......................................................................................387 Function of operating instruments......................................................................387 Crane control display..................................................................................389 Display elements in main menu..........................................................................389 10.2.3 Outrigger, outrigger pressure indicator, electronic level...........................................391 Display fields on the carrier..........................................................................391 Submenu for Outrigger/electronic level.................................................................393 10.2.4 Counterweight submenu...............................................................................397 Submenu for counterweight, version 1...................................................................397 Submenu for counterweight, version 2...................................................................400 10.2.5 Hoists..............................................................................................403 Main hoist.............................................................................................403 Auxiliary hoist (additional equipment).................................................................404 10.2.6 Slewing gear........................................................................................406 10.2.7 Derricking gear.....................................................................................408 Derricking the lattice extension.......................................................................409 10.2.8 Telescoping gear....................................................................................410 Control consoles.......................................................................................410 Control lever for telescoping..........................................................................410 Telescoping submenu....................................................................................411 10.2.9 Safe load indicator (SLI) .........................................................................420 10.2.10 Hydraulic system...................................................................................430 On the instrument panels...............................................................................430 Control consoles.......................................................................................430 In submenu Monitoring carrier..........................................................................430 In submenu Settings/displays..........................................................................430 10.2.11 Electrics, lighting, windscreen wiper/washing system...............................................432 Electrics..............................................................................................432 Lighting...............................................................................................432 Windscreen wiper/ washing system....................................................................433 10.2.12 Crane cab heating system...........................................................................434 10.2.13 Air-conditioning system (additional equipment).....................................................436 10.2.14 Other operating instruments in the crane cab.......................................................437 Keys...................................................................................................437 Crane cab door.........................................................................................437 Window.................................................................................................438 Seat adjustment........................................................................................440 Fire extinguisher (additional equipment)...............................................................440 10.2.15 Control box for emergency operation without crane control..........................................441 10.3 Functional description of the display and operating elements for driving from inside the cr..............444 10.3.1 Diesel engine.......................................................................................444 10.3.2 Gearbox.............................................................................................445 10.3.3 Axle drive..........................................................................................446 10.3.4 Brakes..............................................................................................448 10.3.5 Steering............................................................................................449 Normal steering mode...................................................................................449 Separate steering......................................................................................449 10.3.6 Other operating instruments.........................................................................450 10.4 Functional description of the safety devices..............................................................451 10.4.1 Safe load indicator (SLI)...........................................................................451 10.4.2 Lowering limit switch...............................................................................453 10.4.3 Lifting limit switch................................................................................454 Overriding lifting limit switch shutdown...............................................................454 10.4.4 Dead man's and seat contact switches................................................................456 11 Crane operation.................................................................................................459 11.1 Checking the truck crane before working with the crane....................................................459 11.1.1 CHECKLIST: Condition for working with a truck crane supported on outriggers.........................459 11.1.2 CHECKLIST: Condition for working with a free on wheels truck crane..................................463 11.1.3 Checking the condition of the hoist rope............................................................468 Checking the reservoir of the windscreen washing system..............................................468 Visual inspection of the entire crane..................................................................468 Checking the mirror settings...........................................................................469 Checking the position of the hoist ropes...............................................................470 Checking the electrical system.........................................................................470 11.1.4 Checking safety equipment...........................................................................471 Checking the safe load indicator.......................................................................471 Checking the lifting limit switch.....................................................................472 Seat contact switch and dead man's switch system......................................................472 Crane control emergency stop Crane control.............................................................473 11.1.5 Preheating the hydraulic oil........................................................................474 When the oil temperature is between –15 C and 0 C:...................................................474 For oil temperatures below –15 C:....................................................................474 11.1.6 Switching off the boom floating position............................................................475 11.1.7 Switching off boom pre-tensioning...................................................................475 11.1.8 Switching off slewing gear freewheel................................................................477 Before slewing.........................................................................................478 11.1.9 Locking/unlocking the superstructure................................................................479 11.2 Starting and stopping the diesel engine from inside the crane cab.........................................481 11.2.1 When starting the engine the first time in the day..................................................481 11.2.2 Start warm diesel engine............................................................................483 Checks on carrier before starting......................................................................483 Switching on the ignition..............................................................................483 Start diesel engine..................................................................................486 11.2.3 Checks after starting the diesel engine.............................................................487 Checks on the instrument panel.........................................................................487 Checks on the Crane control display...................................................................488 11.2.4 Shutting down the diesel engine.....................................................................489 11.3 Operating the safe load indicator (SLI)...................................................................491 11.3.1 Switching on the SLI................................................................................491 To switch on...........................................................................................491 Lamp test on theSLI...................................................................................493 Dimmers for the SLI displays...........................................................................493 11.3.2 Setting rigging mode................................................................................494 Setting via the SLIcode...............................................................................494 Setting using individual components..................................................................494 General instructions...................................................................................495 Sequence during setting................................................................................495 Switching on entry mode................................................................................496 Entering values........................................................................................497 Confirming entry.......................................................................................499 Accepting values.......................................................................................499 Switching over Hoist position lights...................................................................500 11.3.3 Checks before working with the crane................................................................501 11.3.4 During crane work...................................................................................503 Continuous displays...................................................................................503 Optional displays.....................................................................................504 SLI early warning......................................................................................505 SLI shutdown...........................................................................................505 Monitor overall height................................................................................506 Error message..........................................................................................507 Error messages with additional optical displays........................................................508 SLIoverride...........................................................................................509 11.3.5 Monitoring the overall height.......................................................................510 Display current overall height.........................................................................510 Display maximum permissible overall height.............................................................511 Enter maximum permissible overall height...............................................................511 Switching off monitoring of overall height.............................................................512 Display entered height for the crane carrier...........................................................513 Overshooting the maximum permissible overall height....................................................513 Overriding shutdown of overall height..................................................................514 11.4 Crane work with main boom.................................................................................515 11.4.1 External influences during crane operation..........................................................515 Horizontal alignment...................................................................................515 Safedistances.........................................................................................515 Monitoring wind speed without an anemometer............................................................516 Monitoring wind speed with an anemometer..............................................................517 When the maximum allowed wind speed has been exceeded..................................................517 Permissible windload.................................................................................518 Earthing the load......................................................................................519 11.4.2 Permissable slewing ranges and working positions for cranework.....................................520 360 slewing range.....................................................................................520 Working position 0 to the rear........................................................................520 Free-standing truck crane..............................................................................521 11.4.3 Main hoist..........................................................................................522 Switching on the main hoist............................................................................522 Lifting and lowering..................................................................................523 Switching off the main hoist..........................................................................525 11.4.4 Auxiliary hoist (additional equipment)..............................................................526 Switching on the auxiliary hoist:.....................................................................526 Lifting and lowering..................................................................................527 Switching off the auxiliary hoist.....................................................................527 11.4.5 Derricking gear.....................................................................................528 Switching on the derricking gear.......................................................................528 Raising and lowering...................................................................................529 Switching off the derricking gear.....................................................................529 11.4.6 Slewing gear........................................................................................531 Switching on the slewing gear.........................................................................531 Slewing................................................................................................532 Braking slewing movement...............................................................................533 Tracking the slewing gear..............................................................................534 Maximum permissible slewing speed......................................................................534 Switching off the slewing gear........................................................................536 11.4.7 Telescoping gear....................................................................................537 Structure of the chapter...............................................................................537 Description of functioning.............................................................................538 Main boom fixed length, intermediate length, telescoping length........................................539 Telescope status.......................................................................................540 Notes on the telescoping sequence......................................................................543 Checking before the first tele- scoping................................................................543 Switching on telescoping gear..........................................................................544 Function of the control lever..........................................................................544 Switching off telescoping gear.........................................................................546 Example of the procedure for telescoping...............................................................546 Check initial position.................................................................................548 Unlocking the telescoping cylinder.....................................................................553 Extend/retract telescoping cylinder....................................................................556 Locking the telescoping cylinder.......................................................................557 Unlocking the telescopic part..........................................................................561 Telescope telescopic section..........................................................................563 Locking telescope section.............................................................................565 Telescoping the telescopic section to intermediate retracting..........................................569 Lock telescopic section for on- road driving..........................................................569 Telescoping with fully automatic control...............................................................570 Lowering the main boom for maintenance................................................................575 Telescoping the main boom into ahorizontal position..................................................575 11.4.8 Fast speed..........................................................................................577 11.4.9 Special menus on the crane control display..........................................................578 Operating hours meter submenu........................................................................578 Driving gear speeds submenu..........................................................................579 Warning message submenu................................................................................582 Error menu.............................................................................................584 Changing the background colour of the display..........................................................586 11.4.10 Setting a constant engine speed....................................................................587 11.4.11 Inclining crane cab................................................................................588 11.4.12 Cooling the hydraulic oil..........................................................................589 Standard oil cooler....................................................................................589 Additional oil cooler..................................................................................589 11.4.13 Possible movement combinations.....................................................................590 11.5 Driving the truck crane from inside the crane cab.........................................................591 11.5.1 Preparing to drive..................................................................................592 In the driver's cab....................................................................................592 Prerequisites..........................................................................................592 11.5.2 Driving route.......................................................................................593 11.5.3 Operating the gear box..............................................................................593 11.5.4 Steering............................................................................................594 Adapting the steering direction to the superstructure setting..........................................594 Normal steering mode...................................................................................594 Separate steering......................................................................................595 11.5.5 Driving the rigged truck crane......................................................................597 Driving................................................................................................598 Align free on wheels truck crane horizontally..........................................................598 11.5.6 Possible gear changes...............................................................................599 Drive of the second axle line/ longitudinal differential locks.........................................599 Switching off drive/longitudinal differential locks....................................................600 Activating transverse differential locks...............................................................600 Deactivating transverse differential locks.............................................................600 11.5.7 After driving.......................................................................................601 11.6 Work break................................................................................................603 11.6.1 Short work break....................................................................................603 11.6.2 Work breaks lasting more than 8 hours...............................................................603 11.7 Crane cab heating and ventilation.........................................................................605 11.7.1 Heating the crane cab...............................................................................605 Switching heating on/off...............................................................................605 Regulate temperature..................................................................................606 Setting air distribution..............................................................................606 Setting air escape jets................................................................................607 Setting recirculated air/fresh air operation...........................................................608 Fuel tank.............................................................................................608 Storing automatic heating start........................................................................609 Setting automatic heating length.......................................................................610 Switching automatic heating start on/off...............................................................610 Setting remaining time.................................................................................611 Seting time and day....................................................................................611 11.7.2 Ventilating the crane cab...........................................................................612 11.8 Air-conditioning system (additional equipment)............................................................613 11.8.1 To switch on........................................................................................613 11.8.2 Setting the air flow................................................................................614 11.8.3 To switch off.......................................................................................614 11.8.4 Air conditioning....................................................................................615 How to ensure pleasant air-conditioning................................................................615 Dehumidifying the crane cab air........................................................................616 12 Rigging work for outriggers and main boom.......................................................................619 12.1 Checklists for rigging work for crane operation with main boom............................................619 12.1.1 CHECKLIST: Rigging..................................................................................619 12.1.2 CHECKLIST: Unrigging................................................................................622 12.2 Choosing a suitable site..................................................................................624 12.2.1 Load bearing capacity of the ground and the outrigger...............................................624 Outrigger surface area enlarge.........................................................................626 12.2.2 Safe distance from banks and pits...................................................................627 12.2.3 Safe distance from electrical lines.................................................................628 12.2.4 Earthing the truck crane............................................................................631 Earthing the truck crane...............................................................................631 12.3 Outrigger.................................................................................................633 12.3.1 CHECKLIST: Extending the outrigger..................................................................633 12.3.2 CHECKLIST: Retracting the outrigger.................................................................635 12.3.3 Permissible outrigger spans.........................................................................636 Outrigger span 8.10 x 7.00 m...........................................................................637 Outrigger span 8.10 x 6.00 m...........................................................................637 Outrigger span 8.10 x 5.00 m...........................................................................638 Outrigger span 8.10 x 2.32 m...........................................................................638 12.3.4 Preparing the truck crane...........................................................................639 Align horizontally....................................................................................639 Locking the suspension................................................................................639 Switch on/off display field on the carrier.............................................................639 12.3.5 Securing/releasing outrigger beam for crane operations..............................................641 Securing the outrigger beams..........................................................................641 Releasing the outrigger beams.........................................................................642 12.3.6 Extending/retracting the outrigger beams............................................................644 Operation from the carrier.............................................................................644 Operation from the cranecabin.........................................................................646 Setting outrigger spans................................................................................649 12.3.7 Securing outrigger beam for on-road driving.........................................................651 12.3.8 Moving the outrigger pads into working/driving position.............................................652 Moving the outrigger pads into working position........................................................652 Moving the outrigger pads into driving position.......................................................653 12.3.9 Extending/retracting the support cylinder...........................................................654 Operation from the carrier.............................................................................654 Operation from the crane cabin.........................................................................658 12.3.10 Checking the alignment of the truck crane..........................................................661 Electronic level on the carrier........................................................................661 Electronic level on crane control display.............................................................663 12.3.11 Aligning the truck crane horizontally..............................................................665 If the boom is in the boom support.....................................................................665 If the boom israised.................................................................................665 Automatic aligning.....................................................................................665 12.3.12 Outrigger pressure display.........................................................................667 Outrigger pressure display on the carrier.............................................................667 Outrigger pressure display on superstructure...........................................................668 12.4 Rigging work on the main boom.............................................................................669 12.4.1 Hook block on the bumper............................................................................669 Picking up the hook block from the bumper..............................................................669 Attach the hook block to the bumper....................................................................670 12.4.2 Hook block on a separate vehicle....................................................................671 Picking up the hookblock from the separate vehicle....................................................671 Positioning the hook block on the separate vehicle and securing the hoist rope for on- road driving....672 12.4.3 Reeving and unreeving the hoist rope................................................................673 Rope end clamp.........................................................................................673 Reeve the hoist rope..................................................................................675 Lifting limit switch on the main boom..................................................................677 12.4.4 Possible reeving on the main boom for standard design with 6sheaves................................680 12.4.5 Possible reeving on the main boom for additional equipment with 8sheaves...........................683 12.4.6 Anemometer..........................................................................................686 13 Counterweight rigging work......................................................................................689 13.1 Permissible counterweight versions........................................................................689 13.2 Counterweight rigging– version 1.........................................................................691 13.2.1 Counterweight parts and identification..............................................................691 Counterweight parts...................................................................................691 Identification.........................................................................................691 13.2.2 Counterweight versions..............................................................................692 13.2.3 Slinging points on the counterweight sections.......................................................694 13.2.4 CHECKLIST: Rigging the counterweight................................................................695 13.2.5 CHECKLIST: Unrigging the counterweight..............................................................698 13.2.6 Lower 3.3 t counterweight section on the counterweight platform.....................................700 13.2.7 Assembling the counterweight version................................................................701 13.2.8 Counterweight lifting unit..........................................................................703 Checks to be carried out prior to lifting..............................................................703 Recall counterweight sub-menu.........................................................................703 Checking the current hoist unit status................................................................704 Display incorrectstatus.............................................................................705 Extending/ retracting the lifting cylinder.............................................................705 Unlock/lock counterweight.............................................................................708 13.2.9 Removing/installing the 2.0 t counterweight section ontheturntable................................710 Opening the mechanical lock..........................................................................711 Closing the mechanical lock...........................................................................712 13.2.10 Slewing with the rigged counterweight..............................................................713 13.3 Counterweight rigging– version 2.........................................................................715 13.3.1 Counterweight parts and identification..............................................................715 Counterweight parts...................................................................................715 Identification.........................................................................................715 13.3.2 Counterweight versions..............................................................................716 13.3.3 Slinging points on the counterweight sections.......................................................719 Lifting individual counterweight sections.............................................................719 Lifting stacked counterweight sections................................................................720 13.3.4 CHECKLIST: Rigging the counterweight................................................................721 13.3.5 CHECKLIST: Unrigging the counterweight..............................................................724 13.3.6 Lower 3.3 t baseplate on the counterweight platform.................................................727 13.3.7 Check the position of the locking pins..............................................................728 Checking the 1.3 t counterweight section...............................................................728 Check on the 5.0 t and 2.0 t counterweight sections....................................................729 13.3.8 Assembling the counterweight version................................................................730 Procedures.............................................................................................730 Versions that can be installed on the turntable.......................................................731 Combinations that can be differently assembled.......................................................733 13.3.9 Counterweight lifting unit..........................................................................737 Check the position of the locking pins.................................................................737 Recall counterweight sub-menu........................................................................738 Checking the current hoist unit status...............................................................739 Display incorrect status.............................................................................740 Extending/ retracting the lifting cylinder.............................................................740 Unlock/lock counterweight............................................................................742 13.3.10 Removing/installing the counterweight sections ontheturntable....................................744 Installing counterweight sections......................................................................744 Uninstalling counterweight sections...................................................................745 13.3.11 Locking/unlocking the 2.0 t and 5.0 t counterweight sections.......................................746 Locking counterweight sections.........................................................................746 Unlocking the counterweight sections...................................................................747 13.3.12 Slewing with the rigged counterweight..............................................................748 14 Malfunctions on the superstructure..............................................................................751 14.1 Superstructure emergency stop device......................................................................751 Turning off the diesel engine..............................................................................751 Crane control emergency stop switch........................................................................752 14.2 What to do in the event of a malfunction when working with the crane......................................753 Load cannot be lowered.....................................................................................753 14.3 Electrical system.........................................................................................755 14.3.1 Plug-in modules and consoles........................................................................755 14.3.2 Fuses...............................................................................................757 Fuses on turntable.....................................................................................757 Fuses in crane cab.....................................................................................759 Fuses on input- output bedplates.......................................................................761 14.3.3 SLI fuses...........................................................................................762 Replacing fuses........................................................................................762 14.4 Troubleshooting and remedy................................................................................765 14.4.1 Vehicle engine malfunctions during the crane operations.............................................765 14.4.2 Malfunctions when driving from crane cab............................................................765 14.4.3 Main hoist malfunctions.............................................................................766 14.4.4 Auxiliary hoist malfunctions........................................................................768 14.4.5 Derricking gear malfunctions........................................................................770 14.4.6 Telescoping gear malfunctions.......................................................................772 Error messages concerning telescoping gear.............................................................774 14.4.7 Slewing gear malfunctions...........................................................................777 14.4.8 Malfunctions at the counterweight hoist unit........................................................778 14.4.9 Hydraulic system/hydraulic oil cooler malfunctions..................................................779 14.4.10 Outrigger malfunctions.............................................................................779 14.4.11 Crane control malfunctions.........................................................................780 14.4.12 Malfunctions on the SLI............................................................................781 Other malfunctions on the SLI..........................................................................781 SLI error message table................................................................................782 Switch off sensor/ indicator during malfunction........................................................790 Check function of remaining emergency operation........................................................791 Take over telescoping from the values..................................................................792 Checking SLI lines and connections.....................................................................793 14.4.13 Emergency retract operation........................................................................795 Check prior to every emergency operation...............................................................795 Procedure for retracting...............................................................................796 Mechanical emergency operation.........................................................................797 Hydraulic emergency operation..........................................................................799 14.5 Error messages on Crane control display...................................................................811 Crane control program version..............................................................................811 14.5.1 Meaning of displayed symbols........................................................................811 Symbols for Devices...................................................................................812 Symbols for Groups....................................................................................813 Symbols for Types of errors...........................................................................814 Index displays allocation.............................................................................815 Control leves error table..............................................................................822 Locking system error table.............................................................................823 Error messages via Can-Bus.............................................................................826 14.5.2 Connections for the crane control control units.....................................................829 Control units connections position.....................................................................829 Layout of connections.................................................................................830 Truck crane for defective control unrigging units......................................................832 Example for unrigging with three control units.........................................................832 Replacing control units................................................................................834 14.5.3 Sub-menu emergency program telescoping..............................................................836 Starting emergency program............................................................................836 Emergency program display and operating elements.......................................................837 Retracting with an error on the length indicator.......................................................839 Retracting with an error on the proximity switch.......................................................843 Emergency program end.................................................................................845 Table for approaching the locking points...............................................................845 14.5.4 Enter telescope status after emergency operation....................................................846 14.5.5 Emergency operation in case of the crane control failure............................................849 Truck crane preparation................................................................................849 Emergency operation switch on.........................................................................850 Operating driving gears................................................................................850 Movements stopping....................................................................................852 Stopping the movent in case of an emergency............................................................852 14.6 Hydraulic emergency stop according to ZH1/461.............................................................853 14.6.1 Important instructions for hydraulic emergency operation............................................853 14.6.2 Functioning and accessories.........................................................................855 14.6.3 Establishing hose connections.......................................................................856 For the emergency operation with the transformer.......................................................856 For the emergency operation with the hand pump.........................................................858 14.6.4 Establishing required hydraulic circuits............................................................859 Taps connecting points.................................................................................859 Additional connections for the main hoist..............................................................861 Additional connections for the slewing gear............................................................862 14.6.5 Executing emergency operation.......................................................................863 Emergency operation main hoist movement................................................................864 Emergency operation driving derricking gear............................................................864 Emergency operation driving the slewing gear...........................................................866 14.6.6 After the emergency operation.......................................................................867 Establishing hydraulic circuits for crane operation ..................................................867 Loosen established hose connections....................................................................867 15 Technical information for superstructure........................................................................871 15.1 Technical description of the superstructure...............................................................871 15.1.1 Turntable...........................................................................................871 15.1.2 Crane operator's cab................................................................................871 15.1.3 Crane engine and hydraulic system...................................................................872 15.1.4 Control system......................................................................................872 15.1.5 Main boom...........................................................................................873 15.1.6 Telescoping gear....................................................................................873 15.1.7 Hoists..............................................................................................874 15.1.8 Slewing gear........................................................................................874 15.1.9 Derricking cylinder.................................................................................875 15.1.10 Electrical system.................................................................................875 15.1.11 Counterweight......................................................................................875 15.1.12 Safety equipment...................................................................................876 15.2 Technical data............................................................................................877 15.2.1 Maximum load bearing capacity (DIN/ISO/EN)..........................................................877 15.2.2 Max. lifting capacity (85%)........................................................................877 15.2.3 Dimensions, weights and axle load...................................................................878 Dimensions when driving on public roads................................................................878 Total weight and axle load.............................................................................879 15.2.4 Dimensions and weights of removable parts...........................................................879 Hook blocks and hook tackle............................................................................879 Counterweight sections – version 1....................................................................880 Counterweight sections – version2....................................................................880 Counterweight versions – version1.....................................................................881 Counterweight versions – version2.....................................................................882 15.2.5 Technical data for superstructure...................................................................884 Main hoist.............................................................................................884 Auxiliary hoist (additional equipment)................................................................884 Slewing gear...........................................................................................884 Derricking gear........................................................................................884 Main boom..............................................................................................885 Working speed and times without load...................................................................885 16 Alphabetical index..............................................................................................889 A..............................................................................................................891 B..............................................................................................................891 C..............................................................................................................892 D..............................................................................................................894 E..............................................................................................................896 F..............................................................................................................896 G..............................................................................................................897 H..............................................................................................................897 I..............................................................................................................898 K..............................................................................................................898 L..............................................................................................................898 M..............................................................................................................898 O..............................................................................................................899 P..............................................................................................................900 R..............................................................................................................901 S..............................................................................................................901 T..............................................................................................................903 V..............................................................................................................904 W..............................................................................................................904
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