Grove Crane GMK4100 Operating Manual Part 1 Driving 3112344 – PDF DOWNLOAD

Description

Grove Crane GMK4100 Operating Manual Part 1 Driving 3112344 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK4100 Operating Manual Part 1 Driving 3112344 – PDF DOWNLOAD

Language : English
Pages : 832
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Grove Crane GMK4100 Operating Manual Part 1 Driving 3112344 – PDF DOWNLOAD

Intended use:

• The GMK 4100 is a state-of-the-art truck crane, designed in accordance with
  approved safety regulations. Nevertheless, the operator or third parties can
  still be endangered and the crane or other property put at risk while using it.
  Modifications may only be made to the truck crane following the approval
  of Manitowoc Crane Group Germany GmbH.
• The GMK 4100 truck crane may only be used in a perfect technical condition
  as intended and with due attention paid to safe operation and possible hazards.
  Any malfunctions that could impair safety must be eliminated immediately.
  The GMK 4100 truck crane may only be operated without the corresponding
  special equipment within the permitted temperature range; àTechnical
  information on the carrier, p. 8 – 1.
• The GMK 4100 truck crane is designed solely for lifting loads which are
  within the permitted GMK 4100 lifting capacities. The load must be slung as
  prescribed to a hook block which is positioned vertically over the load prior
  to lifting.

Intended use also includes
– Observing the entire crane documentation, consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove Crane GMK4100 Operating Manual Part 1 Driving 3112344 – PDF DOWNLOAD

1 Overview......................................................................................  7
	1.1 Identification..........................................................................  7
	1.2 EC Declaration of Conformity............................................................ 11
	1.3 Documentation supplied.................................................................. 12
	1.4 Information about the operating instructions............................................ 13
		1.4.1 What do the symbols used mean?.................................................... 13
		1.4.2 How are the operating instructions structured?.................................... 15
			Division............................................................................ 15
			Structure of the chapters........................................................... 15
			Structure of the pages.............................................................. 16
		1.4.3 How do I find the information I need?............................................. 17
			Cross-references example............................................................ 18
		1.4.4 What information is available for operations planning?............................ 20
	1.5 Conversion table for US measurements.................................................... 21
2 Basic safety instructions..................................................................... 25
	2.1 Intended use............................................................................ 25
		2.1.1 Improper use...................................................................... 26
	2.2 Organisational measures................................................................. 27
	2.3 Qualifications of the personnel......................................................... 29
	2.4 Safety instructions for driving the truck crane......................................... 30
	2.5 Safety instructions for crane operation................................................. 31
3 Operating elements for driving................................................................ 35
	3.1 Overview of the operating elements...................................................... 35
		3.1.1 On the outside of the truck crane................................................. 36
		3.1.2 Driver's cab...................................................................... 38
			Overview............................................................................ 38
			Behind the cover.................................................................... 40
		3.1.3 Instrument panel.................................................................. 41
			Left / right........................................................................ 41
			Middle.............................................................................. 42
		3.1.4 Display, driver's cab............................................................. 44
		3.1.5 Steering column / steering wheel.................................................. 45
		3.1.6 Transmission operating elements................................................... 46
		3.1.7 Tachograph........................................................................ 47
		3.1.8 ECOS control unit................................................................. 48
		3.1.9 ECOS display – main menu.......................................................... 50
		3.1.10 ECOS display – submenus.......................................................... 52
			Level adjustment system submenu..................................................... 52
			Settings submenu.................................................................... 54
			Operating hours submenu............................................................. 55
			Warning submenu..................................................................... 55
			Transmission emergency program submenu.............................................. 56
			Error submenu....................................................................... 57
		3.1.11 Heating / Air-conditioning system................................................ 58
			Standard heating system............................................................. 58
			Auxiliary heater.................................................................... 59
		3.1.12 Sockets for hand-held control.................................................... 60
		3.1.13 Outrigger control units.......................................................... 61
	3.2 Short description of the operating elements............................................. 63
		3.2.1 Definition of positional references............................................... 63
			Basic rules......................................................................... 63
			Switches and buttons................................................................ 64
		3.2.2 General information on the operating elements..................................... 64
		3.2.3 General rules for buttons and symbols on the display.............................. 65
		3.2.4 Engine............................................................................ 66
			Steering column..................................................................... 66
			Multipurpose switch................................................................. 66
			Instrument panel.................................................................... 67
		3.2.5 Electrical system................................................................. 68
		3.2.6 ECOS crane control................................................................ 68
			Control unit........................................................................ 68
		3.2.7 Transmission...................................................................... 71
			Transmission display................................................................ 71
			ECOS display........................................................................ 71
			Operating elements.................................................................. 72
			Instrument panel.................................................................... 73
		3.2.8 Transfer case..................................................................... 75
			Main menu........................................................................... 75
		3.2.9 Final drive....................................................................... 76
		3.2.10 Brakes........................................................................... 77
			Service brake....................................................................... 77
			Parking brake....................................................................... 78
			Additional brakes................................................................... 79
		3.2.11 Steering / separate steering..................................................... 80
			ECOS display........................................................................ 80
			Driver's door....................................................................... 80
		3.2.12 Suspension....................................................................... 81
		3.2.13 Lighting / windscreen wipers / horn.............................................. 82
			Steering column..................................................................... 82
			Instrument panel.................................................................... 82
			Roof................................................................................ 84
		3.2.14 Level adjustment system.......................................................... 84
		3.2.15 Tachograph / speedometer......................................................... 86
			Tachograph.......................................................................... 86
			Speedometer......................................................................... 86
		3.2.16 Diagnostics...................................................................... 87
			Displays / submenu.................................................................. 87
		3.2.17 On-board computer................................................................ 88
		3.2.18 Push-up roof..................................................................... 90
		3.2.19 Windows, doors, keys............................................................. 90
			Window winder....................................................................... 90
			Doors............................................................................... 91
			Keys................................................................................ 91
		3.2.20 Front flap....................................................................... 92
		3.2.21 Storage compartment.............................................................. 92
4 Starting / turning off the engine for driving................................................. 95
	4.1 Starting the engine from the driver's cab............................................... 95
		4.1.1 CHECKLIST: Starting the engine.................................................... 95
		4.1.2 CHECKLIST: if the temperature is low.............................................. 98
		4.1.3 Ladders and access ladders........................................................ 99
			Access ladders...................................................................... 99
			Ladders............................................................................. 99
		4.1.4 Refuelling........................................................................101
		4.1.5 Checks before starting the engine.................................................102
			On the hydraulic tank...............................................................102
			Battery master switch...............................................................102
			Checking the hand-held control......................................................103
		4.1.6 Switching on the ignition.........................................................103
		4.1.7 Lamp test / equalisation of the switching states..................................104
			Lamp test...........................................................................104
			Equalisation of the switching states................................................105
		4.1.8 Display – setting the brightness..................................................106
		4.1.9 To start the engine...............................................................107
			Without flame start system..........................................................108
			With flame start system.............................................................109
		4.1.10 Checks after starting the engine.................................................110
		4.1.11 Control elements.................................................................111
			Instrument panel....................................................................111
			ECOS display........................................................................112
			Display, driver's cab...............................................................112
		4.1.12 Setting the idling speed.........................................................113
	4.2 Turning off the engine..................................................................115
		4.2.1 On the ignition lock / with hand-held control.....................................115
			After turning off...................................................................115
		4.2.2 With emergency stop switches......................................................116
			Resetting the emergency stop switch.................................................116
	4.3 Air intake inhibitor....................................................................117
		Releasing the air intake inhibitor......................................................117
5 Driving.......................................................................................121
	5.1 Before driving..........................................................................121
		5.1.1 CHECKLIST: inspections before on-road driving.....................................121
		5.1.2 Checking the condition of the truck crane.........................................126
			Windscreen washing system...........................................................126
			Electrical system...................................................................126
			Adjusting the mirrors...............................................................127
			Warning plates for vehicle width....................................................128
			Displaying the vehicle height.......................................................128
			Supply pressure.....................................................................129
			Parking brake.......................................................................130
		5.1.3 Adjusting the seats and steering column...........................................131
			Driver's seat.......................................................................131
			Passenger's seat....................................................................132
			Adjusting the steering column.......................................................133
		5.1.4 Switching the suspension on / off.................................................134
			Opening the submenu.................................................................134
			Switching on the suspension.........................................................135
			To switch off the suspension........................................................135
		5.1.5 Adjusting the tachograph..........................................................136
			Prerequisites.......................................................................136
			In the event of malfunctions........................................................136
			Adjusting the tachograph............................................................137
			Additional displays.................................................................140
		5.1.6 Displaying the operating hours....................................................141
		5.1.7 Settings / displays with the on-board computer....................................142
			Operation...........................................................................142
			Overview............................................................................143
			Inspection information..............................................................143
			Error information...................................................................144
			Alarm clock.........................................................................144
			Language............................................................................145
			Settings............................................................................145
			Diagnostics.........................................................................146
	5.2 Operating the transmission..............................................................149
		5.2.1 Switching on......................................................................149
		5.2.2 Switching the transmission to neutral position....................................150
		5.2.3 Changing the operating mode.......................................................150
			Change-over to automatic mode.......................................................150
			Change-over to manual mode..........................................................150
		5.2.4 Display of the selected gears.....................................................151
		5.2.5 Selecting the direction of travel and starting gear...............................151
			Selecting the driving direction.....................................................151
			Selecting the starting gear.........................................................152
		5.2.6 Starting..........................................................................153
		5.2.7 Driving and changing gears........................................................154
			In automatic operating mode.........................................................154
			In manual operating mode............................................................155
		5.2.8 Changing the driving direction....................................................156
			Quick change of gear................................................................156
		5.2.9 Stopping..........................................................................157
			Stopping for a long period of time..................................................157
		5.2.10 On the roller type dynamometer...................................................157
	5.3 Driving and turning off the truck crane.................................................159
		5.3.1 Inspections while driving.........................................................159
			Immediately after you start to move.................................................159
			While driving.......................................................................160
		5.3.2 Tempomat..........................................................................161
			Switching on........................................................................161
			Switching off.......................................................................162
		5.3.3 Temposet..........................................................................163
			Switching on........................................................................163
			Switching off.......................................................................163
		5.3.4 Driving downhill..................................................................164
			Starting............................................................................164
			Inspections when driving downhill...................................................164
			Downshifting........................................................................165
			Additional brakes...................................................................166
		5.3.5 Driving uphill....................................................................167
			Starting............................................................................167
			Driving.............................................................................167
		5.3.6 Warning submenu...................................................................168
			Meaning of the symbols..............................................................168
			Exiting the submenu.................................................................169
		5.3.7 Error submenu.....................................................................170
		5.3.8 Messages on the on-board computer display.........................................170
			Warnings............................................................................171
			Warning messages....................................................................172
			Error messages......................................................................173
			Information.........................................................................175
		5.3.9 Turning off the truck crane.......................................................178
			Secure against rolling away.........................................................178
			When stationary for more than 8hours...............................................179
	5.4 Off-road driving........................................................................181
		Adjustments to the transmission.........................................................181
		Connections.............................................................................181
		Changing the vehicle level..............................................................181
		Rocking the vehicle free and towing.....................................................181
		5.4.1 Transfer case – off-road gear on / off............................................182
			Neutral position....................................................................182
		5.4.2 Longitudinal and transverse differential locks....................................183
		5.4.3 Operation of the level adjustment system..........................................185
			Opening the submenu.................................................................185
			Setting the on-road level...........................................................186
			Pre-selecting suspension struts.....................................................186
			Changing the vehicle level..........................................................187
			Viewing the current inclination.....................................................187
			Exiting the submenu.................................................................188
		5.4.4 Freeing the truck crane stuck in terrain..........................................189
			Rocking the truck crane free........................................................189
			Towing free forwards................................................................190
			Towing free in reverse gear.........................................................190
		5.4.5 Separate steering.................................................................191
			Switching to separate steering......................................................191
			Steering............................................................................192
			Switching to normal steering mode...................................................193
	5.5 Heating and air-conditioning system.....................................................195
		5.5.1 Standard heating system...........................................................195
			Switching on........................................................................195
			Heating.............................................................................195
			Air distribution....................................................................196
			Examples............................................................................197
			Switching off.......................................................................197
		5.5.2 Air-conditioning system...........................................................198
			Warnings............................................................................198
			Switching on / off..................................................................198
			Cooling.............................................................................199
			Drying..............................................................................199
		5.5.3 Auxiliary heater..................................................................200
			Switching on........................................................................200
			Temperature.........................................................................201
			Setting the day and time............................................................201
			Storing the heating start...........................................................202
			Setting the heating period..........................................................203
			Switching the heating start on and off..............................................203
			Switching off.......................................................................204
			Setting the remaining time..........................................................204
	5.6 Towing a trailer........................................................................205
		Effects on the axle loads...............................................................205
		Coupling the trailer....................................................................206
		Connecting the supply lines.............................................................207
		Removing the supply lines...............................................................208
		Uncoupling the trailer..................................................................208
		Checking the braking force..............................................................210
6 Driving modes.................................................................................213
	6.1 Driving modes...........................................................................213
		Information on the axle loads...........................................................213
		6.1.1 Information on how to use the tables..............................................214
		6.1.2 Table for a maximum axle load of 12 t.............................................215
			For 14.00 R25 tyres.................................................................215
			For 16.00 R25 tyres.................................................................216
			For 20.5 R25 tyres..................................................................217
		6.1.3 Maximum permitted speeds with an axle load of over 12 t...........................218
	6.2 Rigging work for driving with a trailer.................................................219
		6.2.1 Switching on the slewing gear freewheel...........................................220
		6.2.2 Switching on boom floating position...............................................221
		6.2.3 Switching on boom pre-tensioning..................................................222
		6.2.4 Switching the superstructure driving lights on / off..............................224
			Switching off.......................................................................224
			Switching on........................................................................224
7 Malfunctions in driving mode..................................................................227
	7.1 Emergency stop switch...................................................................227
	7.2 What to do when a malfunction occurs in road traffic....................................229
	7.3 Towing the truck crane..................................................................231
		7.3.1 Towing in the event of engine or transmission damage..............................232
			Compressed-air supply...............................................................232
			Electric power supply...............................................................232
			On the transmission.................................................................233
			Axle drives.........................................................................234
			Transfer case.......................................................................234
			Parking brake.......................................................................234
			Towing the truck crane out of the danger area.......................................235
		7.3.2 Starting to tow...................................................................236
	7.4 Wheels and tyres........................................................................237
		7.4.1 Wheel change......................................................................237
			Removing a damaged wheel............................................................238
			On the spare wheel holder...........................................................238
			Mounting a wheel....................................................................239
		7.4.2 Filling the tyres yourself........................................................241
			Connecting the filling hose.........................................................241
			Filling the tyres...................................................................242
			Removing the filling hose...........................................................242
	7.5 Fuses...................................................................................243
		Notes on changing fuses.................................................................243
		7.5.1 Fuses in the driver's cab.........................................................244
			F1 to F 41..........................................................................244
			A1 to A3............................................................................246
		7.5.2 Fuses in the battery box..........................................................248
	7.6 Finding and eliminating malfunctions....................................................249
		7.6.1 Malfunctions on the engine........................................................249
		7.6.2 Malfunctions on the transmission..................................................251
		7.6.3 Service brake malfunctions........................................................252
		7.6.4 Steering malfunctions.............................................................253
		7.6.5 Transfer case malfunctions........................................................253
		7.6.6 Malfunctions in the differential locks............................................254
		7.6.7 Malfunctions in the hydraulic system / hydraulic oil cooler.......................254
		7.6.8 Malfunctions on the suspension....................................................255
		7.6.9 Malfunctions on the level adjustment system.......................................255
		7.6.10 Malfunctions on the ECOS carrier.................................................256
			ECOS program version................................................................256
			General malfunctions................................................................256
			Error messages......................................................................257
			Exiting the submenu.................................................................258
			On the control units................................................................259
	7.7 Procedure in the event of malfunctions..................................................261
		7.7.1 Switching on emergency operation in coolant circuit...............................261
		7.7.2 Procedure in the event of malfunctions to the transmission and engine.............262
			Engine..............................................................................262
			Transmission........................................................................263
			Transmission emergency program submenu..............................................264
			Switching gears mechanically in emergency mode......................................267
			ID number of the transmission.......................................................271
8 Technical information on the carrier..........................................................275
	8.1 Technical data..........................................................................275
		8.1.1 Dimensions and weights of the truck crane, axle loads.............................276
			Dimensions..........................................................................277
			Weight and axle loads...............................................................277
		8.1.2 Dimensions and weights of removable parts.........................................278
			Spare wheel.........................................................................278
			Outriggers..........................................................................278
		8.1.3 Carrier...........................................................................279
			Engine..............................................................................279
			Transmission........................................................................279
			Transfer case.......................................................................279
			Axle lines..........................................................................279
			Steering............................................................................279
			Tyres...............................................................................279
			Electrical system...................................................................280
			Tools...............................................................................280
			Towing couplings....................................................................280
			Outriggers..........................................................................280
			Driving speeds......................................................................281
			Climbing ability....................................................................281
			Turning circle radiuses.............................................................281
9 Index.........................................................................................285
	A...........................................................................................287
	B...........................................................................................287
	C...........................................................................................288
	D...........................................................................................289
	E...........................................................................................291
	F...........................................................................................293
	H...........................................................................................293
	I...........................................................................................294
	K...........................................................................................294
	L...........................................................................................295
	M...........................................................................................295
	O...........................................................................................296
	P...........................................................................................297
	R...........................................................................................297
	S...........................................................................................298
	T...........................................................................................299
	V...........................................................................................301
	W...........................................................................................301
10 Operating elements for crane operation.......................................................311
	10.1 Overview of the operating elements.....................................................311
		10.1.1 On the outside of the truck crane................................................312
		10.1.2 Crane cab........................................................................314
		10.1.3 Front panel......................................................................316
		10.1.4 Side panel.......................................................................317
			Bottom..............................................................................317
			Top.................................................................................318
			Standard heating system.............................................................321
			Auxiliary water heater..............................................................322
			Auxiliary air heater................................................................323
		10.1.5 Control panels...................................................................324
			Left................................................................................324
			Right...............................................................................325
		10.1.6 Control lever assignment.........................................................326
			Version 1...........................................................................326
			Version 2...........................................................................327
		10.1.7 ECOS control unit................................................................328
		10.1.8 ECOS display – main menu.........................................................330
		10.1.9 ECOS display – submenus..........................................................332
			Counterweight submenu...............................................................332
			Slewing gear / Houselock submenu....................................................333
			Outriggers submenu..................................................................334
			Telescoping submenu.................................................................336
			Power unit speeds submenu...........................................................338
			Monitoring submenu..................................................................339
			Settings submenu....................................................................340
			Operating hours submenu.............................................................342
			Warning submenu.....................................................................343
			Error submenu.......................................................................345
			Working range limitation submenu....................................................346
			Driving submenu.....................................................................348
		10.1.10 SLI control unit................................................................350
		10.1.11 SLI display – main menu.........................................................352
		10.1.12 SLI display – submenus..........................................................353
			Enter rigging mode submenu..........................................................353
			Monitoring submenu..................................................................354
			Rigging mode monitoring submenu.....................................................356
			Lifting capacity table submenu......................................................357
			Working range submenu...............................................................358
			Error submenu.......................................................................359
			Settings submenu....................................................................361
		10.1.13 Hand-held control...............................................................362
			Outriggers control panel............................................................363
		10.1.14 Outrigger control units.........................................................364
			Outriggers..........................................................................365
			Outrigger pressure display..........................................................365
			Inclination display.................................................................365
	10.2 Short description of the operating elements............................................367
		10.2.1 Definition of positional references..............................................367
			Basic rule..........................................................................367
			Switch..............................................................................368
		10.2.2 General rules for buttons and symbols on the display.............................368
		10.2.3 Engine for crane operation.......................................................369
			Side panel..........................................................................369
			ECOS display........................................................................370
		10.2.4 Engine for driving...............................................................371
			Side panel..........................................................................371
			Outriggers submenu..................................................................371
		10.2.5 Seat contact switch and dead man's switch........................................372
		10.2.6 ECOS crane control...............................................................373
			Control unit........................................................................373
		10.2.7 Outriggers.......................................................................376
			Hand-held control...................................................................376
			In the outriggers submenu...........................................................377
			In the settings submenu.............................................................378
			On the outrigger control units......................................................379
		10.2.8 Inclination displays.............................................................381
		10.2.9 Outrigger pressure displays......................................................382
			Outriggers submenu..................................................................382
			Outrigger control units.............................................................382
		10.2.10 Anemometer display..............................................................382
		10.2.11 Counterweight submenu...........................................................383
			Counterweight submenu...............................................................383
		10.2.12 Main hoist......................................................................386
		10.2.13 Auxiliary hoist.................................................................388
		10.2.14 Slewing gear....................................................................389
			Submenu.............................................................................389
		10.2.15 Derricking gear.................................................................391
		10.2.16 Telescoping mechanism...........................................................392
			Control panels......................................................................392
			Submenu.............................................................................393
			In the settings submenu.............................................................397
		10.2.17 Hydraulic system................................................................399
		10.2.18 Houselock.......................................................................400
		10.2.19 Safe load indicator (SLI).......................................................401
			Control unit........................................................................401
			Main menu...........................................................................403
			Enter rigging mode submenu..........................................................404
			Monitoring submenu..................................................................407
			Lifting capacity table submenu......................................................411
			Working range submenu...............................................................411
			Other...............................................................................412
		10.2.20 Electrical system...............................................................413
		10.2.21 Lighting, windscreen wiper / washing system.....................................413
			Lighting............................................................................413
			Windscreen wiper/ washing system...................................................415
		10.2.22 Hand-held control...............................................................416
			Sockets for hand- held control......................................................416
			Engine control panel................................................................417
			Horn................................................................................417
			Outriggers control panel............................................................418
		10.2.23 Diagnostics.....................................................................420
		10.2.24 Windows, doors, keys............................................................421
			Windows.............................................................................421
			Crane cab door......................................................................421
			Keys................................................................................422
	10.3 Short description of the operating elements – driving from the crane cab...............423
		10.3.1 Driving submenu..................................................................423
		10.3.2 Engine for driving...............................................................424
		10.3.3 Transmission.....................................................................425
		10.3.4 Final drive......................................................................426
		10.3.5 Brakes...........................................................................427
			Side panel..........................................................................427
			ECOS display........................................................................427
		10.3.6 Steering.........................................................................428
			Normal steering.....................................................................429
			Separate steering...................................................................429
11 Starting / turning off the engine – for crane operation......................................433
	11.1 Starting the engine – from the crane cab...............................................433
		11.1.1 CHECKLIST: Starting the engine...................................................433
		11.1.2 CHECKLIST: If the temperature is low.............................................436
		11.1.3 Refuelling.......................................................................437
			For standard equipment..............................................................437
			With additional equipment...........................................................438
		11.1.4 Inspections before starting the engine...........................................439
			On the hydraulic tank...............................................................439
			Battery master switch...............................................................439
			Checking the hand-held control......................................................440
		11.1.5 Switch on the ignition...........................................................440
		11.1.6 Lamp test / equalisation of the switching states.................................441
			Lamp test...........................................................................441
			Equalisation of the switching states................................................442
		11.1.7 Set brightness of display........................................................443
		11.1.8 To start the engine..............................................................444
			Without flame start system..........................................................444
			With flame start system.............................................................445
		11.1.9 Inspections after starting the engine............................................446
		11.1.10 Monitoring submenu..............................................................447
		11.1.11 Setting the idling speed........................................................448
	11.2 Starting the engine – with the hand-held control.......................................449
		Prerequisites...........................................................................449
		To start the engine.....................................................................449
	11.3 Turning off the engine.................................................................451
		11.3.1 During normal operation, with the ignition lock / with the hand- held control....451
			After parking.......................................................................451
		11.3.2 In emergencies, with the emergency-stop switches.................................452
			Resetting the emergency stop switch.................................................452
	11.4 Air intake inhibitor...................................................................453
		Releasing the air intake inhibitor......................................................453
12 Crane operation..............................................................................457
	12.1 Before crane operation.................................................................457
		12.1.1 CHECKLIST: Inspections prior to crane operation..................................457
		12.1.2 Checking the condition of the truck crane........................................461
			Tank for windscreen washing system..................................................461
			Auxiliary heater – tank.............................................................461
			Visual inspection...................................................................462
			Checking the position of the hoist ropes............................................462
			Checking the electrical system......................................................463
		12.1.3 Adjusting the crane cab seat and front panel.....................................463
			Crane cab seat......................................................................463
			Front panel.........................................................................464
		12.1.4 Checking the safety devices......................................................465
			Safe load indicator.................................................................465
			Lifting limit switch................................................................465
			Emergency stop switch...............................................................466
			Seat contact switch.................................................................467
		12.1.5 Earthing the load................................................................468
		12.1.6 Preheating the hydraulic oil.....................................................469
		12.1.7 Switching the houselock on / off.................................................470
			Switching on the houselock..........................................................470
			Switching off the houselock.........................................................472
	12.2 Operation of the safe load indicator...................................................473
		12.2.1 Switching on the SLI.............................................................474
			Switching on........................................................................474
			Brightness of the displays..........................................................476
		12.2.2 Entering the rigging mode........................................................477
			Entering individual components......................................................478
			Entering the SLI code...............................................................481
			Entering the reeving................................................................482
			Accepting the rigging mode..........................................................482
		12.2.3 Inspections prior to crane operation.............................................484
			Opening the submenu.................................................................484
			Inspections.........................................................................485
		12.2.4 Displays during crane operation..................................................487
		12.2.5 SLI early warning................................................................490
		12.2.6 SLI shutdown.....................................................................490
			Shutdown due to overload............................................................490
		12.2.7 Display in the event of errors...................................................492
		12.2.8 SLI override.....................................................................493
		12.2.9 Displaying the lifting capacity tables...........................................494
		12.2.10 Entering the time / date........................................................496
	12.3 Crane operation with main boom.........................................................497
		12.3.1 Checks during crane operation....................................................497
			Horizontal alignment................................................................497
			Safe distances......................................................................497
			Checking the wind speed.............................................................498
		12.3.2 Permissible slewing ranges and working positions.................................499
			360 slewing range..................................................................499
			0 to the rear working position.....................................................499
			180 to the front rigging position..................................................500
			Free-on-wheels working position.....................................................500
		12.3.3 Main hoist.......................................................................501
			Switching on the main hoist.........................................................502
			Lifting and lowering................................................................502
			Switching off the main hoist........................................................503
		12.3.4 Auxiliary hoist..................................................................504
			Switching on the auxiliary hoist....................................................504
			Lifting and lowering................................................................505
			Switching off the auxiliary hoist...................................................506
		12.3.5 Lifting limit switch and lowering limit switch...................................507
			Lifting limit switch................................................................507
			Lowering limit switch...............................................................509
		12.3.6 Derricking gear..................................................................510
			Switching on the derricking gear....................................................510
			Raising and lowering the boom.......................................................511
			Switching off the derricking gear...................................................512
			Lowering the main boom to a horizontal position.....................................512
		12.3.7 Telescoping mechanism............................................................513
			Overview............................................................................514
			Telescoping process................................................................514
			Assignment for display..............................................................516
			Fixed length, intermediate length, telescoping length...............................518
			Telescoping.........................................................................519
			Telescoping sequence................................................................519
			Inspections prior to starting operations............................................520
			Switching on the telescoping mechanism..............................................521
			Function of the control lever.......................................................521
			Switching off the telescoping mechanism.............................................523
			Manual telescoping.................................................................524
			Checking the initial position.......................................................524
			Unlocking the telescoping cylinder................................................527
			Extending / retracting the telescoping cylinder.....................................529
			Locking the telescoping cylinder....................................................530
			Unlocking the telescopic section...................................................531
			Telescoping the telescopic section..................................................533
			Locking the telescopic section......................................................534
			Locking the telescopic section for on-road driving..................................535
			Telescopic extension with teleautomation............................................536
			Telescoping the main boom in horizontal position....................................541
		12.3.8 High speed.......................................................................542
			Switch on function..................................................................542
			Derricking gear / Telescoping mechanism.............................................542
			Hoists..............................................................................543
		12.3.9 Slewing gear.....................................................................544
			Switching on the slewing gear.......................................................544
			Slewing.............................................................................544
			Slewing to 0 or 180...............................................................546
			Braking the slewing movement........................................................547
			Slewing gear freewheel..............................................................547
			Switching off the slewing gear......................................................548
		12.3.10 Possible movement combinations..................................................548
		12.3.11 Hydraulic oil cooling...........................................................549
	12.4 Settings and displays for crane operation..............................................551
		12.4.1 Inclining the crane cab..........................................................551
		12.4.2 Setting the idling speed.........................................................551
		12.4.3 Adjusting the stroke interval of the windscreen wiper............................552
		12.4.4 Limiting the power unit speeds...................................................552
		12.4.5 Setting the characteristic curve for the control levers..........................554
		12.4.6 Critical load control............................................................555
			Function............................................................................555
			Switching on and off................................................................555
		12.4.7 Operation of the directional spotlights..........................................556
		12.4.8 Displaying the operating hours...................................................557
		12.4.9 Warning submenu..................................................................558
			Meaning of the symbols..............................................................558
			Exiting the submenu.................................................................561
		12.4.10 Error submenu...................................................................562
	12.5 Working range limiter..................................................................563
		12.5.1 Opening the Working range limiter submenu........................................564
		12.5.2 Viewing current settings.........................................................564
		12.5.3 Entering limit values............................................................566
			Overall height / Working radius.....................................................566
			Slewing angle.......................................................................567
			Entering objects....................................................................569
		12.5.4 Entering limit values / objects manually.........................................572
			Limit values........................................................................572
			Objects.............................................................................573
		12.5.5 Switching monitoring functions on / off..........................................574
		12.5.6 Shutdown by working range limiter................................................575
	12.6 Work break.............................................................................577
		12.6.1 Short work breaks................................................................577
		12.6.2 Work breaks of more than 8 hours.................................................578
			To secure the truck crane...........................................................578
	12.7 Heating and air-conditioning system....................................................579
		12.7.1 Standard heating system..........................................................579
			Switching on........................................................................579
			Heating.............................................................................579
			Air distribution....................................................................580
			Switching off.......................................................................581
		12.7.2 Air-conditioning system..........................................................581
			Warnings............................................................................581
			Switching on / off..................................................................582
			Cooling.............................................................................582
			Drying the air......................................................................583
		12.7.3 Auxiliary water heater...........................................................583
			Preheating the engine...............................................................584
			Preheating the crane cab............................................................584
			Switching on........................................................................585
			Setting the day and time............................................................586
			Storing the heating start...........................................................587
			Setting the heating period..........................................................588
			Switching heating start on / off....................................................588
			Switching off.......................................................................589
			Setting the remaining time..........................................................589
		12.7.4 Auxiliary air heater.............................................................590
			Switching on........................................................................590
			Temperature.........................................................................591
			Switching off.......................................................................591
			Additional functions................................................................591
13 Rigging work.................................................................................595
	13.1 Rigging work checklists for crane operation with the main boom.........................595
		13.1.1 CHECKLIST: Rigging...............................................................595
		13.1.2 CHECKLIST: Unrigging.............................................................599
	13.2 Choosing a suitable site...............................................................603
		13.2.1 Determining the required ground bearing area.....................................603
		13.2.2 Safe distance from slopes and pits...............................................606
		13.2.3 Earthing the truck crane.........................................................607
		13.2.4 Safe distance from electrical lines..............................................608
	13.3 Rigging work after driving with a trailer..............................................611
		13.3.1 Switching off the boom floating position.........................................611
		13.3.2 Switching off the slewing gear freewheel.........................................612
			Before slewing......................................................................612
		13.3.3 Switching off boom pre-tensioning................................................613
	13.4 Connecting / disconnecting the hand-held control.......................................614
	13.5 Starting the engine for driving for rigging work.......................................615
		13.5.1 Starting / turning off the engine with the hand-held control.....................615
			Prerequisites.......................................................................615
			To start the engine.................................................................616
			Turning off the engine..............................................................616
		13.5.2 Starting / turning off the engine from the crane cab.............................617
			Prerequisites.......................................................................617
			To start the engine.................................................................617
			After starting the engine...........................................................618
			Turning off the engine..............................................................618
	13.6 Outriggers.............................................................................619
		13.6.1 CHECKLIST: Extending the outriggers..............................................619
		13.6.2 CHECKLIST: Retracting the outriggers.............................................621
		13.6.3 Permissible outrigger spans......................................................622
		13.6.4 Preparing the truck crane........................................................623
			In the driver's cab.................................................................623
			Control units (outrigger)...........................................................623
		13.6.5 Setting the spans................................................................624
			For on-road driving.................................................................625
		13.6.6 Extending / retracting outriggers................................................626
			From the control units..............................................................627
			With the hand- held control.........................................................628
			From the crane cab..................................................................630
		13.6.7 Moving the outrigger pads into working / driving position........................632
		13.6.8 Enlarging the ground bearing area................................................633
		13.6.9 Extending / retracting supporting cylinders......................................635
			From the control units..............................................................636
			With the hand- held control.........................................................637
			From the crane cab..................................................................638
		13.6.10 Levelling the truck crane on outriggers.........................................640
			Inclination displays................................................................640
			Prerequisites.......................................................................641
			Manual alignment....................................................................642
			Automatic alignment.................................................................643
		13.6.11 Levelling the free-standing truck crane.........................................645
		13.6.12 Outrigger pressure display......................................................647
	13.7 Rigging / unrigging the counterweight..................................................649
		13.7.1 Counterweight parts..............................................................649
			Version A...........................................................................649
			Version B...........................................................................650
			Version C...........................................................................650
		13.7.2 Identification...................................................................651
		13.7.3 Slinging points..................................................................652
		13.7.4 CHECKLIST: Rigging counterweight.................................................653
		13.7.5 CHECKLIST: Unrigging counterweight...............................................654
		13.7.6 Assembling counterweight versions................................................655
			On the turntable....................................................................655
			With the base plate.................................................................656
			With version A......................................................................658
			With version B......................................................................660
			With version C......................................................................662
		13.7.7 counterweight hoist unit.........................................................666
			Counterweight submenu...............................................................666
			Extending / retracting the lifting cylinders........................................667
			Automatic mode, rigging.............................................................668
			Automatic mode, unrigging...........................................................669
			Cancel automatic mode...............................................................670
		13.7.8 Removing / installing the counterweight on the turntable.........................671
			Mounting............................................................................672
			Removing............................................................................673
		13.7.9 Setting down counterweight for driving the truck crane...........................674
		13.7.10 Slewing with rigged counterweight...............................................676
	13.8 Rigging work on the main boom..........................................................677
		13.8.1 Hook block on the bumper.........................................................677
			Picking up the hook block...........................................................677
			Attaching the hook block............................................................678
		13.8.2 Hook block on a separate vehicle.................................................679
			Hook block (picking up).............................................................680
			Hook block (setting down)...........................................................680
		13.8.3 Reeving and unreeving the hoist rope.............................................682
			Fastening the rope end clamp........................................................682
			Reeving the hoist rope..............................................................684
			Hoist rope (unreeving)..............................................................687
		13.8.4 Possible reeving methods on the main boom........................................688
			With 7 head sheaves.................................................................688
			With 8 head sheaves.................................................................691
		13.8.5 Installing / removing the lifting limit switch...................................694
			Installing the lifting limit switch.................................................694
			Removing the lifting limit switch...................................................697
		13.8.6 Locking / Unlocking the lifting limit switch.....................................698
			Locking.............................................................................698
			Unlocking...........................................................................699
		13.8.7 Anemometer and air traffic control light.........................................700
			Mounting............................................................................700
			Removing............................................................................701
	13.9 Other rigging work.....................................................................703
		13.9.1 Rigging in free on wheels working position.......................................703
		13.9.2 Railings on the turntable........................................................705
		13.9.3 Mirror for crane operation.......................................................706
14 Driving the rigged truck crane...............................................................709
	14.1 Route..................................................................................710
	14.2 permissible rigging modes and axle loads...............................................710
		14.2.1 To drive without a load..........................................................710
		14.2.2 To drive with a load.............................................................711
		14.2.3 Axle loads.......................................................................711
	14.3 Before driving the rigged truck crane..................................................712
		14.3.1 Checking the tyre pressure and the wind speed....................................712
	14.4 Driving from the driver's cab..........................................................713
		14.4.1 Preparing to drive...............................................................713
			Transmission........................................................................713
			Switching on separate steering......................................................713
			Connections.........................................................................713
		14.4.2 While driving....................................................................714
	14.5 Driving from the crane cab.............................................................715
		14.5.1 Preparing to drive...............................................................716
		14.5.2 Opening / closing the Driving mode submenu.......................................716
			Automatically.......................................................................716
			Manually............................................................................718
			Closing.............................................................................718
		14.5.3 Starting / turning off the engine for driving....................................719
			To start the engine.................................................................719
			Turning off the engine..............................................................720
		14.5.4 Steering.........................................................................720
			Switching on........................................................................720
			Adapt steering direction............................................................720
			Displays when steering..............................................................721
			Normal steering.....................................................................721
			Separate steering...................................................................722
		14.5.5 Operating the transmission.......................................................723
			Driving direction...................................................................724
			Selecting the transmission mode.....................................................724
		14.5.6 Starting.........................................................................725
		14.5.7 While driving....................................................................725
		14.5.8 Warning messages.................................................................726
		14.5.9 Possible connections.............................................................727
			Longitudinal / transverse differential locks........................................728
		14.5.10 After driving...................................................................729
15 Malfunctions during crane operation..........................................................733
	15.1 Emergency stop switch..................................................................733
	15.2 What to do when a malfunction occurs during crane operation............................735
		Load can be lowered....................................................................735
		Load cannot be lowered..................................................................735
	15.3 Fuses..................................................................................737
		Notes on changing fuses.................................................................737
		15.3.1 Fuses on the turntable...........................................................738
			Fuse groups F1/F2...................................................................738
			Fuses on the circuit board..........................................................739
		15.3.2 Fuses in the crane cab...........................................................740
		15.3.3 Fuses in the battery box.........................................................742
		15.3.4 SLI fuses........................................................................743
	15.4 Finding and eliminating malfunctions...................................................745
		15.4.1 Malfunctions on the engine.......................................................745
		15.4.2 Malfunctions on the main hoist / auxiliary hoist.................................747
		15.4.3 Malfunctions on the derricking gear..............................................748
		15.4.4 Malfunctions in the telescoping mechanism........................................749
			Telescoping mechanism error messages................................................750
		15.4.5 Malfunctions on the slewing gear.................................................752
		15.4.6 Malfunctions on the counterweight hoist unit.....................................753
		15.4.7 Malfunctions in the hydraulic system / hydraulic oil cooler......................754
		15.4.8 Malfunctions when inclining the crane cab........................................754
		15.4.9 Malfunctions when operating with the hand-held control...........................754
		15.4.10 Malfunctions when driving from the crane cab....................................755
		15.4.11 Malfunctions on the outriggers..................................................756
		15.4.12 Troubleshooting on the SLI......................................................757
			General malfunctions................................................................757
			Error messages in the monitoring submenu............................................758
			Displays in the error submenu.......................................................760
			Table of error codes................................................................762
			Switching off the sensor / tachogenerator..........................................765
		15.4.13 Malfunctions ECOS – superstructure..............................................766
			ECOS program version................................................................766
			General malfunctions................................................................766
			Error messages......................................................................767
			Exiting the submenu.................................................................768
	15.5 Emergency operations and programs......................................................769
		15.5.1 Mechanical emergency operation for retracting....................................770
			Check prior to the emergency operation..............................................770
			Procedure...........................................................................770
			Mechanical emergency operation......................................................771
		15.5.2 Telescoping emergency program....................................................773
			Starting the emergency program......................................................773
			Determining the type of error.......................................................774
			If there is an error on the length indicator........................................775
			If there is an error on a proximity switch..........................................779
			Terminating the emergency program...................................................780
			Tables for approaching the locking points...........................................781
		15.5.3 Entering the current telescoping.................................................783
		15.5.4 Emergency operation with the hand-held control...................................785
			Preparations........................................................................785
			Operating a power unit..............................................................786
			Stopping movements..................................................................788
			Stopping movements in emergencies...................................................788
			Turning off the engine..............................................................788
		15.5.5 Switching on emergency operation in coolant circuit..............................789
	15.6 Hydraulic emergency operation..........................................................791
		15.6.1 Operating principle..............................................................791
		15.6.2 Connecting/disconnecting hoses...................................................792
		15.6.3 Activating/deactivating emergency operation......................................793
		15.6.4 Establishing the required hydraulic circuits.....................................794
			Switching over valves...............................................................794
			For lifting/ lowering..............................................................796
			For slewing.........................................................................797
		15.6.5 Carrying out emergency operation.................................................798
			Slewing.............................................................................798
			Derricking..........................................................................799
			Lifting/lowering....................................................................799
		15.6.6 After emergency operation........................................................800
			Switching offemergency operation..................................................800
			Switching to crane operation........................................................800
			Disconnecting the hoses.............................................................800
		15.6.7 Emergency supply of another crane................................................801
			Before emergency supply.............................................................801
			After emergency supply..............................................................801
16 Technical information for the superstructure.................................................805
	16.1 Technical data.........................................................................805
		16.1.1 Maximum lifting capacity (DIN / ISO / EN)........................................805
		16.1.2 Dimensions and weights of the truck crane, axle loads............................806
		16.1.3 Dimensions and weights of removable parts........................................806
			Hook blocks and hook tackle.........................................................806
			Counterweight parts.................................................................807
			Counterweight versions..............................................................807
		16.1.4 Superstructure...................................................................808
			Engine..............................................................................808
			Hoists..............................................................................808
			Slewing gear........................................................................808
			Derricking gear.....................................................................808
			Main boom...........................................................................809
			Lattice extension...................................................................809
			Operating speeds....................................................................809
17 Index........................................................................................813
	A...........................................................................................815
	B...........................................................................................815
	C...........................................................................................816
	D...........................................................................................817
	E...........................................................................................819
	F...........................................................................................821
	H...........................................................................................821
	I...........................................................................................822
	K...........................................................................................822
	L...........................................................................................823
	M...........................................................................................823
	O...........................................................................................824
	P...........................................................................................825
	R...........................................................................................825
	S...........................................................................................826
	T...........................................................................................827
	V...........................................................................................829
	W...........................................................................................829

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