Grove Crane GMK6300 Part 1-Driving Operating Instructions Manual SN 3112200 – PDF DOWNLOAD

Description

Grove Crane GMK6300 Part 1-Driving Operating Instructions Manual SN 3112200 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK6300 Part 1-Driving Operating Instructions Manual SN 3112200 – PDF DOWNLOAD

Language : English
Pages : 878
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Grove Crane GMK6300 Part 1-Driving Operating Instructions Manual SN 3112200 – PDF DOWNLOAD

Operating instructions:

• These operating instructions contain the information required to operate the truck crane.
• The operating instructions are divided into two parts. Part 1 with chapters
  1 to 10 contains the Description of the vehicle section of the truck crane,
  Part 2 with chapters 11 to 18 contains the Description of the crane section.
• The Basic safety instructions can be found in chapter 2. Please read and observe
  these instructions, even if you are familiar with the safety manual.
• The Basic safety instructions can be found in this chapter only. Special safety
  instructions that refer to specific hazards can be found in the section describing
  the operation related to the hazard.
• Chapter 3 contains Information for operations planning. It is intended primarily
  for the truck crane operator and those who are responsible for operations
  planning.

This chapter contains
– The qualifications required by those involved in planning operations of
the truck crane
– Special safety instructions
– Information that is relevant to operations planning

• You can find the information required for Driving the truck crane in chapter 4
  to 6, including descriptions of all parts and control elements, clearly defined
  checklists for rigging modes and work and the operating instructions for onroad
  and off-road driving and the removal and installation of the auxiliary
  hoist.
• Rigging for on-road driving is described in chapter 7.
• You can find information on Troubleshooting in the event of malfunctions at
  the vehicle section of the truck crane in chapter 8.
• Chapter 9 contains the Technical description of the individual parts and functional
  elements of the vehicle section as well as the Technical specifications.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Grove Crane GMK6300 Part 1-Driving Operating Instructions Manual SN 3112200 – PDF DOWNLOAD

Part 1 - Drivin.........................................................................................................  1
	Additional pages....................................................................................................  3
		SLI override....................................................................................................  3
	1 Overview.......................................................................................................... 19
		1.1 Vehicle identification...................................................................................... 19
		1.2 EC Declaration of Conformity................................................................................ 23
		1.3 Overview and contents of the truck crane user information.................................................. 25
			1.3.1 Operating instructions................................................................................ 25
			1.3.2 Lattice extension operating instructions.............................................................. 26
			1.3.3 Maintenance manual.................................................................................... 26
			1.3.4 Lifting capacity tables............................................................................... 27
			1.3.5 Outrigger pressure table.............................................................................. 27
			1.3.6 Safety manual......................................................................................... 27
			1.3.7 Circuit diagrams...................................................................................... 27
			1.3.8 Spare parts list...................................................................................... 28
		1.4 Instructions for using this documentation................................................................... 29
			1.4.1 How are the operating instructions structured?........................................................ 29
			1.4.2 How are the pages of the operating instructions structured?........................................... 30
			1.4.3 How can I find required information quickly and easily?............................................... 31
				Example of how touse the cross- references............................................................. 32
				How to use theindex................................................................................... 37
			1.4.4 Definition of indications of direction................................................................ 37
				Basic rule.............................................................................................. 37
				Buttons and switches.................................................................................... 37
			1.4.5 Conversion table for US units of measurement.......................................................... 38
	2 Basic Safety Instructions for the Crane Operator.................................................................. 41
		2.1 Warnings and symbols........................................................................................ 41
		2.2 Intended use................................................................................................ 43
		2.3 Organisational measures..................................................................................... 45
		2.4 Personnel qualifications.................................................................................... 47
		2.5 Safety instructions for driving the truck crane............................................................. 49
		2.6 Safety instructions for working with the truck crane........................................................ 51
	3 Information for operations planning............................................................................... 55
		3.1 Safety instructions......................................................................................... 55
			3.1.1 Intended use.......................................................................................... 55
			3.1.2 Organisational measures............................................................................... 55
			3.1.3 Personnel qualifications.............................................................................. 56
		3.2 Operations planning......................................................................................... 57
			3.2.1 Prerequisites for operations planning................................................................. 57
			3.2.2 Information for operations planning contained in the user information................................ 58
	4 Description of the truck crane – vehicle section.................................................................. 61
		4.1 Overview of the operating and display elements.............................................................. 61
			4.1.1 Overview of the vehicle............................................................................... 61
			4.1.2 Overview of the driver's cab.......................................................................... 64
				Overhead in the driver's cab............................................................................ 67
			4.1.3 Front instrument panel................................................................................ 68
				Left.................................................................................................... 68
				Middle.................................................................................................. 70
				Right................................................................................................... 72
			4.1.4 Side instrument panel................................................................................. 76
				For the transmission................................................................................... 78
				Auxiliary water heater with timer...................................................................... 79
				Auxiliary air heater.................................................................................. 80
			4.1.5 Outrigger box locking pin switch boxes................................................................ 81
		4.2 Functional description of the display and operating elements.............................................. 83
			4.2.1 On the instrument panels.............................................................................. 83
				Vehicle engine.......................................................................................... 83
				Automatic transmission.................................................................................. 84
				Transfer case........................................................................................... 87
				Axle drive.............................................................................................. 89
				Brakes.................................................................................................. 90
				Suspension.............................................................................................. 91
				Hydraulic system........................................................................................ 93
				Steering................................................................................................ 94
				Electricity............................................................................................. 95
				Level adjustment system................................................................................ 97
				Driver's cab heating system............................................................................ 98
				Auxiliary water heater..................................................................................100
				Auxiliary air heater...................................................................................101
				Air-conditioning system.................................................................................102
				Cab lighting............................................................................................103
				Other operating elements...............................................................................103
			4.2.2 Other operating elements of the vehicle section.......................................................105
				Keys....................................................................................................105
				Doors...................................................................................................105
				Windows.................................................................................................106
				Access ladders..........................................................................................108
				Ladders.................................................................................................108
				Vehicle engine diagnostics plug........................................................................110
				Fire extinguisher.......................................................................................110
				Folding berth...........................................................................................111
	5 Vehicle engine....................................................................................................115
		5.1 Starting/turning off the vehicle engine.....................................................................115
			5.1.1 CHECKLIST: Starting the vehicle engine................................................................115
			5.1.2 CHECKLIST: In winter..................................................................................118
			5.1.3 Inspections prior to starting the vehicle engine......................................................119
				Checking the shut- off valves of the hydraulic system...................................................119
				Switching on the battery master switch..................................................................119
				Pre-check of the oil level of the automatic transmission...............................................120
				Checking the coolant level.............................................................................121
				Checking the hydraulic oil level.......................................................................122
				Checking the oil level in the vehicle engine............................................................122
				Topping up theengine oil...............................................................................123
			5.1.4 Refuelling............................................................................................124
			5.1.5 Starting the vehicle engine...........................................................................125
				Turning on the ignition................................................................................125
				Starting the vehicle engine............................................................................127
			5.1.6 Inspections after starting the vehicle engine.........................................................129
				Checking the instruments...............................................................................129
			5.1.7 Turning off the vehicle engine........................................................................135
			5.1.8 Emergency stop by means of the air intake inhibitor...................................................136
				Switching on the air intake inhibitor...................................................................136
				Releasing the airintake inhibitor manually.............................................................137
	6 Driving the truck crane...........................................................................................141
		6.1 Inspections on the truck crane before driving...............................................................141
			6.1.1 CHECKLIST: Condition of the truck crane for on-road driving...........................................141
			6.1.2 Checking the condition of the truck crane.............................................................145
				Checking the reservoir of the windscreen washing system...............................................145
				Warning signs for vehicle width.........................................................................145
				Checking the tyres......................................................................................146
				Checking the electrical system.........................................................................146
				Checking the mirror settings...........................................................................147
				Checking the compressed air and brake systems...........................................................147
				Checking the suspension................................................................................149
				Checking the on- road level.............................................................................149
				Checking the transverse differential locks..............................................................150
				Checking the drive of the second axle line/longitudinal differential locks..............................150
				Checking the transfer case..............................................................................150
				Checking the steering locks.............................................................................150
				Checking the Main boom not set down warning lamp........................................................151
			6.1.3 Adjusting the seats and steering column...............................................................152
				Adjusting the driver's seat............................................................................152
				Adjusting the steering column...........................................................................152
			6.1.4 Trip recorder.........................................................................................153
				Inserting the 24-hour disc in thetrip recorder.........................................................153
		6.2 General operation...........................................................................................155
			6.2.1 Operation of the automatic transmission...............................................................155
				Switching on............................................................................................155
				Changing the driving modes..............................................................................156
				Selecting the driving direction........................................................................156
				Selecting highest gear/starting gear....................................................................157
				Starting................................................................................................158
				Driving and changing gears..............................................................................158
				Switching the transmission to neutral position..........................................................160
				Changing the driving direction.........................................................................161
				Stopping the truck crane................................................................................161
				On the roller type dynamometer..........................................................................161
			6.2.2 Monitoring the control instruments while driving......................................................163
			6.2.3 Driving downhill......................................................................................167
				Retarder................................................................................................167
				Gear pre-selection......................................................................................168
			6.2.4 Driving uphill........................................................................................169
			6.2.5 Tempomat..............................................................................................169
				Switching on the Tempomat...............................................................................170
				Driving with the Tempomat...............................................................................170
				Switching off the Tempomat..............................................................................171
				Eddy current retarder..................................................................................171
			6.2.6 Parking the truck crane...............................................................................173
				Applying the parking brake.............................................................................173
				Automatic transmission in neutral position..............................................................173
				Turning off the vehicle engine.........................................................................173
				Securing the truck crane against rolling away...........................................................173
				Switch off the battery master switch if the truck crane isat a standstill for a long period of time....174
				Securing the truck crane against unauthorised use.......................................................174
		6.3 Off-road driving............................................................................................175
			6.3.1 Off-road gear.........................................................................................176
				Engaging the off- road gear.............................................................................176
				Switching off the off-road gear.........................................................................177
			6.3.2 Drive of the second axle line/longitudinal differential locks.........................................178
				Activating the drive/longitudinal differential locks....................................................178
				Switching off the drive/longitudinal differential locks.................................................179
			6.3.3 Transverse differential locks in all driven axle lines................................................180
				Switching on the transverse differential locks..........................................................180
				Switching off thetransverse differential locks........................................................181
			6.3.4 Level adjustment system...............................................................................182
				Switching on the level adjustment system................................................................182
				Raising or lowering the entire truck crane..............................................................183
				Tilting the truck crane lengthwise or crosswise.........................................................184
				Bringing the truck crane to On-road level...............................................................185
				Switching off the level adjustment system...............................................................185
			6.3.5 Freeing the immobilised truck crane...................................................................186
				Freeing the truck crane without external assistance.....................................................186
				Towing free in reverse gear............................................................................187
				Towing free forwards...................................................................................187
		6.4 Separate steering...........................................................................................189
			6.4.1 Switching on separate steering........................................................................191
			6.4.2 Steering axle lines with separate steering............................................................192
				All-wheel steering......................................................................................192
				Crab travel mode........................................................................................192
			6.4.3 Switching off separate steering and locking the steering..............................................193
				Locking the steering in straight ahead position.........................................................193
				Locking in other positions..............................................................................194
			6.4.4 Adjusting the steering angle..........................................................................195
		6.5 Heating and ventilation.....................................................................................197
			6.5.1 Heating in the driver's cab...........................................................................197
				Adjusting the air vent..................................................................................198
				Ventilating the driver's cab............................................................................198
			6.5.2 Auxiliary water heater................................................................................199
				Preheating the vehicle engine..........................................................................199
				Preheating the driver's cab.............................................................................199
				Switching on the auxiliary heater.......................................................................200
				Switching off the auxiliary heater......................................................................201
			6.5.3 Auxiliary water heater with timer.....................................................................202
				Preheating the vehicle engine..........................................................................202
				Preheating the driver's cab.............................................................................202
				Switching on the auxiliary heater.......................................................................203
				Switching off the auxiliary heater......................................................................204
				Setting the time and weekday............................................................................204
				Saving the automatic heating start......................................................................205
				Setting the automatic heating period..................................................................206
				Switching the automatic heating start on/off...........................................................206
				Setting the remaining time.............................................................................207
			6.5.4 Auxiliary air heater with timer.......................................................................209
				Switching on the auxiliary heater.......................................................................209
				Regulating the temperature..............................................................................210
				Switching off the auxiliary heater......................................................................210
				Setting the remaining time.............................................................................211
		6.6 Air-conditioning system.....................................................................................213
			6.6.1 Switching on the system...............................................................................213
			6.6.2 Switching off the system..............................................................................213
			6.6.3 Air conditioning......................................................................................214
				How to use air conditioning conveniently................................................................214
				Dehumidifying the air in the driver's cab...............................................................215
		6.7 Roof ventilator.............................................................................................215
		6.8 Towing a trailer............................................................................................217
			Effects on the axle loads...................................................................................217
			Coupling the trailer.......................................................................................218
			Connecting the supply lines.................................................................................219
			Removing the supply lines...................................................................................220
			Uncoupling the trailer......................................................................................220
			Test position of the parking brake when towing a trailer....................................................222
	7 Driving modes and rigging for on-road driving.....................................................................225
		7.1 Driving modes...............................................................................................227
			Information on theaxle loads...............................................................................227
			7.1.1 Information on how to use the tables..................................................................228
			7.1.2 Tables for a maximum axle load of 12 t................................................................229
				For 14.00 R 25 tyres...................................................................................229
				For 16.00 R 25 tyres...................................................................................230
		7.2 Rigging work for driving with a trailer.....................................................................231
			7.2.1 Switching on the slewing gear freewheel...............................................................232
				Prerequisites...........................................................................................232
			7.2.2 Switching on the boom floating position...............................................................234
				Setting the main boom down on the trailer...............................................................234
			7.2.3 Switching on boom pre-tensioning......................................................................236
		7.3 Rigging the outrigger beams.................................................................................239
			Equipment...................................................................................................239
			7.3.1 CHECKLIST: Removal of the outrigger beams.............................................................240
			7.3.2 CHECKLIST: Installation of the outrigger beams........................................................242
			7.3.3 Preparing the truck crane for the removal/installation................................................245
				Prerequisites for the installation/ removal............................................................245
				Preparing the truck crane...............................................................................245
			7.3.4 Removing/applying the outrigger pads..................................................................246
				Removing the outrigger pads.............................................................................246
				Applying the outrigger pads............................................................................247
			7.3.5 Disconnecting/establishing the hydraulic connection...................................................247
				Disconnecting the hydraulic connection..................................................................248
				Establishing the hydraulic connection...................................................................249
			7.3.6 Establishing/disconnecting the electrical connection for the outrigger pressure indicator.............250
			7.3.7 Transport/operating position of the holding angle.....................................................251
			7.3.8 Locking the extension cylinder/releasing the locking pin..............................................252
				Releasing the locking pin...............................................................................252
				Locking the extension cylinder..........................................................................253
			7.3.9 Pulling out/inserting the outrigger beam..............................................................254
				Pulling out the outrigger beam..........................................................................254
				Inserting the outrigger beam...........................................................................256
			7.3.10 Transporting the outrigger beams/pads................................................................258
		7.4 Rigging the rear outrigger box (ROB)........................................................................259
			7.4.1 CHECKLIST: Removal of the outrigger box...............................................................260
			7.4.2 CHECKLIST: Installation of the outrigger box..........................................................262
			7.4.3 Preparing the truck crane for the removal/installation................................................264
				Preparing for removal..................................................................................264
				Preparing for installation.............................................................................264
			7.4.4 Crane movements during the installation and removal procedures.......................................265
				Prerequisites...........................................................................................265
				Before the installation.................................................................................265
				After the removal.......................................................................................265
			7.4.5 Slinging points on the rear outrigger box (ROB).......................................................266
			7.4.6 Establishing/disconnecting the electrical connection..................................................267
			7.4.7 Disconnecting/establishing the hydraulic connection...................................................268
				Establishing the hydraulic connection...................................................................268
				Disconnecting the hydraulic connection..................................................................268
			7.4.8 Attaching/raising the outrigger box with the truck crane..............................................269
				Removing the outrigger box..............................................................................270
				Attaching the outrigger box.............................................................................270
			7.4.9 Locking the outrigger box to the carrier and unlocking it again.......................................271
				Locking the outrigger box...............................................................................271
				Releasing the locking pins..............................................................................271
				Extending and retracting the pins......................................................................272
			7.4.10 Establishing/disconnecting the pneumatic connection..................................................272
			7.4.11 Slewing with the rear outrigger box (ROB) removed....................................................273
				Prerequisites for slewing...............................................................................273
			7.4.12 Transportation on a separate vehicle.................................................................274
			7.4.13 Setting down the main boom on a trailer with the rear outrigger box (ROB) removed...................275
				Packing the truck crane.................................................................................275
				Setting down the main boom..............................................................................276
		7.5 Rigging the main boom.......................................................................................277
			Additional equipment required...............................................................................277
			7.5.1 CHECKLIST: Removal of the main boom...................................................................278
				Prerequisites...........................................................................................278
				Removing the main boom..................................................................................278
			7.5.2 CHECKLIST: Installation of the main boom..............................................................281
				Prerequisites...........................................................................................281
				Installing the main boom................................................................................281
			7.5.3 Rigging work with the auxiliary crane.................................................................284
				Lifting the main boom from the turntable................................................................285
				Lifting the main boom onto the turntable................................................................286
			7.5.4 Establishing/disconnecting the hydraulic connection to thelattice extension (additional eq...........286
				Disconnecting the hydraulic connection..................................................................287
				Establishing the hydraulic connection...................................................................287
			7.5.5 Pulling device on the main boom pivot pin.............................................................288
				Pin-type keepers, pivot pin.............................................................................288
				Hydraulic connection....................................................................................289
				Retracting/ extending the pins.........................................................................290
			7.5.6 Locking pin on the derricking cylinder head eyelet....................................................291
				Operation of the lifting device.........................................................................291
				Retracting/ extending the pin..........................................................................293
			7.5.7 Hydraulic connections on the main boom................................................................294
				Removing/ Applying the guide plates....................................................................295
				Establishing the hydraulic connection...................................................................295
				Disconnecting the hydraulic connection..................................................................296
			7.5.8 Electrical connections on the main boom...............................................................297
			7.5.9 Inspections after the main boom installation..........................................................298
				Inspection of the hydraulic system.....................................................................298
				Inspection of the electrical system....................................................................299
			7.5.10 Before on-road driving...............................................................................301
				Securing the derricking cylinder for on-road driving....................................................301
				Transportation of the main boom.........................................................................301
			7.5.11 Relieving the pressure on the derricking cylinder....................................................302
				Switching on pressure relief............................................................................302
				Switching off pressure relief...........................................................................303
	8 Malfunctions on the carrier.......................................................................................307
		8.1 Emergency stop device on the carrier........................................................................307
			Turning off the vehicle engine.............................................................................307
		8.2 What to do in the event of a breakdown on the road..........................................................309
		8.3 Towing away the truck crane.................................................................................311
			8.3.1 Towing away the truck crane in the event of engine or transmission damage............................312
				Towing the truck crane out of the danger area...........................................................312
				Compressed-air supply in the event of vehicle engine failure............................................313
				Electric power supply...................................................................................313
				Transmission............................................................................................314
				Vehicle engine..........................................................................................314
				Parking brake...........................................................................................314
				Releasing the parking brake mechanically...............................................................315
				Towing procedure........................................................................................316
				Unlocking all spring-loaded brake cylinders mechanically................................................316
				Starting to tow.........................................................................................316
		8.4 Wheels......................................................................................................317
			8.4.1 Wheel change..........................................................................................317
				Removing a damaged wheel...............................................................................317
				Removing the wheel from thespare wheel holder..........................................................318
				Mounting a damaged wheel onto the spare wheel holder....................................................319
				Mounting the spare wheel................................................................................320
			8.4.2 Filling the tyres yourself............................................................................321
				Connecting the filling hose.............................................................................321
				Filling the tyres.......................................................................................322
				Removing the tyre inflator hose.........................................................................322
		8.5 Fuses on the carrier........................................................................................323
			Notes on changing fuses....................................................................................323
			8.5.1 Fuses in the driver's cab.............................................................................324
			8.5.2 Fuses in the battery box..............................................................................327
		8.6 Finding and eliminating malfunctions........................................................................329
			8.6.1 Malfunctions of the vehicle engine....................................................................329
			8.6.2 Malfunctions of the automatic transmission............................................................331
			8.6.3 Malfunctions of the transfer case.....................................................................332
			8.6.4 Malfunctions of the differential locks................................................................333
			8.6.5 Malfunctions of the service brake.....................................................................334
			8.6.6 Malfunctions of the steering..........................................................................335
			8.6.7 Malfunctions of the outriggers........................................................................336
			8.6.8 Malfunctions of the suspension locking system.........................................................336
			8.6.9 Malfunctions of the level adjustment system...........................................................336
		8.7 Procedure in the event of malfunctions......................................................................337
			8.7.1 Switching the fan thermostat to emergency mode........................................................337
			8.7.2 Procedure in the event of malfunctions of the automatic transmission.................................338
				Error detection.........................................................................................338
				Effects of the errors..................................................................................338
				Reading out error codes.................................................................................339
			8.7.3 Emergency operation of the solenoid valves for the outriggers.........................................341
			8.7.4 Separate steering emergency operation mode............................................................344
				Bringing the steering into a condition for on-road driving..............................................345
	9 Technical information on the carrier..............................................................................349
		9.1 Dimensions and weights of the truck crane...................................................................350
			9.1.1 Dimensions of the truck crane.........................................................................350
				Dimensions for driving on public roads..................................................................351
			9.1.2 Dimensions and weights of removable parts.............................................................352
				Spare wheel (additional equipment)......................................................................352
				Main boom...............................................................................................352
				Outriggers..............................................................................................352
		9.2 Technical specifications of the carrier.....................................................................353
			Vehicle engine..............................................................................................353
			Manual transmission........................................................................................353
			Transfer case...............................................................................................353
			Axle lines..................................................................................................353
			Steering....................................................................................................353
			Tyres.......................................................................................................354
			Vehicle's electrical system.................................................................................354
			Tools.......................................................................................................354
			Outriggers..................................................................................................355
			Driving speeds..............................................................................................356
			Climbing ability............................................................................................356
			Turning circle radiuses....................................................................................357
	10 Index............................................................................................................361
		A...............................................................................................................363
		B...............................................................................................................364
		C...............................................................................................................364
		D...............................................................................................................366
		E...............................................................................................................367
		F...............................................................................................................368
		H...............................................................................................................368
		I...............................................................................................................369
		K...............................................................................................................369
		L...............................................................................................................369
		M...............................................................................................................370
		O...............................................................................................................371
		P...............................................................................................................371
		R...............................................................................................................372
		S...............................................................................................................372
		T...............................................................................................................374
		V...............................................................................................................375
		W...............................................................................................................375
Part 2 - Crane operation................................................................................................379
	Additional pages....................................................................................................381
		SLI override....................................................................................................381
	11 Description of the truck crane – crane section...................................................................397
		11.1 Overview of the operating and display instruments..........................................................397
			11.1.1 Overview of the crane section........................................................................397
			11.1.2 Overview of the crane cab............................................................................400
			11.1.3 Front instrument panel...............................................................................402
				Front instrument panel..................................................................................402
				Auxiliary water heater with timer.......................................................................408
				Auxiliary air heater with timer........................................................................409
				Controls and fittings behind the crane operator's seat..................................................417
			11.1.4 Left-hand control panel..............................................................................418
			11.1.5 Right-hand control panel.............................................................................419
			11.1.6 Control lever assignment.............................................................................420
				Version 1 (standard)...................................................................................420
				Version 2 (additional equipment).......................................................................421
			11.1.7 Switch box for outrigger operation...................................................................422
			11.1.8 Counterweight hoist button unit......................................................................423
			11.1.9 Switch box for electronic level......................................................................424
		11.2 Functional description of the display and operating elements.............................................425
			11.2.1 Crane work...........................................................................................425
				Crane engine............................................................................................425
				Outrigger operation....................................................................................426
				Counterweight hoist unit and lock.......................................................................428
				Crane control...........................................................................................430
				Main hoist..............................................................................................432
				Auxiliary hoist.........................................................................................433
				Slewing gear............................................................................................434
				Derricking gear.........................................................................................435
				Telescoping mechanism...................................................................................436
				Safe load indicator....................................................................................441
				Input elements with displays............................................................................441
				Display elements........................................................................................445
				Hydraulic system........................................................................................448
				Electrical system.......................................................................................448
				Other operating elements...............................................................................449
				Switch box for electronic level.........................................................................451
				Crane cab electronic level.............................................................................452
				Crane cab heating system................................................................................453
				Auxiliary water heater with timer......................................................................453
				Auxiliary air heater with timer........................................................................455
				Air-conditioning system version 1.......................................................................456
				Air-conditioning system version 2......................................................................457
				Houselock...............................................................................................457
				Anemometer..............................................................................................458
			11.2.2 Other operating elements on the crane cab............................................................459
				Doors, keys, windows...................................................................................459
				Fire extinguisher.......................................................................................461
				Cab lighting............................................................................................461
				Crane engine diagnostics plug..........................................................................462
		11.3 Functional description of the safety devices...............................................................463
			11.3.1 Safe load indicator (SLI)............................................................................463
			11.3.2 Lowering limit switch................................................................................464
			11.3.3 Lifting limit switch.................................................................................465
				Overriding the lifting limit switch shutdown............................................................466
			11.3.4 Dead man's switch and seat contact switch............................................................467
	12 Crane engine.....................................................................................................471
		12.1 Starting/turning off the crane engine......................................................................471
			12.1.1 CHECKLIST: Starting the crane engine.................................................................471
			12.1.2 CHECKLIST: In winter.................................................................................473
			12.1.3 Inspections prior to starting the crane engine.......................................................474
				Checking the shut- off valve in the hydraulic system...................................................474
				Switching on thebattery master switch..................................................................474
				Checking the coolant level.............................................................................475
				Checking the hydraulic oil level.......................................................................476
				Checking the oil level in the crane engine..............................................................476
				Topping up the engine oil..............................................................................477
				Refuelling..............................................................................................478
			12.1.4 Starting the crane engine............................................................................479
				Turning on the ignition................................................................................479
				Starting the crane engine...............................................................................481
			12.1.5 Inspections after starting the crane engine..........................................................483
				Checking the instruments...............................................................................483
		12.2 Turning off the crane engine...............................................................................485
			12.2.1 Emergency stop by means of the air intake inhibitor..................................................486
				Switching on the air intake inhibitor...................................................................486
				Releasing the air intake inhibitor manually.............................................................487
	13 Crane operation..................................................................................................491
		13.1 Checking the truck crane before working with thecrane.....................................................491
			13.1.1 CHECKLIST: With rigged truck crane...................................................................491
			13.1.2 Adjusting the crane operator's seat..................................................................495
			13.1.3 Checking the condition of the truck crane............................................................496
				Checking the reservoir of the windscreen washing system...............................................496
				Visual inspection of the entire crane...................................................................496
				Checking the position of the hoist ropes...............................................................497
				Electrical system.......................................................................................497
			13.1.4 Inspection of the safety devices.....................................................................498
				Safe load indicator.....................................................................................498
				Lifting limit switch....................................................................................498
				Dead man's switch system................................................................................499
				Crane control emergency stop circuit....................................................................499
			13.1.5 Pre-warming the hydraulic oil........................................................................500
				At an oil temperature of between –15C and 0C::........................................................500
				At an oil temperature of below –15C:..................................................................500
			13.1.6 Superstructure lock..................................................................................501
				Unlocking..............................................................................................502
				Engaging the lock......................................................................................502
			13.1.7 Houselock............................................................................................503
				Switching on the houselock..............................................................................503
				Switching off the houselock.............................................................................504
			13.1.8 Adjusting the mirrors................................................................................505
		13.2 Operation of the safe load indicator (SLI).................................................................507
			13.2.1 Switching on the SLI.................................................................................508
				Switching on the SLI....................................................................................508
				Lamp test on the SLI....................................................................................510
				Brightness of the displays..............................................................................510
			13.2.2 Entering the rigging mode............................................................................511
				Entering the SLI code..................................................................................512
				Entering the reeving value............................................................................514
				Entering individual components..........................................................................516
			13.2.3 Inspections before operating the crane...............................................................519
			13.2.4 Displays during crane operation......................................................................521
				Continuous displays...................................................................................521
				Optional displays......................................................................................523
			13.2.5 SLI early warning....................................................................................525
			13.2.6 SLI shutdown.........................................................................................526
				Shutdown due to overload................................................................................526
			13.2.7 Error message........................................................................................527
			13.2.8 SLI override.........................................................................................528
			13.2.9 Displaying and entering the time and date............................................................529
				Display.................................................................................................529
				Input...................................................................................................530
		13.3 Crane work with the main boom..............................................................................531
			13.3.1 External influences when working with the crane......................................................531
				Horizontal alignment....................................................................................531
				Safe distances.........................................................................................531
				Effect of wind on crane operation.......................................................................532
				Anemometer..............................................................................................532
				Permissible wind load...................................................................................533
				Earthing of the load....................................................................................534
			13.3.2 Permissible slewing ranges when working with the crane...............................................535
				360 slewing range......................................................................................535
				Working position 0 to the rear.........................................................................535
			13.3.3 Hoists...............................................................................................536
				Main hoist..............................................................................................536
				Auxiliary hoist.........................................................................................539
			13.3.4 Derricking gear......................................................................................541
			13.3.5 Slewing gear.........................................................................................543
				Slewing gear holding brake..............................................................................543
				Slewing.................................................................................................543
				Slewing speed...........................................................................................544
				Tracking the slewing gear..............................................................................544
				Maximum permissible slewing speed.......................................................................545
			13.3.6 Telescoping mechanism................................................................................547
				Structure of thechapter................................................................................547
				Description of theoperating principle..................................................................548
				Main boom fixed length, intermediate length, telescoping length........................................549
				Telescoping.............................................................................................551
				Notes on the telescoping sequence.......................................................................553
				Inspection before telescoping for the first time........................................................553
				Control lever functions................................................................................554
				Example of a telescoping sequence.......................................................................556
				Checking the initial position..........................................................................557
				Unlocking the telescoping cylinder.....................................................................560
				Extending/ Retracting and locking the telescoping cylinder.............................................562
				Unlocking the telescopic section........................................................................565
				Telescoping a telescopic section to afixed length and locking it.......................................567
				Telescoping the telescopic section to an intermediate length............................................571
				Locking telescopic sections.............................................................................572
				Telescoping in fully automatic mode.....................................................................573
				Example of telescoping with teleautomation.............................................................576
				Lowering the main boom for maintenance.................................................................577
				Telescoping the main boom into ahorizontal position....................................................578
			13.3.7 High-speed mode......................................................................................579
			13.3.8 Menus on the crane control display...................................................................580
				Display statuses menu...................................................................................580
				Telescoping display and teleautomation menu.............................................................584
				Power unit speeds/ critical load control menu...........................................................584
				Access emergency operation menu.........................................................................588
				Displaying an error message............................................................................589
			13.3.9 Setting a constant engine speed......................................................................591
			13.3.10 Critical load control...............................................................................592
			13.3.11 Inclining the crane cab.............................................................................593
			13.3.12 Cooling the hydraulic oil...........................................................................594
				Standard oil cooler.....................................................................................594
				Additional oil cooler...................................................................................594
			13.3.13 Possible combinations of operations.................................................................595
			13.3.14 Operation of the directional spotlights.............................................................596
				Switching on/off........................................................................................596
				Changing the direction.................................................................................596
		13.4 Driving with the rigged crane..............................................................................597
			13.4.1 Route................................................................................................597
			13.4.2 Rigging mode and axle loads..........................................................................598
				Main boom positions....................................................................................598
			13.4.3 Driving the rigged crane.............................................................................600
				Locking the superstructure and engaging the slewing gear holding brake................................600
				Retracting the outriggers..............................................................................600
				Switching over the suspension locking system............................................................600
				Switching on separate steering.........................................................................601
				Driving.................................................................................................601
				Extending the outriggers...............................................................................602
				After the procedure with 100 t counterweight............................................................602
		13.5 Work break.................................................................................................603
			13.5.1 During short work breaks.............................................................................603
			13.5.2 For work breaks of more than 8 hours.................................................................603
		13.6 Heating and ventilation....................................................................................605
			13.6.1 Heating the crane cab................................................................................605
				Adjusting the air vents.................................................................................606
				Ventilating the crane cab...............................................................................606
			13.6.2 Auxiliary water heater...............................................................................607
				Preheating the crane engine.............................................................................607
				Preheating the crane cab................................................................................607
				Switching on the auxiliary heater.......................................................................608
				Switching off the auxiliary heater......................................................................609
			13.6.3 Auxiliary water heater with timer....................................................................610
				Preheating the crane engine.............................................................................610
				Preheating the crane cab................................................................................610
				Switching on the auxiliary heater.......................................................................611
				Switching off the auxiliary heater......................................................................612
				Setting the time and weekday............................................................................612
				Saving the automatic heating start......................................................................613
				Setting the automatic heating period..................................................................614
				Switching the automatic heating start on/off...........................................................614
				Setting the remaining time.............................................................................615
			13.6.4 Auxiliary air heater with timer......................................................................616
				Switching on the auxiliary heater.......................................................................616
				Regulating the temperature..............................................................................617
				Switching off the auxiliary heater.....................................................................617
				Setting the remaining time.............................................................................618
		13.7 Air-conditioning system....................................................................................619
			13.7.1 Version 1............................................................................................619
				Switching on............................................................................................619
				Switching off...........................................................................................620
			13.7.2 Version 2............................................................................................620
			13.7.3 Air conditioning.....................................................................................621
				How to use air conditioning conveniently................................................................621
				Dehumidifying the crane cab air.........................................................................621
	14 Rigging work.....................................................................................................625
		14.1 Rigging work checklists for crane operation with themain boom.............................................625
			14.1.1 CHECKLIST: Rigging...................................................................................625
			14.1.2 CHECKLIST: Unrigging.................................................................................629
		14.2 Choosing a suitable site...................................................................................633
			14.2.1 Load bearing capacity of the ground and the outriggers...............................................633
				Enlarging the ground bearing area.......................................................................635
			14.2.2 Safe distance from slopes and pits...................................................................636
			14.2.3 Earthing the truck crane.............................................................................637
				Earthing the truck crane................................................................................637
			14.2.4 Safe distance from electrical lines..................................................................638
		14.3 Rigging work after driving with a trailer..................................................................641
			14.3.1 Switching off the slewing gear freewheel.............................................................642
				Before slewing..........................................................................................643
			14.3.2 Switching off the boom floating position.............................................................644
			14.3.3 Switching off boom pre-tensioning....................................................................644
		14.4 Outriggers.................................................................................................647
			14.4.1 CHECKLIST: Extending the outriggers..................................................................647
			14.4.2 CHECKLIST: Retracting outriggers.....................................................................649
			14.4.3 Outrigger span.......................................................................................651
				Outrigger span 8.70x8.50m............................................................................652
				Outrigger span 8.70x6.00m............................................................................652
				Outrigger span 8.70x2.68m............................................................................653
				Outrigger span 8.70 x 8.50/2.84 m.......................................................................654
				Outrigger span 8.70x8.50/2.4m........................................................................655
			14.4.4 Preparing the outriggers.............................................................................657
				Levelling the truck crane...............................................................................657
				Locking the suspension.................................................................................657
				Safety for on-road driving..............................................................................657
				Safety during crane operation...........................................................................658
			14.4.5 Extending/retracting the outrigger beams.............................................................659
				Extending the outrigger beams...........................................................................659
				Retracting the outrigger beams.........................................................................663
			14.4.6 Moving the outrigger pads into working/driving position..............................................664
				Moving the outrigger pads into working position.........................................................664
				Moving the outrigger pads into driving position .......................................................665
			14.4.7 Extending/retracting the outrigger cylinders........................................................666
				Extending the outrigger cylinders.......................................................................666
				Retracting theoutrigger cylinders.....................................................................668
			14.4.8 Checking the alignment of the truck crane............................................................669
				On the carrier..........................................................................................669
				In the crane cab........................................................................................671
			14.4.9 Levelling the truck crane on outriggers..............................................................673
				If the main boom is on the boom rest...................................................................673
				If the main boom is raised..............................................................................673
			14.4.10 Outrigger pressure indicator........................................................................673
				On the carrier..........................................................................................674
				In the crane cab........................................................................................675
		14.5 Counterweight..............................................................................................677
			14.5.1 Counterweight sections and identification............................................................677
				Counterweight sections..................................................................................677
				Identification..........................................................................................677
			14.5.2 Counterweight versions...............................................................................678
			14.5.3 Slinging points on the counterweight sections........................................................681
			14.5.4 CHECKLIST: Rigging counterweight.....................................................................682
				Counterweight rigging...................................................................................682
			14.5.5 CHECKLIST: Unrigging counterweight...................................................................685
				Unrigging counterweight................................................................................685
			14.5.6 Setting down the 8 t base plate......................................................................688
				On the counterweight platform...........................................................................688
			14.5.7 Preparing the 8 t base plate.........................................................................689
				Swinging the safety hook in/out........................................................................689
			14.5.8 Establishing/Disconnecting hydraulic connection......................................................690
			14.5.9 Assembling the counterweight version.................................................................692
			14.5.10 Extending/retracting the lifting cylinders of the 8 t base plate or raising/lowering the...........695
				Extending the lifting cylinders........................................................................696
				Retracting the lifting cylinders.......................................................................697
			14.5.11 Locking/unlocking the counterweight to the turntable................................................697
				Safety valve............................................................................................697
				Locking the counterweight...............................................................................698
				Unlocking the counterweight.............................................................................699
			14.5.12 Slewing with rigged counterweight...................................................................700
		14.6 Rigging work on the main boom..............................................................................701
			14.6.1 Hook block on the bumper.............................................................................701
				Picking up the hook block from the bumper...............................................................701
				Attaching the hook block to the bumper..................................................................702
			14.6.2 Hook block on a separate vehicle.....................................................................703
				Picking up the hook block..............................................................................703
				Setting down the hook block............................................................................704
			14.6.3 Reeving and unreeving the hoist rope.................................................................706
				Rope end clamp..........................................................................................706
				Installing/removing front rope grab.....................................................................708
				Positioning the hoist rope.............................................................................709
	15 Installing/Removing the auxiliary hoists.........................................................................733
		15.1 CHECKLISTS: Installing/removing with auxiliary crane.......................................................735
			15.1.1 CHECKLIST: Installing with auxiliary crane...........................................................735
				Prerequisites...........................................................................................735
			15.1.2 CHECKLIST: Removing with auxiliary crane.............................................................737
				Prerequisites...........................................................................................737
		15.2 CHECKLISTS: Installing/removing with counterweight hoist...................................................739
			15.2.1 CHECKLIST: Installing with counterweight hoist.......................................................739
				Prerequisites...........................................................................................739
			15.2.2 CHECKLIST: Removing with counterweight hoist.........................................................742
				Prerequisites...........................................................................................742
		15.3 Rigging work during installing/removing....................................................................745
			15.3.1 Slinging points and transport........................................................................745
				Slinging points.........................................................................................745
				Transporting............................................................................................746
			15.3.2 Attaching and reeving the guy unit...................................................................748
				Locking the lower hook block............................................................................749
				Reeving the upper/lower hook block.....................................................................749
			15.3.3 Lifting the auxiliary hoist to the main hoist with the auxiliary crane...............................751
			15.3.4 Locking/unlocking the auxiliary hoist................................................................752
				Unlocking the auxiliary hoist...........................................................................752
			15.3.5 Establishing/disconnecting the hydraulic connection..................................................753
			15.3.6 Establishing/disconnecting the electrical connection.................................................754
			15.3.7 Lifting/lowering the auxiliary hoist with the counterweight..........................................755
				Folding the folding carriers in/out.....................................................................755
				Placing the auxiliary hoist onto the folding carriers...................................................756
				Lifting the auxiliary hoist.............................................................................756
				Lowering the auxiliary hoist...........................................................................757
			15.3.8 Checking the auxiliary hoist for correct functioning.................................................758
			15.3.9 Transport protection for the upper hook block........................................................759
			15.3.10 Permissible applications for the auxiliary hoists...................................................760
				Replacement for the main hoist..........................................................................760
				Alternating operation with the main and the auxiliary hoist.............................................761
	16 Malfunctions on the superstructure...............................................................................765
		16.1 Emergency stop devices on the superstructure...............................................................765
			Switching off the crane engine.............................................................................765
			Emergency stop switch for Crane control.....................................................................766
		16.2 Procedure in the event of a malfunction while working with the crane......................................767
			Load cannot belowered......................................................................................767
		16.3 Fuses on the superstructure................................................................................769
			Information on replacing fuses............................................................................769
			16.3.1 Fuses at the front of the crane cab..................................................................770
			16.3.2 Fuses underneath the batteries.......................................................................774
			16.3.3 Fuses for the SLI....................................................................................775
		16.4 Finding and eliminating malfunctions.......................................................................777
			16.4.1 Malfunctions on the crane engine.....................................................................777
			16.4.2 Malfunctions on the main hoist.......................................................................779
			16.4.3 Malfunctions on the auxiliary hoist..................................................................781
			16.4.4 Malfunctions on the derricking gear..................................................................783
			16.4.5 Malfunctions in the telescoping mechanism............................................................785
			16.4.6 Malfunctions on the slewing gear.....................................................................787
			16.4.7 Malfunctions on locking pin/counterweight hoist......................................................788
			16.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler............................................789
			16.4.9 Malfunctions on the crane control....................................................................789
			16.4.10 Malfunctions on the SLI.............................................................................791
				General malfunctions...................................................................................791
				Error messages onthe SLI controlunit..................................................................792
				Table – error messages.................................................................................794
			16.4.11 Emergency operation for retraction..................................................................796
				Check prior to each emergency operation.................................................................796
				Procedures for retracting..............................................................................797
				Mechanical emergency operation..........................................................................798
				Hydraulic emergency operation...........................................................................800
			16.4.12 Switching the fan thermostat to emergency operation.................................................812
		16.5 Crane control error messages...............................................................................813
			16.5.1 Error messages concerning control units..............................................................813
			16.5.2 Error messages concerning power units................................................................814
				Detecting adefective part..............................................................................815
				Determining the area of error...........................................................................816
				Error causes andeffects................................................................................817
			16.5.3 Telescoping error messages...........................................................................819
			16.5.4 Changing the connections in the control units........................................................820
				Connections and control units...........................................................................820
				Unrigging the truck crane with defective control unit...................................................820
				Inserting and removing connections....................................................................823
			16.5.5 Control lever emergency program......................................................................824
				Indication on thedisplay...............................................................................824
				Executing emergency program.............................................................................825
			16.5.6 Emergency operation submenu..........................................................................826
				Retracting in the event of an error on the length indicator............................................827
				Retracting in the event of an error on the proximity switch.............................................830
				Table for approaching the locking points................................................................831
			16.5.7 “Enter telescoping after emergency operation” menu...................................................832
		16.6 Superstructure hydraulic emergency operation compliant with ZH1/461.......................................835
			16.6.1 Important instructions for hydraulic emergency operation.............................................835
			16.6.2 Operating principle and accessories..................................................................836
			16.6.3 Connecting the transformer...........................................................................837
			16.6.4 Switching emergency operation on/off.................................................................838
			16.6.5 Establishing the required hydraulic circuits.........................................................839
				Emergency operation positions...........................................................................840
				Crane operation positions...............................................................................840
			16.6.6 Carrying out emergency operation.....................................................................841
				Emergency main hoist operation..........................................................................842
				“Move derricking gear” emergency operation..............................................................842
				“Move slewing gear” emergency operation.................................................................844
			16.6.7 After emergency operation............................................................................845
	17 Technical information for the superstructure.....................................................................849
		17.1 Dimensions and weights.....................................................................................849
			17.1.1 Maximum lifting capacity.............................................................................849
				DIN/ISO/EN..............................................................................................849
				ANSI B 30.5 (85%).......................................................................................849
			17.1.2 Guarantee information................................................................................849
			17.1.3 Dimensions and weights of the truck crane............................................................850
				Dimensions when driving on public roads................................................................851
			17.1.4 Dimensions and weights of removable parts............................................................852
				Counterweight parts....................................................................................852
				Hook blocks and hook tackle.............................................................................853
				Auxiliary hoist.........................................................................................853
				Main boom...............................................................................................854
				Counterweight versions..................................................................................854
		17.2 Technical data for the superstructure......................................................................855
			Crane engine................................................................................................855
			Crane electrical system.....................................................................................855
			Main hoist..................................................................................................855
			Auxiliary hoist (additional equipment)......................................................................856
			Slewing gears...............................................................................................856
			Derricking gear.............................................................................................856
			Main boom...................................................................................................856
			Operating speeds and times without a load..................................................................857
	18 Index............................................................................................................861
		A...............................................................................................................863
		B...............................................................................................................864
		C...............................................................................................................864
		D...............................................................................................................866
		E...............................................................................................................867
		F...............................................................................................................868
		H...............................................................................................................868
		I...............................................................................................................869
		K...............................................................................................................869
		L...............................................................................................................869
		M...............................................................................................................870
		O...............................................................................................................871
		P...............................................................................................................871
		R...............................................................................................................872
		S...............................................................................................................872
		T...............................................................................................................874
		V...............................................................................................................875
		W...............................................................................................................875

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