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Grove GMK 6300 Driving & Crane Operating Instruction Manual 3112200 – PDF DOWNLOAD
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Description
Grove GMK 6300 Driving & Crane Operating Instruction Manual 3112200 – PDF DOWNLOAD
FILE DETAILS:
Grove GMK 6300 Driving & Crane Operating Instruction Manual 3112200 – PDF DOWNLOAD
Language : English
Pages : 878
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove GMK 6300 Driving & Crane Operating Instruction Manual 3112200 – PDF DOWNLOAD
Overview and contents of the truck crane user information:
1.3.1 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 ob- serve 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 de- scribing 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 on- road 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 func- tional elements of
the vehicle section as well as the Technical specifications.
TABLE OF CONTENTS:
Grove GMK 6300 Driving & Crane Operating Instruction Manual 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 –15 C and 0 C::........................................................500 At an oil temperature of below –15 C:..................................................................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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