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Grove GMK 4100 Operating Instructions Manual

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Table of Contents

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Operating instructions
Part 1 – Driving
3 112 343 en
Serial number
23.11.2006

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Afonso
March 12, 2025

Aonde **** o tanque de combustivel?

0
1 comments:
Mr. Anderson
May 14, 2025

The fuel tank on the Grove GMK 4100 is indicated by the display showing the fuel supply and is referred to as tank (1). However, the exact physical location of the fuel tank is not specified in the provided context.

This answer is automatically generated

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Summary of Contents for Grove GMK 4100

  • Page 1 Operating instructions Part 1 – Driving 3 112 343 en Serial number 23.11.2006...
  • Page 2 Dissemination or duplication of this document as well as utilization and disclosure of its contents are prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved. 3 112 343 en Operating instructions GMK 4100...
  • Page 3 4 Starting / turning off the engine for driving 5 Driving 6 Driving modes 7 Malfunctions in driving mode 8 Technical information on the carrier 9 Index You will find chapters 10 to 17 in part 2 – Crane Operation. Operating instructions GMK 4100 3 112 343 en...
  • Page 4 Blank page 3 112 343 en Operating instructions GMK 4100...

  • Page 5: Table Of Contents

    Conversion table for US measurements ....... . . 1 - 15 Operating instructions GMK 4100...
  • Page 6 3 112 343 en Operating instructions GMK 4100...

  • Page 7: Overview

    Overview 1.1 Identification Overview Identification These operating instructions are intended only for the truck crane with the serial number specified on the front cover. Operating instructions GMK 4100 3 112 343 en 1 - 1...
  • Page 8 Overview 1.1 Identification 1 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 9 5 The chassis number in front of the first axle line in the frame The location of the identification numbers on removable rigging parts (e.g. counterweights, lattice extension) is described in the corresponding chap- ters or in the specific operating instructions supplied. Operating instructions GMK 4100 3 112 343 en 1 - 3...
  • Page 10 Overview 1.1 Identification Blank page 1 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 11: Ec Declaration Of Conformity

    Operators of truck cranes which are delivered to EU member countries receive a declaration of conformity as a supplement to the delivery protocol. An example of the declaration of conformity is illustrated below. Operating instructions GMK 4100 3 112 343 en 1 - 5...

  • Page 12: Documentation Supplied

    Circuit diagrams for the electrical system, hydraulic system and pneu- matic system are supplied. – Lifting capacity table Information on the lifting capacity when the truck crane is in different rig- ging modes. 1 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 13: Information About The Operating Instructions

    This symbol indicates hazards related to the described operation that may cause personal injury. The type of danger (e.g. danger to life, risk of injury or danger of being crushed) usually precedes the warning. Operating instructions GMK 4100 3 112 343 en 1 - 7...
  • Page 14 This symbol indicates that the topic is continued on the next page. Turn to the next page. Horizontal lines always indicate the start or the end of an example. The text used for examples is in a different font. 1 - 8 3 112 343 en Operating instructions GMK 4100...

  • Page 15: How Are The Operating Instructions Structured

    If in doubt, always read the section first which is referred to in the checklist. Operating instructions GMK 4100 3 112 343 en 1 - 9...
  • Page 16 – Designations of operating elements and switching states, such as auto- matic or manual . – Headings of sections to which a reference is made. – The names of other documents to which a reference is made. 1 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 17: How Do I Find The Information I Need

    The following pages give an example of how to use the cross-references. Operating instructions GMK 4100 3 112 343 en 1 - 11...
  • Page 18 1.4 Information about the operating instructions Cross-references The illustrations and texts in this section are only an example and may differ example from the conditions on your truck crane. 1 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 19 There may be additional cross-references here, such as to related pages in the chapter Malfunctions . Operating instructions GMK 4100 3 112 343 en 1 - 13...

  • Page 20: What Information Is Available For Operations Planning

    – Turning circle radii; p. 8 - 7, à – The permitted outrigger spans; p. 13 - 28, à – The size of the outrigger pads; p. 8 - 6. 1 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 21 1.60935 lbf ft 0.7375 °C °F 1.8 x °C + 32 °F °C (°F-32) / 1.8 t / m lbs / ft 204,8 / lbs 0,04882 Operating instructions GMK 4100 3 112 343 en 1 - 15...

  • Page 22: 1.5 Conversion Table For Us Measurements

    Overview 1.5 Conversion table for US measurements Blank page 1 - 16 3 112 343 en Operating instructions GMK 4100...
  • Page 23 Safety instructions for crane operation........2 - Operating instructions GMK 4100...
  • Page 24 3 112 343 en Operating instructions GMK 4100...

  • Page 25: Basic Safety Instructions

    Modifications may only be made to the truck crane following the approval Manitowoc Crane Group Germany GmbH The GMK 4100 truck crane may only be used in a perfect technical condition as intended and with due attention paid to safe operation and possible haz- ards.

  • Page 26: Improper Use

    Basic safety instructions 2.1 Intended use The GMK 4100 may only be operated with parts of equipment which are permitted by , and which are labelled Manitowoc Crane Group Germany GmbH with the serial number of the GMK 4100. The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK 4100 truck crane.

  • Page 27: Organisational Measures

    Use your personal protective gear whenever necessary or prescribed. Observe all safety instructions and warnings on the truck crane. Keep all safety instructions and warnings on the truck crane in a legible con- dition. Operating instructions GMK 4100 3 112 343 en 2 - 3...
  • Page 28 Monitor the work of personnel, at least occasionally, and make sure they work in accordance with the operating instructions in a safe and conscien- tious manner. 2 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 29: Qualifications Of The Personnel

    Manitowoc Crane Group Germany GmbH crane operator courses and technical courses. Operating instructions GMK 4100 3 112 343 en 2 - 5...

  • Page 30: Safety Instructions For Driving The Truck Crane

    Check all operating and control elements in the driver's cab before starting the engine. After starting the engine, take note of all the lights and control elements. After driving, secure the truck crane against unauthorized use. 2 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 31: Safety Instructions For Crane Operation

    Inform any banksmen and helpers about this issue as well. Support the truck crane with the outrigger span required for the currently rigged counterweight before turning the superstructure. Operating instructions GMK 4100 3 112 343 en 2 - 7...
  • Page 32 Please observe the instructions in the section titled Crane operation under special operating conditions in the Safety manual and the respective national regulations. 2 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 33 Storage compartment ..........3 - 58 Operating instructions GMK 4100...
  • Page 34 3 112 343 en Operating instructions GMK 4100...

  • Page 35: Operating Elements For Driving

    These designations are made in this section only and are not repeated in the following sections. Some figures show details from a different perspective than the total view. The perspective is indicated by the symbol (1). Operating instructions GMK 4100 3 112 343 en 3 - 1...

  • Page 36: On The Outside Of The Truck Crane

    Operating elements for driving 3.1 Overview of the operating elements 3.1.1 On the outside of the truck crane 3 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 37 4 - 23 à 24 Adjusting the mirrors p. 5 - 7 à 25 Battery master switch p. 4 - 8 26 Central lubrication Additional equipment à Maintenance manual Operating instructions GMK 4100 3 112 343 en 3 - 3...

  • Page 38: Driver's Cab

    Operating elements for driving 3.1 Overview of the operating elements 3.1.2 Driver's cab Overview 3 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 39: 15 Instrument Panel

    22 Sockets 12 V / 24 V p. 3 - 34 à 23 Behind the cover p. 3 - 6 Additional equipment à Separate operating instructions à Maintenance manual Operating instructions GMK 4100 3 112 343 en 3 - 5...
  • Page 40 Behind the cover à 1 Fuses p. 7 - 17 à 2 Hydraulic emergency operation on / off p. 15 - 57 à 3 Diagnostics p. 3 - 53 Additional equipment 3 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 41 Version 2 à 8 Heating / Air-conditioning system p. 3 - 24 à 9 Voltage 12 V on / off p. 3 - 34 Additional equipment à Separate operating instructions Operating instructions GMK 4100 3 112 343 en 3 - 7...
  • Page 42 Operating elements for driving 3.1 Overview of the operating elements Middle 3 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 43 17 Flame start system indicator lamp p. 3 - 33 à 18 Show journey data / reset p. 3 - 55 19 No function à 20 Instrument lighting p. 3 - 50 Additional equipment Operating instructions GMK 4100 3 112 343 en 3 - 9...

  • Page 44: Display, Driver's Cab

    3 - 55 à 2 On-board computer display p. 3 - 54 à 3 Transmission display p. 3 - 37 à 4 Information status display p. 3 - 54 3 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 45: Steering Column / Steering Wheel

    – Engine retarder / transmission retarder p. 3 - 45 à 3 Ignition lock p. 3 - 32 à 4 Adjusting the steering column p. 5 - 13 Additional equipment Operating instructions GMK 4100 3 112 343 en 3 - 11...

  • Page 46: Transmission Operating Elements

    3 - 39 à 3 Gearshift lever p. 3 - 38 à 4 Additional function, gearshift lever p. 3 - 38 à 5 Changing the operating mode p. 3 - 38 3 - 12 3 112 343 en Operating instructions GMK 4100...

  • Page 47: Tachograph

    5 - 18 à 6 Set time group – driver 2 p. 5 - 18 à 7 Correcting the time p. 3 - 52 à 8 Drawer p. 5 - 17 Operating instructions GMK 4100 3 112 343 en 3 - 13...

  • Page 48: Ecos Control Unit

    Operating elements for driving 3.1 Overview of the operating elements 3.1.8 ECOS control unit 3 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 49 The functions of the buttons in the displayed menu correspond to the symbols next to or above the buttons; à p. 3 - 34. Operating instructions GMK 4100 3 112 343 en 3 - 15...

  • Page 50: Ecos Display - Main Menu

    Operating elements for driving 3.1 Overview of the operating elements 3.1.9 ECOS display – main menu 3 - 16 3 112 343 en Operating instructions GMK 4100...
  • Page 51 Separate steering on / off p. 3 - 46 à 11 Serial number / program version display p. 3 - 36 à 12 Warning display p. 3 - 36 Additional equipment Operating instructions GMK 4100 3 112 343 en 3 - 17...

  • Page 52: Ecos Display - Submenus

    Operating elements for driving 3.1 Overview of the operating elements 3.1.10 ECOS display – submenus Level adjustment system submenu 3 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 53 11 Lowering / raising the level p. 3 - 51 à 12 Lowering / raising the level p. 3 - 51 à 13 Suspension operating pressure gauge p. 3 - 47 Additional equipment Operating instructions GMK 4100 3 112 343 en 3 - 19...
  • Page 54 6 Display – setting the brightness p. 4 - 12 à 7 Transmission emergency program submenu p. 3 - 22 à 8 AMG diagnostics p. 3 - 53 For service personnel only 3 - 20 3 112 343 en Operating instructions GMK 4100...
  • Page 55 Warning submenu Description of the displays; 1 Air intake inhibitor triggered 2 Hydraulic oil too hot 3 Replacing the hydraulic oil filter 4 Supply pressure in secondary consumers too low Operating instructions GMK 4100 3 112 343 en 3 - 21...
  • Page 56 7 Towing mode on / off display p. 7 - 7 à 8 Switching group display p. 7 - 40 à 9 Towing mode on p. 7 - 7 3 - 22 3 112 343 en Operating instructions GMK 4100...
  • Page 57 1 Display of error / total errors p. 7 - 31 à 2 Next error p. 7 - 31 à 3 Previous error p. 7 - 31 à 4 Error display p. 7 - 32 Operating instructions GMK 4100 3 112 343 en 3 - 23...

  • Page 58: Heating / Air-Conditioning System

    5 - 75 à 2 Air distribution p. 5 - 76 à 3 Setting the temperature p. 5 - 75 à 4 Air-conditioning system p. 5 - 78 3 - 24 3 112 343 en Operating instructions GMK 4100...
  • Page 59 5 – Switching on p. 5 - 80 à – Switching off p. 5 - 84 à 6 Input – p. 5 - 81 à 7 Input + p. 5 - 81 Operating instructions GMK 4100 3 112 343 en 3 - 25...

  • Page 60: Sockets For Hand-Held Control

    Since these operating elements are required for crane operation, they are à described in Part 2 – Crane operation ; Hand-held control , p. 10 - 44. 3 - 26 3 112 343 en Operating instructions GMK 4100...

  • Page 61: Outrigger Control Units

    Contain operating elements for crane operation; p. 10 - 46. When driving, error messages relating to the carrier electronics can be read à on this display; p. 7 - 33. Operating instructions GMK 4100 3 112 343 en 3 - 27...
  • Page 62 Operating elements for driving 3.1 Overview of the operating elements Blank page 3 - 28 3 112 343 en Operating instructions GMK 4100...

  • Page 63: Short Description Of The Operating Elements

    Backwards always means the rear lights on the carrier are to the front of the direction of travel. On the superstructure The main boom head is always at the front, which means that: 1: front 2: right 3: rear 4: left Operating instructions GMK 4100 3 112 343 en 3 - 29...

  • Page 64: General Information On The Operating Elements

    – first press the lock button – then press lower part of switch down – To switch off: press top half of switch down until the lock button latches into place 3 - 30 3 112 343 en Operating instructions GMK 4100...

  • Page 65: General Rules For Buttons And Symbols On The Display

    – If the instruction given in this section is to “Press the button once...“, for instance, this always refers to the button (2) next to or below the symbol shown (1). Even when the button itself is not visible in the illustration. Operating instructions GMK 4100 3 112 343 en 3 - 31...

  • Page 66: Engine

    (4) 2 Down: switch on or decrease the speed (4) 3 To the front: switch off Tempomat on = current speed (4) is maintained à p. 5 - 41 3 - 32 3 112 343 en Operating instructions GMK 4100...
  • Page 67 Soot particle filter indicator lamp – Version 1 1 Yellow lamp lights up: early warning: clean soot particle filtering system 2 Orange lamp lights up: clean / replace soot particle filtering system; à Maintenance manual Operating instructions GMK 4100 3 112 343 en 3 - 33...

  • Page 68: Electrical System

    3.2.6 ECOS crane control The truck crane GMK 4100 is equipped with the ECOS electronic crane con- trol (Electronic Crane Operating System). ECOS includes a control unit in the crane cab, an operating unit in the driver's cab and several control units (ESX0, ESX1, ESX2 etc.) and circuit boards (I/O 0, I/O 1 etc.) which are dis-...
  • Page 69 Input mode is activated. – To the right: increases the value – To the left: reduces the value Slow turning changes the value slowly. Fast turning changes the value fast. Operating instructions GMK 4100 3 112 343 en 3 - 35...
  • Page 70 1 Shows the symbol of a current warning message – for several warning messages, the displays are shown one after the other in continuous à sequence; p. 5 - 48. 3 - 36 3 112 343 en Operating instructions GMK 4100...

  • Page 71: Transmission

    5 Automatic operating mode on 6 Manual operating mode on ECOS display Transmission emergency program submenu – To open: Press button once – submenu opens à p. 7 - 38 Operating instructions GMK 4100 3 112 343 en 3 - 37...
  • Page 72 – Push forwards once: shift up starting gear – 1 gear – Push to the rear once: shift down starting gear – 1 gear à p. 5 - 32 3 - 38 3 112 343 en Operating instructions GMK 4100...
  • Page 73 – ½ gear à p. 5 - 35 Instrument panel Prompt to brake – On: downshifting not possible; warning buzzer sounds – brake truck crane à p. 5 - 35 Operating instructions GMK 4100 3 112 343 en 3 - 39...
  • Page 74 Operating elements for driving 3.2 Short description of the operating elements Blank page 3 - 40 3 112 343 en Operating instructions GMK 4100...

  • Page 75: Transfer Case

    2 Off-road gear off – on-road driving 3 Neutral position on 4 Error – violet The displays in the main menu (6) and the Settings submenu (5) always show the same symbol. Operating instructions GMK 4100 3 112 343 en 3 - 41...

  • Page 76: Final Drive

    B Longitudinal differential locks display The current status is shown using different symbols: 1 Green – locks off 2 Red – locks on 3 Yellow – intermediate position 4 Violet – error 3 - 42 3 112 343 en Operating instructions GMK 4100...

  • Page 77: Brakes

    6 km/h (4 mph) not reached ABS trailer faulty – Off: approx. 6 km/h (4 mph) exceeded, and ABS trailer ready to function à p. 5 - 40 Operating instructions GMK 4100 3 112 343 en 3 - 43...
  • Page 78 – Press in the lever and pull it further backwards The parking brake for the trailer is released; à p. 5 - 90. Parking brake indicator lamp – On: parking brake engaged – Off: parking brake released 3 - 44 3 112 343 en Operating instructions GMK 4100...
  • Page 79 4 To the rear: Engine retarder, transmission retarder 100% Instrument panel Checking the additional brake – On: Engine retarder / transmission retarder on – Off: Engine retarder / transmission retarder off Operating instructions GMK 4100 3 112 343 en 3 - 45...

  • Page 80: Steering / Separate Steering

    – turn to the left – To the right: third and fourth axle lines – turn to the right à p. 5 - 72 3 - 46 3 112 343 en Operating instructions GMK 4100...

  • Page 81: Suspension

    2 Suspension pressure, first and second axle lines, right-hand side 3 Suspension pressure, third and fourth axle lines, left-hand side 4 Suspension pressure, third and fourth axle lines, right-hand side Operating instructions GMK 4100 3 112 343 en 3 - 47...

  • Page 82: Lighting / Windscreen Wipers / Horn

    – full beam off Indicator lamp for turn signal indicator 1 – Flashing: turn signal indicator on – Off: turn signal indicator off, or turn signal indicator on and bulb defective 3 - 48 3 112 343 en Operating instructions GMK 4100...
  • Page 83 – To switch on: press up – To switch off: press down Outrigger lighting on / off – To switch on: press up – To switch off: press down Operating instructions GMK 4100 3 112 343 en 3 - 49...

  • Page 84: Level Adjustment System

    7 6 9 8 The following functions are operated in the same manner: – Front level pre-selection – Rear level pre-selection – Right level pre-selection – Left level pre-selection 3 - 50 3 112 343 en Operating instructions GMK 4100...
  • Page 85 Press the button until the symbol (1) is green à p. 5 - 66 Display of current inclination 1 Measuring range display 2 Inclination display 3 Directional indicator à p. 5 - 67 Operating instructions GMK 4100 3 112 343 en 3 - 51...

  • Page 86: Tachograph / Speedometer

    2 Indicates the speed in mph Kilometre counter The ignition is switched on. 1 Overall route in kilometres - Position after the decimal point: 1 = 100 m (33 ft) 3 - 52 3 112 343 en Operating instructions GMK 4100...

  • Page 87: Diagnostics

    If there is a malfunction, press button (2) once, read the values in the submenu and report to CraneCARE à Further displays are shown on the Driving display; Diagnostics , p. 5 - 26. Operating instructions GMK 4100 3 112 343 en 3 - 53...

  • Page 88: On-Board Computer

    3 - 55 B Can be retrieved with (1): à – Display menus; p. 5 - 22 When ignition off / on, the last set display is shown. 3 - 54 3 112 343 en Operating instructions GMK 4100...
  • Page 89 – Displays All values apply from the start of the journey 1 Journey route 2 Journey duration 3 Journey speed – average 4 Current consumption 5 Day's kilometre counter Operating instructions GMK 4100 3 112 343 en 3 - 55...

  • Page 90: Push-Up Roof

    B Window winder, passenger door 1 To open the window 2 To close the window The movement stops after the button is released and when an end position is reached 3 - 56 3 112 343 en Operating instructions GMK 4100...
  • Page 91 Pull the handle (2) Keys Different keys are supplied. 1 Door locks / ignition lock of driver's cab 2 Control unit, outriggers 3 Fuel tank 4 Covers Additional equipment Operating instructions GMK 4100 3 112 343 en 3 - 57...

  • Page 92: Front Flap

    Press the button (2) – the door (1) opens. Closing • Press the door inwards (1) and press the lever (3) – latches into place. • Lock if necessary. 3 - 58 3 112 343 en Operating instructions GMK 4100...
  • Page 93 Air intake inhibitor........... 4 - 23 Operating instructions GMK 4100...
  • Page 94 3 112 343 en Operating instructions GMK 4100...

  • Page 95: Starting / Turning Off The Engine For Driving

    4 - 8. à 2. Check the coolant level of the engine; Maintenance manual . à Maintenance manual . 3. Check the oil level in the hydraulic system; Operating instructions GMK 4100 3 112 343 en 4 - 1...
  • Page 96 à p. 4 - 9. 9. If necessary, set the brightness à – on the ECOS display; p. 4 - 12 à – Instrument lighting; p. 3 - 50. 4 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 97 14. Conduct the necessary checks after starting the engine; p. 4 - 16. à 15. In the event of low outside temperatures; CHECKLIST: if the temper- ature is low , p. 4 - 4. Operating instructions GMK 4100 3 112 343 en 4 - 3...

  • Page 98: Checklist: If The Temperature Is Low

    2. The engine coolant must contain sufficient antifreeze; engine operating instructions, provided by the manufacturer . 3. The windscreen washing system must contain sufficient antifreeze; à Windscreen washing system , p. 5 - 6. 4 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 99: Ladders And Access Ladders

    Push the ladder (4) into the clamp (1). • Place the clamp (3) over the rungs (2). • Secure the clamp (3) from below with a retaining pin or a lock. Operating instructions GMK 4100 3 112 343 en 4 - 5...
  • Page 100 Push the ladder (5) under the clamp (4) and secure it with the retaining pin on the clamp (6). • Place the ladder (2) between the clamp (3) and secure it with the spring latch (1). 4 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 101: Refuelling

    Risk of accidents if the tank is not closed! Close the tank each time you have refuelled. In this way you can prevent other vehicles from being endangered by the cap falling off or fuel escaping. Operating instructions GMK 4100 3 112 343 en 4 - 7...

  • Page 102: Checks Before Starting The Engine

    You can only start the engine when the battery master switch is switched switch • Switch on the battery master switch (1). The battery master switch is switched on if you are unable to pull off the selector handle. 4 - 8 3 112 343 en Operating instructions GMK 4100...

  • Page 103: Switching On The Ignition

    Insert the ignition key into the ignition lock and turn the key to position 2. After switching on the ignition, a lamp test is carried out, and switching states are checked. Operating instructions GMK 4100 3 112 343 en 4 - 9...

  • Page 104: Lamp Test / Equalisation Of The Switching States

    CraneCARE not go on. If you could not check all the lamps in the specified time, you can conduct the lamp test again as follows. 4 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 105 à Switching to normal steering mode , p. 5 - 73. Operating instructions GMK 4100 3 112 343 en 4 - 11...

  • Page 106: Display - Setting The Brightness

    Adopt the minimum brightness entered – press the button (2) once. The red bar below the display goes out. The brightness is automatically regulated between the newly set value and 100%. 4 - 12 3 112 343 en Operating instructions GMK 4100...

  • Page 107: To Start The Engine

    • Check that the parking brake is applied. à With flame start sys- If the engine is equipped with a flame start system; tem , p. 4 - 15 Operating instructions GMK 4100 3 112 343 en 4 - 13...
  • Page 108 If the engine does not go on, abort the starting procedure after about 15 sec- onds and wait one minute before trying again. à Malfunctions on the If the engine does not go on after several attempts; engine , p. 7 - 23. 4 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 109 If the engine does not go on, abort the starting procedure after about 15 seconds and wait one minute before trying again. à Malfunctions on the If the engine does not go on after several attempts; engine , p. 7 - 23. Operating instructions GMK 4100 3 112 343 en 4 - 15...

  • Page 110: Checks After Starting The Engine

    Immediately after you start to move , p. 5 - 39. – Display (2) – when a warning message is à Warning submenu , p. 5 - 48. shown; 4 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 111: Control Elements

    B: coolant Is shown automatically when the limit value is exceeded; à Messages on the on-board computer display , p. 5 - 50. à Set the temperature unit ( °C / °F); p. 5 - 25. Operating instructions GMK 4100 3 112 343 en 4 - 17...
  • Page 112 Red: limit value exceeded (or fallen short of) – warning message; à p. 5 - 48. à Inspection information , p. 5 - 23 Display, driver's cab 4 - 18 3 112 343 en Operating instructions GMK 4100...

  • Page 113: Setting The Idling Speed

    / reduced by 20 rpm. Switching off the idling speed change: • Push the switch forwards once. The idling speed is set automatically. • Accelerate over 20 km/h (12 mph). Operating instructions GMK 4100 3 112 343 en 4 - 19...
  • Page 114 Starting / turning off the engine for driving 4.1 Starting the engine from the driver's cab Blank page 4 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 115: Turning Off The Engine

    In this case it is not possible to switch off the engine with the ignition lock. à • After turning off If you want to park the truck crane; p. 5 - 58. Operating instructions GMK 4100 3 112 343 en 4 - 21...

  • Page 116: With Emergency Stop Switches

    If air intake inhibitors are fitted, they must be released; à Releasing the air intake inhibitor , p. 4 - 23. à Releasing the air intake inhibitor , p. 11 - 21. 4 - 22 3 112 343 en Operating instructions GMK 4100...

  • Page 117: Air Intake Inhibitor

    (A) – The indicator (2) is in the closed position. (B) – Turn the indicator (2) clockwise until it engages into the Released position. You can close the air intake inhibitor manually with the lever (3). Operating instructions GMK 4100 3 112 343 en 4 - 23...
  • Page 118 Starting / turning off the engine for driving 4.3 Air intake inhibitor Blank page 4 - 24 3 112 343 en Operating instructions GMK 4100...
  • Page 119 Towing a trailer ........... . . 5 - 85 Operating instructions GMK 4100...
  • Page 120 3 112 343 en Operating instructions GMK 4100...

  • Page 121: Driving

    6 - 8 à – The boom pre-tensioning may be switched on; p. 6 - 10 à – The houselock may be switched off; p. 12 - 14 Operating instructions GMK 4100 3 112 343 en 5 - 1...
  • Page 122 Ladders , p. 4 - 5. 8. Check the tyres: à – tyre pressure when tyres are cold in on-road mode; p. 8 - 5. à Maintenance manual . – Further checks; 5 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 123 13. All additional parts which may be transported are secured against fall- ing down. 14. Carry out all activities and inspections required for starting the engine; à CHECKLIST: Starting the engine , p. 4 - 1. Operating instructions GMK 4100 3 112 343 en 5 - 3...
  • Page 124 19. Set the tachograph, insert the diagram sheet; p. 5 - 16. à Checks after starting the 20. Start the engine and carry out all inspections; engine , p. 4 - 16. 5 - 4 3 112 343 en Operating instructions GMK 4100...
  • Page 125 5 - 63 à – Steering locked; p. 5 - 73 à – On-road level is set ; p. 5 - 66 Establish the switching states for on-road driving if necessary. Operating instructions GMK 4100 3 112 343 en 5 - 5...

  • Page 126: Checking The Condition Of The Truck Crane

    – Parking light / headlight, rotating beacons, fog tail light, side marker lights – Hazard warning system – Brake lights – Reversing lamp / buzzer – Full-beam headlight – Turn signal indicator – Windscreen wipers – Windscreen washing system – Horn 5 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 127 3 below 4 left Mirror heating 1 To switch on: Press button once – lamp (3) lights up 2 To switch off: Press button once – lamp (3) goes out Operating instructions GMK 4100 3 112 343 en 5 - 7...
  • Page 128 (1) appears. Risk of accidents from exceeding the permissible overall height Check that the symbol is shown. Otherwise the given overall height will also be exceeded at on-road level. 5 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 129 – approx. 8 bar (116 psi) are reached and – a valve audibly releases pressure. Now there is sufficient supply pressure. You can also show the pressure on the On-board computer display; à p. 5 - 23. Operating instructions GMK 4100 3 112 343 en 5 - 9...
  • Page 130 • Release the parking brake. The parking brake is released and the light (1) goes out when the supply pressure is sufficient. 5 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 131: Adjusting The Seats And Steering Column

    4 Seat heating on / off 5 Angle of the back rest 6 Length adjustment of the seat 7 Seat cushion angle 8 Length adjustment of the seat cushion Additional equipment Operating instructions GMK 4100 3 112 343 en 5 - 11...
  • Page 132 Empty air cushion: press – Fill air cushion: press + Passenger's seat The passenger's seat is adjusted mechanically. 1 Angle of the back rest 2 Length adjustment of the seat 5 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 133 • Bring the steering column into the desired position. • Press the button (1) up once. Or wait until the steering column is locked automatically (after about 6 seconds). Operating instructions GMK 4100 3 112 343 en 5 - 13...

  • Page 134: Switching The Suspension On / Off

    The Level adjustment system submenu opens. The dot (1) indicates the selected switching state: Dot is green: switch on suspension has been selected Dot is black: switch off suspension has been selected 5 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 135 The axle lines may become damaged and the steering behaviour may change if the suspension is switched off. • Press the button (2) once – dot black. When the suspension is switched off, the symbol (1) is red. Operating instructions GMK 4100 3 112 343 en 5 - 15...

  • Page 136: Adjusting The Tachograph

    If a malfunction has occurred, – The On-board computer display shows an error message (2) – The Tachograph display (1) shows an error à Separate operating instructions message; of the tachograph manufacturer. 5 - 16 3 112 343 en Operating instructions GMK 4100...
  • Page 137 Take all the diagram sheets out of the diagram sheet mounting. • Close the drawer. The time setting is corrected automatically. • Open the drawer and insert the required diagram sheets. Operating instructions GMK 4100 3 112 343 en 5 - 17...
  • Page 138 Push the drawer (2) back in until it engages. For single-driver operation the diagram sheet mounting under the isolating plate is empty and only the diagram sheet (1) for driver 1 is inserted. 5 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 139 The set time group is shown with the symbol (1.1). Set the time group for driver 2 using the but- ton (2). The set time group is shown with the symbol (2.1). Operating instructions GMK 4100 3 112 343 en 5 - 19...
  • Page 140 Otherwise an error message will appear. You can also show the current steering and idle times on the On-board com- Additional à puter display; Social data / tachograph , p. 5 - 23. displays 5 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 141: Displaying The Operating Hours

    1680 hours – The value (2) indicates the minutes, e.g. 12 minutes The other displays relate to crane operation; à Displaying the operating hours , p. 12 - 101. Operating instructions GMK 4100 3 112 343 en 5 - 21...

  • Page 142: Settings / Displays With The On-Board Computer

    • (C) – Use (3) or (4) to select the required set- ting, e.g. 3pm. • Save with (2) – display B. You can quit the menus with (1). 5 - 22 3 112 343 en Operating instructions GMK 4100...
  • Page 143 Driver 1 or driver 2. 5 Driving time 6 Resting time Supply pressure Display of the current supply pressure 1 For brake circuit 1 2 For brake circuit 2 Operating instructions GMK 4100 3 112 343 en 5 - 23...
  • Page 144 Text (5): Set the hours • Use (3), (4) to set, and (2) to store. Text (5): Set the minutes • Use (3), (4) to set, and (2) to store. 5 - 24 3 112 343 en Operating instructions GMK 4100...
  • Page 145 Text (5): Temperature unit • Select with (3), (4): Degrees (6) – Celsius / Fahrenheit. • Store with (2) – the unit applies to all tem- perature displays on the Driving display. Operating instructions GMK 4100 3 112 343 en 5 - 25...
  • Page 146 Display (5) error code, e.g. 8000 for TCO. • Show additional errors with (3), (4), if present. • Go back with (1). Additional displays are only intended for service work. 5 - 26 3 112 343 en Operating instructions GMK 4100...
  • Page 147 Yes / no. • Store with (2) – when “Yes“ selected, all messages on the Driving display are deleted. Binary values • Select with (3), (4), display with (2): Operating instructions GMK 4100 3 112 343 en 5 - 27...
  • Page 148 Driving 5.1 Before driving Blank page 5 - 28 3 112 343 en Operating instructions GMK 4100...

  • Page 149: Operating The Transmission

    Driving 5.2 Operating the transmission Operating the transmission The GMK 4100 truck crane is equipped with a transmission with automatic gear change. The transmission automatically controls the clutch operating mechanism and gear changing. Despite this, gears can be changed manu- ally at any time.

  • Page 150: Switching The Transmission To Neutral Position

    Gears can only be shifted with the switch lever or with the two-stop rocker. Gears are not shifted automatically. The various functions in the two operating modes are described in detail in the following sections. 5 - 30 3 112 343 en Operating instructions GMK 4100...

  • Page 151: Display Of The Selected Gears

    Press the button (1) and additionally push the switch lever forwards once. For reverse travel • Press the button (1) and additionally push the switch lever backwards once. Depending on the equipment, an acoustic signal can be heard. Operating instructions GMK 4100 3 112 343 en 5 - 31...
  • Page 152 Push the two-stop rocker upwards / downwards once. The starting gear is upshifted / downshifted by a half gear. The changed starting gear is displayed, e.g. the fourth gear as half a gear. 5 - 32 3 112 343 en Operating instructions GMK 4100...

  • Page 153: Starting

    When a transmission malfunction is detected, the On-board computer display à shows corresponding entries; Messages on the on-board computer display , p. 5 - 50. Operating instructions GMK 4100 3 112 343 en 5 - 33...

  • Page 154: Driving And Changing Gears

    Also, you can change gears manually at any time. Proceed in the same man- ner as with Manual operating mode. Automatic mode immediately switches back to a suitable gear, depending on the current load, speed and position of the accelerator. 5 - 34 3 112 343 en Operating instructions GMK 4100...
  • Page 155 (1) lights up. • In this case, apply the brakes. The gear will be shifted as soon as a permissible engine speed has been reached. Operating instructions GMK 4100 3 112 343 en 5 - 35...

  • Page 156: Changing The Driving Direction

    Press the button (1) and additionally push the switch lever backwards once. The reverse gear R is engaged. Direct gear changeover is released until you switch to neutral gear. 5 - 36 3 112 343 en Operating instructions GMK 4100...

  • Page 157: Stopping

    – Apply the parking brake time – Shift the transmission to neutral position 5.2.10 On the roller type dynamometer • Always switch to neutral position after driving onto a roller type dynamometer. Operating instructions GMK 4100 3 112 343 en 5 - 37...
  • Page 158 Driving 5.2 Operating the transmission Blank page 5 - 38 3 112 343 en Operating instructions GMK 4100...

  • Page 159: Driving And Turning Off The Truck Crane

    You may continue to drive slowly in order to reach the next garage if one of the steering circuits fails. à Steering malfunctions , p. 7 - 27 Operating instructions GMK 4100 3 112 343 en 5 - 39...
  • Page 160 – When the lamp (1) is lit, the on-board computer display shows a correspond- à ing message; p. 5 - 50. à – When the ECOS display shows a warning message (1); Warning sub- menu , p. 5 - 48. 5 - 40 3 112 343 en Operating instructions GMK 4100...

  • Page 161: Tempomat

    (1) is shown and maintained, e.g. 40 km/h. You can exceed the speed (1) with the acceler- ator. After the accelerator is released, the tem- pomat goes back down to the speed (1) Operating instructions GMK 4100 3 112 343 en 5 - 41...
  • Page 162 – When 10 km/h (6 mph) is exceeded – When the temposet function is switched on – When the ignition is switched off – And when you push the switch forwards once 5 - 42 3 112 343 en Operating instructions GMK 4100...

  • Page 163: Temposet

    Press the switch (2) upwards / downwards once. The speed (1) will increase / reduce by 0.5 km/h (0.3 mph). Switching off • Push the switch (2) forwards once. The temposet is switched off, and the display (1) disappears. Operating instructions GMK 4100 3 112 343 en 5 - 43...

  • Page 164: Driving Downhill

    Brake the truck crane before the engine speed increases into the red range (1) – over 2300 min (rpm). When the maximum permissible engine speed is reached, a warning buzzer sounds. 5 - 44 3 112 343 en Operating instructions GMK 4100...
  • Page 165 If the maximum permitted speed is also reached in the lower gear, you must brake again, or switch on the engine retarder / eddy current retarder. Operating instructions GMK 4100 3 112 343 en 5 - 45...
  • Page 166 75% power 100% power Switching off the additional brakes • Press the switch forwards to level 5.0. When the additional brake is switched on, the lamp (1) lights up. 5 - 46 3 112 343 en Operating instructions GMK 4100...

  • Page 167: Driving Uphill

    For the subsequent procedure; p. 5 - 33. Driving The transmission can switch between two gears for certain gradients. In that case, either release the accelerator slightly or downshift by one gear. Operating instructions GMK 4100 3 112 343 en 5 - 47...

  • Page 168: Warning Submenu

    Observe the following information in good time and take the appropriate remedial measures if a warning message appears. In this way, you can pre- vent these malfunctions from causing malfunctions on the truck crane. 5 - 48 3 112 343 en Operating instructions GMK 4100...
  • Page 169 If the same warning messages are still present, the lamps (1) and (2) light If no warning message is present, both lamps will have gone out. Both lamps start to flash again as soon as a new warning message occurs. Operating instructions GMK 4100 3 112 343 en 5 - 49...

  • Page 170: Error Submenu

    (2) requests you to do so. Message elements Messages consist of texts (1) and symbols / abbreviations (4). When the symbol (3) is shown, you can dis- play an additional text by pressing (2). 5 - 50 3 112 343 en Operating instructions GMK 4100...
  • Page 171 Always read off the error codes before contacting CraneCARE For an overview of the control devices and reading off the error codes; à p. 5 - 26. Operating instructions GMK 4100 3 112 343 en 5 - 51...
  • Page 172 If the supply pressure on both displays is below approx. 5.5 bar (80 psi), apply the park- ing brake. You may only continue driving after the vehicle has been repaired. 5 - 52 3 112 343 en Operating instructions GMK 4100...
  • Page 173 The engine coolant is hotter than approx. 115° C (239 °F). The engine capacity is automatically reduced. à Display of the current temperature; p. 4 - 17. à Possible cause and remedy; p. 7 - 23. Operating instructions GMK 4100 3 112 343 en 5 - 53...
  • Page 174 You may only resume driving once the malfunction has been eliminated. This avoids accidents caused by malfunctions which occur suddenly, e.g. when the parking brake engages because the supply pressure has become too low. 5 - 54 3 112 343 en Operating instructions GMK 4100...
  • Page 175 The full braking force remains intact. Drive with particular care and avoid braking fully if at all possible. à • Service brake malfunc- Have the defective ABS system checked over; tions , p. 7 - 26. Operating instructions GMK 4100 3 112 343 en 5 - 55...
  • Page 176 The retarder cannot be switched off when the accelerator is actuated or while the ABS is active. Drive carefully and arrange for the cause to be remedies as quickly as possible. 5 - 56 3 112 343 en Operating instructions GMK 4100...
  • Page 177 The message is also displayed on the ECOS display; Supply pressure in secondary consumers too low , p. 5 - 49. Engine electronics à Malfunction in the engine electronics; the power is reduced; p. 7 - 23. Operating instructions GMK 4100 3 112 343 en 5 - 57...

  • Page 178: Turning Off The Truck Crane

    Press the locking bar (4) through the bore (5). The chock folds out by spring force. (B) – folding up • Press the chock together until the locking bar (4) engages in the bore (5). 5 - 58 3 112 343 en Operating instructions GMK 4100...
  • Page 179 In this way you can prevent unauthorised persons from starting the engine with the hand-held control. Operating instructions GMK 4100 3 112 343 en 5 - 59...
  • Page 180 Driving 5.3 Driving and turning off the truck crane Blank page 5 - 60 3 112 343 en Operating instructions GMK 4100...

  • Page 181: Off-Road Driving

    5 - 65. à Freeing the truck crane stuck in terrain , Rocking the If the truck crane is stuck in terrain; vehicle free p. 5 - 69. and towing Operating instructions GMK 4100 3 112 343 en 5 - 61...

  • Page 182: Transfer Case - Off-Road Gear On / Off

    If the error symbol is displayed, contact CraneCARE Neutral position For towing away, you can also switch the transfer case to the neutral posi- à tion; p. 7 - 8. 5 - 62 3 112 343 en Operating instructions GMK 4100...

  • Page 183: Longitudinal And Transverse Differential Locks

    Start up slowly – display: – The symbol (3) first turns yellow – The symbol (2) then – red. Differential locks on. If the error symbol is displayed, contact CraneCARE Operating instructions GMK 4100 3 112 343 en 5 - 63...
  • Page 184 – The symbol (3) first turns yellow – The symbol (2) then – green. Differential locks off. If the symbol (2) is not shown, drive forwards and backwards slowly. 5 - 64 3 112 343 en Operating instructions GMK 4100...

  • Page 185: Operation Of The Level Adjustment System

    When the suspension has been switched on, you can – Set the on-road driving level or – Pre-select the suspension struts and change the vehicle level If the symbol (1) for an error is shown, contact CraneCARE Operating instructions GMK 4100 3 112 343 en 5 - 65...
  • Page 186 (1). The corresponding suspension struts remain pre-selected for approx. 5 sec- onds. During this time, the symbols (1) and (2) are black and the corresponding buttons are active. 5 - 66 3 112 343 en Operating instructions GMK 4100...
  • Page 187 Switching over the measuring range You can change the measuring range between 1° and 5°. • Press the button (1) once. The current measuring range is displayed. Operating instructions GMK 4100 3 112 343 en 5 - 67...
  • Page 188 Press the button (1) once. The main menu opens. The Level adjustment system submenu automatically closes as soon as the current speed rises above approx. 5 km/h (3 mph). 5 - 68 3 112 343 en Operating instructions GMK 4100...

  • Page 189: Freeing The Truck Crane Stuck In Terrain

    Drive as far as possible up to the highest point and then let go of the accel- erator • Keep on driving back and forth to rock the crane free, changing gears directly Operating instructions GMK 4100 3 112 343 en 5 - 69...
  • Page 190 – The direction of pull runs along the level of the longitudinal axle and – The direction of pull runs along the longitudinal axis towards the rear without diverting up or down 5 - 70 3 112 343 en Operating instructions GMK 4100...

  • Page 191: Separate Steering

    The locking status for normal steering mode is only restored once the green Locked symbol is displayed. You can only change over to separate steering when the current speed is below approx. 5 km/h (3 mph). Operating instructions GMK 4100 3 112 343 en 5 - 71...
  • Page 192 (B) – for crab travel mode • Steer the third and fourth axle line in the same direction as the first and second axle line. 5 - 72 3 112 343 en Operating instructions GMK 4100...
  • Page 193 The third axle line is now locked and the sys- tem is switched to normal steering. à If the error symbol is displayed, contact p. 7 - 27. CraneCARE Operating instructions GMK 4100 3 112 343 en 5 - 73...
  • Page 194 Driving 5.4 Off-road driving Blank page 5 - 74 3 112 343 en Operating instructions GMK 4100...

  • Page 195: Heating And Air-Conditioning System

    Turn the switch (2) to the required position A colder B warmer • Press the switch (2) several times in succession at least once a month in order to prevent functional errors. Operating instructions GMK 4100 3 112 343 en 5 - 75...
  • Page 196 Air vents (2) and (3) can be set. Adjusting the air vents 1 – To open: upward – To close: press down the switch 2 To direct the air flow 5 - 76 3 112 343 en Operating instructions GMK 4100...
  • Page 197 Switching off the heater • Turn the switch (1) anti-clockwise as far as it will go to cold . Switching off the ventilation • Turn the switch (2) to level 0. Operating instructions GMK 4100 3 112 343 en 5 - 77...

  • Page 198: Air-Conditioning System

    – To switch on: Press the button (1) up – the lamp (2) lights up. • – To switch off: Press the button (1) down – the lamp (2) goes out. 5 - 78 3 112 343 en Operating instructions GMK 4100...
  • Page 199 Close the push-up roof; p. 3 - 56. When drying, the air conditioning and the heating work against each other. After drying, switch off the device you do not require. Operating instructions GMK 4100 3 112 343 en 5 - 79...

  • Page 200: Auxiliary Heater

    – At places where explosive dust can be found or form (e.g. coal dust, wood dust, grain dust) Danger of suffocation when operating the heating Do not operate the heater or the heater with the timer in enclosed rooms (e.g. garages). 5 - 80 3 112 343 en Operating instructions GMK 4100...
  • Page 201 • Press the button (1) for longer than 2 seconds. The displayed time flashes, e.g. 10.00 hrs. Set the current time on the flashing display, e.g. 14.00 hrs. Operating instructions GMK 4100 3 112 343 en 5 - 81...
  • Page 202 Set the day of the week for the required heating start. Wait for approx. 5 seconds until the current time is shown, e.g. 14.00 hrs. Now the new heating start has been stored and switched on. 5 - 82 3 112 343 en Operating instructions GMK 4100...
  • Page 203 To activate a different heating start, press the button repeatedly until the required storage location is displayed. This heating start is activated as soon as the display stops flashing. Operating instructions GMK 4100 3 112 343 en 5 - 83...
  • Page 204 Set the required remaining run time on the flashing display. You can set a remaining run time of 1 to 120 minutes. • Wait for 5 seconds until the current time is shown. The remaining run time is now set. 5 - 84 3 112 343 en Operating instructions GMK 4100...

  • Page 205: Towing A Trailer

    2nd axle lines are reduced by 37 kg (82 lbs). – For every 100 kg (220 lbs) of drawbar load, the axle loads on the 3rd and 4th axle lines are increased by 87 kg (192 lbs). Operating instructions GMK 4100 3 112 343 en 5 - 85...
  • Page 206 Make sure you check the prescribed condition of the coupling after each coupling procedure. The pin (1) may no longer protrude from the guide bushing after the coupling procedure. 5 - 86 3 112 343 en Operating instructions GMK 4100...
  • Page 207 • Check the function of the trailer lighting. • Test the service brake and parking brake immediately after setting off. Operating instructions GMK 4100 3 112 343 en 5 - 87...
  • Page 208 • Open the towbar coupling. Push the lever (1) up until it latches into place. • Drive the truck crane carefully away from the trailer. 5 - 88 3 112 343 en Operating instructions GMK 4100...
  • Page 209 Risk of injury when the automatic closing device is triggered Always close the coupling if no trailer is connected. This prevents people from being injured by the automatic closing device being activated uninten- tionally. Operating instructions GMK 4100 3 112 343 en 5 - 89...
  • Page 210 Even when checking the parking brake has delivered a positive result. Observe the corresponding regulations in your country when doing this. 5 - 90 3 112 343 en Operating instructions GMK 4100...
  • Page 211 Switching the superstructure driving lights on / off ..... . 6 - 12 Operating instructions GMK 4100 3 112 343 en...
  • Page 212 3 112 343 en Operating instructions GMK 4100...

  • Page 213: Driving Modes

    Driving modes 6.1 Driving modes Driving modes This chapter contains tables with driving modes of the GMK 4100, for which the maximum axle load is 12 t (26500 lbs). Driving modes Information on the The GMK 4100 truck crane is designed for driving with maximum axle loads axle loads of 12 t (26500 lbs).

  • Page 214: Information On How To Use The Tables

    – the 17 m (56 ft) lattice extension may be folded to the side and – 6.3 t counterweights may be installed on the turntable. Additional parts must be transported on an accompanying vehicle. 6 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 215 2.2 t base plate on the counter- ● ● weight platform The weight of the hook blocks is based on the information in this operat- à ing manual; p. 16 - 2. Operating instructions GMK 4100 3 112 343 en 6 - 3...
  • Page 216 2.2 t base plate on the counter- ● weight platform The weight of the hook blocks is based on the information in this operat- à ing manual; p. 16 - 2. 6 - 4 3 112 343 en Operating instructions GMK 4100...
  • Page 217 6.3 t counterweight attached to the ● ● turntable The weight of the hook blocks is based on the information in this operat- à ing manual; p. 16 - 2. Operating instructions GMK 4100 3 112 343 en 6 - 5...

  • Page 218: Maximum Permitted Speeds With An Axle Load Of Over 12 T (26 500 Lbs)

    13.5 (29 800) 65 (40) 16.00 R 25 / 9 (130.5) 20.5 R 25 / 7 (101.5) up to 14.5 (32 000) 65 (40) up to 15.5 (34 200) 58 (36) 6 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 219: Rigging Work For Driving With A Trailer

    – Switch on the slewing gear freewheel; p. 6 - 8 à – Switch on the boom floating position; p. 6 - 9 à – Switch on boom pre-tensioning, if necessary; p. 6 - 10 Operating instructions GMK 4100 3 112 343 en 6 - 7...

  • Page 220: Switching On The Slewing Gear Freewheel

    • Switch on the slewing gear freewheel on all slewing gears in the same way. à Switching off the slewing gear freewheel; p. 13 - 18. 6 - 8 3 112 343 en Operating instructions GMK 4100...

  • Page 221: Switching On Boom Floating Position

    • Secure the lever (1) with the padlock (2) The boom floating position is now switched à Switching off the boom floating position; p. 13 - 17. Operating instructions GMK 4100 3 112 343 en 6 - 9...

  • Page 222: Switching On Boom Pre-Tensioning

    Close the valve II – the lever (2) is horizontal • Open the valve III – the lever (3) points • upward You can now fill the pressure accumulator. 6 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 223 • The valve II stays closed – lever (2) is horizon- tal. Now the boom pre-tensioning is switched on. à Switching off the boom pre-tensioning; p. 13 - 19. Operating instructions GMK 4100 3 112 343 en 6 - 11...

  • Page 224: Switching The Superstructure Driving Lights On / Off

    When the main boom is in the boom rest, the Superstructure driving lights Switching on must be switched on. • Push the switch (1) to the left – towards the turntable. 6 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 225 Switching on emergency operation in coolant circuit ..... 7 - 35 7.7.2 Procedure in the event of malfunctions to the transmission and engine ..7 - 36 Operating instructions GMK 4100 3 112 343 en...
  • Page 226 3 112 343 en Operating instructions GMK 4100...

  • Page 227: Malfunctions In Driving Mode

    The battery master switch cannot be used as an emergency stop switch for the engine. The engine continues to run after the battery master switch has been switched off. Operating instructions GMK 4100 3 112 343 en 7 - 1...
  • Page 228 Malfunctions in driving mode 7.1 Emergency stop switch Blank page 7 - 2 3 112 343 en Operating instructions GMK 4100...

  • Page 229: What To Do When A Malfunction Occurs In Road Traffic

    In danger areas, only carry out the repair work required to leave the danger area. If you are unable to rectify the damage yourself, contact or have CraneCARE à Towing the truck crane , p. 7 - 5. the crane towed away; Operating instructions GMK 4100 3 112 343 en 7 - 3...
  • Page 230 Malfunctions in driving mode 7.2 What to do when a malfunction occurs in road traffic Blank page 7 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 231: Towing The Truck Crane

    The front towing coupling is designed for a maximum tractive force of 10 t (22 000 lbs). The tractive force may only be applied forwards or at an angle of 45° to both sides from the longitudinal axle of the truck crane. Operating instructions GMK 4100 3 112 343 en 7 - 5...

  • Page 232: Towing In The Event Of Engine Or Transmission Damage

    – A supply pressure of at least 6 bar (87 psi) must be displayed – The lamp (2) must have gone out Electric power supply • Switch on the battery master switch. • Turn on the ignition. 7 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 233 Towing mode is switched off. If the symbol (3) is displayed, the towing mode is switched on. Even if the display (2) indicates neither H nor L due to a malfunction. Operating instructions GMK 4100 3 112 343 en 7 - 7...
  • Page 234 If damage has occurred to the service brake system, you may only tow the truck crane away from the immediate danger area after receiving permis- sion to do so from CraneCARE 7 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 235 Tow the truck crane at a maximum speed of 10 km/h (6 mph) and over a dis- tance of max. 1 km (0.62 mi). Additional measures must be taken for longer distances. In these cases, contact CraneCARE Operating instructions GMK 4100 3 112 343 en 7 - 9...

  • Page 236: Starting To Tow

    Do not press the accelerator as long as the warning buzzer sounds. Reduce the towing speed until the warning buzzer stops buzzing. • Kick down the accelerator once the speed is high enough to start the engine. The transmission engages automatically. 7 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 237: Wheels And Tyres

    If you lean a wheel against the truck crane briefly when changing a wheel, secure it against falling over with a rope. Only move the outriggers if no wheel is leaning against the truck crane. • Engage the parking brake Operating instructions GMK 4100 3 112 343 en 7 - 11...
  • Page 238 Correct the rigging mode if necessary; p. 13 - 82. • Lift the spare wheel using only lifting gear with sufficient load bearing à Spare wheel , p. 8 - 4. capacity; 7 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 239 Extend or retract the outrigger cylinders until the holes in the wheel rims are in line with the wheel studs. • Push the wheel onto the wheel studs. Make sure the thread of the wheel studs is not damaged. Operating instructions GMK 4100 3 112 343 en 7 - 13...
  • Page 240 – Finally, all wheel nuts with 650 Nm (480 lbf ft) Tighten all wheel nuts after 50 km (30 mi) and 150 km (90 mi) again with 650 Nm (480 lbf ft). 7 - 14 3 112 343 en Operating instructions GMK 4100...

  • Page 241: Filling The Tyres Yourself

    The filling hose has a tyre inflator connection (2) and a connection (1). Connecting the filling hose • Remove the caps (3) and (4). • Fasten the connection (1) to the filler con- nection (2). You can now fill the tyres. Operating instructions GMK 4100 3 112 343 en 7 - 15...
  • Page 242 Risk of damage to the compressed air system Always close the filler connection with the cap. This prevents damage and contamination occurring in the compressed air system. 7 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 243: Fuses

    Notify if a fuse of the same amperage blows again after turning CraneCARE on the ignition. Danger of fire Never repair a blown fuse with other electrically conductive materials. Operating instructions GMK 4100 3 112 343 en 7 - 17...

  • Page 244: Fuses In The Driver's Cab

    Distribution terminal D+ Mirror heating Socket 24 V Tachograph, Engine / transmission diagnostics Trailer socket Trailer socket, trailer ABS Cab lighting – Free Transmission – Free Heater fan, air-conditioning system 7 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 245 Turn signal indicator Windshield wiper washer system Brake lights, reversing lights, trailer socket ABS trailer – Free Windscreen washing system Tachograph Horn Engine / transmission diagnostics plug – Free Seat heating Operating instructions GMK 4100 3 112 343 en 7 - 19...
  • Page 246 – Free Socket 24 V 24 V / 12 V voltage transformer – Free Rotating beacon – Free Display, driver's cab – Free – Free Gearbox control – Free 7 - 20 3 112 343 en Operating instructions GMK 4100...
  • Page 247 Oil cooler Central lubrication Fuel pump ECOS control unit Steering Engine emergency stop switch, Air intake inhibitor Voltage supply CAN bus ESX3 control unit, Voltage supply for I/O circuit boards Operating instructions GMK 4100 3 112 343 en 7 - 21...

  • Page 248: Fuses In The Battery Box

    4 Free • Observe the instructions regarding fuse à changes; p. 7 - 17. Amperage Function Designation Preliminary fuse for auxiliary heater switch timer, tachograph and radio Carrier central fuse 7 - 22 3 112 343 en Operating instructions GMK 4100...

  • Page 249: Finding And Eliminating Malfunctions

    A locking procedure is not yet Lock the differential locks or maximum of 20 km/h completed steering (12 mph) Off-road gear on Switch off the off-road gear; à p. 5 - 62 Operating instructions GMK 4100 3 112 343 en 7 - 23...
  • Page 250 – the power in order to drive on to the next goes back up place where it is possible to stop. Other malfunction: must be notified CraneCARE 7 - 24 3 112 343 en Operating instructions GMK 4100...

  • Page 251: Malfunctions On The Transmission

    Mechanically switch the transmission to neutral position if the engine cannot be started because a gear has been selected and à the air pressure is below 5.5 bar (80 psi); p. 7 - 41 Operating instructions GMK 4100 3 112 343 en 7 - 25...

  • Page 252: Service Brake Malfunctions

    ABS support is (4 mph) still possible. The retarder cannot be Fuse A3F1 defective Replace blown fuses; à switched off p. 7 - 17 7 - 26 3 112 343 en Operating instructions GMK 4100...

  • Page 253: Steering Malfunctions

    Fuse A2F3, A3F2, A3F10, Replace blown à A3F14 defective fuses; p. 7 - 20 Error symbol is displayed ECOS malfunction Read the error messages à p. 7 - 30) and inform CraneCARE Operating instructions GMK 4100 3 112 343 en 7 - 27...

  • Page 254: Malfunctions In The Differential Locks

    à p. 7 - 17 Defective temperature sensor Have the temperature sensor in the hydraulic system (error replaced message is displayed) 7 - 28 3 112 343 en Operating instructions GMK 4100...

  • Page 255: Malfunctions On The Suspension

    Fuses A2F3, A3F2, A3F10, Replace blown fuses; à A3F14 defective p. 7 - 20 Error symbol is displayed ECOS malfunction Read the error messages à p. 7 - 30) and inform CraneCARE Operating instructions GMK 4100 3 112 343 en 7 - 29...

  • Page 256: Malfunctions On The Ecos Carrier

    Fuse A3F2, A3F10 defective. Replace the blown fuse; à remains dark p. 7 - 20. If further malfunctions occur, the corresponding error messages are shown in the ECOS display. 7 - 30 3 112 343 en Operating instructions GMK 4100...
  • Page 257 When you keep a button held down, all errors are shown one after the other continuously. If not all errors have been acknowledged, the buttons have no function – the symbols are grey. Operating instructions GMK 4100 3 112 343 en 7 - 31...
  • Page 258 All errors remain saved until you switch off the ignition, even those errors of which the cause has been eliminated in the meantime. All existing errors are treated as new errors and displayed again after turning on the ignition. 7 - 32 3 112 343 en Operating instructions GMK 4100...
  • Page 259 – next error code, press button (6) – previous error code, press button (5) Switching off the error display • Press the button (1) and additionally the button (2) once. Operating instructions GMK 4100 3 112 343 en 7 - 33...
  • Page 260 Malfunctions in driving mode 7.6 Finding and eliminating malfunctions Blank page 7 - 34 3 112 343 en Operating instructions GMK 4100...

  • Page 261: Procedure In The Event Of Malfunctions

    With a blocked fan wheel, you may only drive up to 1000 km (620 mi). Operating instructions GMK 4100 3 112 343 en 7 - 35...
  • Page 262 (e.g. top up oil). If the malfunction cannot be remedied, à • read the error codes ( p. 5 - 26) and contact CraneCARE 7 - 36 3 112 343 en Operating instructions GMK 4100...
  • Page 263 ( p. 5 - 26) and contact . If necessary, CraneCARE à you can only shift the gear mechanically in emergency mode; p. 7 - 41. Operating instructions GMK 4100 3 112 343 en 7 - 37...
  • Page 264 à shift; p. 7 - 41. After opening the submenu, the On-board computer display has no function. 7 - 38 3 112 343 en Operating instructions GMK 4100...
  • Page 265 à p. 7 - 41. If the symbols (2) to 4) are black, the corre- sponding gears can be selected. Operating instructions GMK 4100 3 112 343 en 7 - 39...
  • Page 266 You can switch to neutral position at any time in both operating modes. In this case you can only downshift to a starting gear, however, with the truck crane at a standstill. 7 - 40 3 112 343 en Operating instructions GMK 4100...
  • Page 267 – The clutch is released and the display (1) indicates the symbol Open (0%). After switching gears in emergency mode, you may only start the engine if the clutch is released. – The ignition is switched off Operating instructions GMK 4100 3 112 343 en 7 - 41...
  • Page 268 (3) • Turn the selector shaft until a cutout (2) is below the mark (4) The transmission is now in neutral position. 7 - 42 3 112 343 en Operating instructions GMK 4100...
  • Page 269 (1). For the third or fourth gear you now need the 3/4 bolt. For the reverse gear you now need the R bolt. Operating instructions GMK 4100 3 112 343 en 7 - 43...
  • Page 270 You can only drive in the gear selected mechanically. It is not possible to change gears while driving. 7 - 44 3 112 343 en Operating instructions GMK 4100...
  • Page 271 In this example the ID number is 71552100 123456 • Note down the ID number, on this page for example, so that you can find it at a later time. Operating instructions GMK 4100 3 112 343 en 7 - 45...
  • Page 272 Malfunctions in driving mode 7.7 Procedure in the event of malfunctions Blank page 7 - 46 3 112 343 en Operating instructions GMK 4100...
  • Page 273 Carrier ............8 - Operating instructions GMK 4100...
  • Page 274 3 112 343 en Operating instructions GMK 4100...

  • Page 275: Technical Information On The Carrier

    Technical information on the carrier 8.1 Technical data Technical information on the carrier Technical data GROVE truck crane GMK 4100 Permissible temperature range: –25 °C to +40 °C (–13 °F to +104 °F) Operating instructions GMK 4100 3 112 343 en...

  • Page 276: Dimensions And Weights Of The Truck Crane, Axle Loads

    Technical information on the carrier 8.1 Technical data 8.1.1 Dimensions and weights of the truck crane, axle loads The dimensions in the illustration are given in mm. 8 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 277 25.0 t (55 100 lbs) in working position, free- standing The axle loads given relate to driving with a rigged truck crane and the maximum load which can be lifted according to Lifting capacity table . Operating instructions GMK 4100 3 112 343 en 8 - 3...

  • Page 278: Dimensions And Weights Of Removable Parts

    (ft) Plastic outrigger pads 0.50 x 0.50 x 0.20 (1.65 x 1.65 x 0.66) (61) Steel outrigger pads 0.50 x 0.50 x 0.20 (1.65 x 1.65 x 0.66) (79) 8 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 279: Carrier

    Tyre pressure with cold tyres for axle loads up to max. 12 t 14.00 R25: 10 bar (145 psi) 16.00 R25: 9 bar (131 psi) 20.5 R25: 7 bar (102 psi) Operating instructions GMK 4100 3 112 343 en 8 - 5...
  • Page 280 Outrigger pressure indica- Depending on the design in the outriggers, tor: integrated with a display in the crane cab and on the outrigger operating units. 8 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 281 16.00 R25 tyres: 20.5 R25 tyres: Turning circle The dimensions in the illustration are given in mm. radiuses = values for normal steering mode = values for all-wheel steering Operating instructions GMK 4100 3 112 343 en 8 - 7...
  • Page 282 Technical information on the carrier 8.1 Technical data Blank page 8 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 283 Index Operating instructions GMK 4100 3 112 343 en...
  • Page 284 3 112 343 en Operating instructions GMK 4100...
  • Page 285 3 and chapter 10, Description of the truck crane . You are referred to more detailed descriptions of these elements from there as usual. Operating instructions GMK 4100 3 112 343 en 9 - 1...
  • Page 286 Index Blank page 9 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 287 ........5 - 90 Operating instructions GMK 4100...
  • Page 288 ............12 - 95 operating elements 9 - 4 3 112 343 en Operating instructions GMK 4100...
  • Page 289 Diagnostics plug ........... 10 - 96 Operating instructions GMK 4100...
  • Page 290 ........... . 5 - 43 9 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 291 SLI fuses ............15 - 11 Operating instructions GMK 4100...
  • Page 292 / equalisation of the switching states ..... 4 - 10 9 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 293 ..........12 - 86 Operating instructions GMK 4100...
  • Page 294 Installing / removing the anemometer ....... . . 13 - 108 9 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 295 ..........7 - 28 Operating instructions GMK 4100...
  • Page 296 / retracting outriggers ........13 - 32 9 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 297 ......6 - 8 switching the superstructure driving lights on / off ....6 - 12 Operating instructions GMK 4100 3 112 343 en...
  • Page 298 ............12 - 88 9 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 299 ......... . 16 - 1 Operating instructions GMK 4100...
  • Page 300 ..........5 - 31 9 - 16 3 112 343 en Operating instructions GMK 4100...
  • Page 301 Windscreen wiper / washing system ........10 - 89 Operating instructions GMK 4100...
  • Page 302 ..........12 - 108 9 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 305 Operating instructions Part 2 – Crane operation 3 112 343 en Serial number 23.11.2006...
  • Page 306 Dissemination or duplication of this document as well as utilization and disclosure of its contents are prohibited unless expressly permitted. Infringement will incur liability for compensation. All rights pertaining to registration of patent or utility model are reserved. 3 112 343 en Operating instructions GMK 4100...
  • Page 307 Chapters 1 to 9 are in Part 1 – Driving This section alone does not make up the complete operating instructions. The basic safety instructions for crane operation are located in Section 1, Chapter 2. Operating instructions GMK 4100 3 112 343 en...
  • Page 308 Blank page 3 112 343 en Operating instructions GMK 4100...
  • Page 309 Windows, doors, keys ..........10 - 97 Operating instructions GMK 4100...
  • Page 310 Steering ............10 - 104 3 112 343 en Operating instructions GMK 4100...

  • Page 311: Operating Elements For Crane Operation

    These designations are made in this section only and are not repeated in the following sections. Some figures show details from a different perspective than the total view. The perspective is indicated by the symbol (1). Operating instructions GMK 4100 3 112 343 en 10 - 1...

  • Page 312: On The Outside Of The Truck Crane

    Operating elements for crane operation 10.1 Overview of the operating elements 10.1.1 On the outside of the truck crane 10 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 313 11 - 1 Oil dipstick / filler neck for engine à 28 Air intake inhibitor p. 11 - 21 29 Coolant reservoir, engine à Maintenance manual Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 3...

  • Page 314: Crane Cab

    Operating elements for crane operation 10.1 Overview of the operating elements 10.1.2 Crane cab 10 - 4 3 112 343 en Operating instructions GMK 4100...
  • Page 315 18 Suction / air vents p. 12 - 123 19 Fire extinguisher à 20 Door unlocking mechanism p. 10 - 98 Additional equipment à Maintenance manual à Separate operating instructions Operating instructions GMK 4100 3 112 343 en 10 - 5...

  • Page 316: Front Panel

    10 - 88 – for SLI – for SLI and lifting limit switch à 4 ECOS control unit p. 10 - 18 à 5 Front panel p. 12 - 8 10 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 317: Side Panel

    10.1 Overview of the operating elements 10.1.4 Side panel Bottom 1 Ashtray à 2 Standard heating system p. 10 - 11 à 3 Diagnostics (behind covering) p. 10 - 96 Operating instructions GMK 4100 3 112 343 en 10 - 7...
  • Page 318 Operating elements for crane operation 10.1 Overview of the operating elements 10 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 319 20 Soot particle filter indicator lamp – Version 1 p. 10 - 52 1), 2) Version 2 à 21 Ignition lock p. 10 - 51 22 Cigarette lighter (24 volts) Additional equipment à Separate operating instructions Operating instructions GMK 4100 3 112 343 en 10 - 9...
  • Page 320 Operating elements for crane operation 10.1 Overview of the operating elements Blank page 10 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 321 12 - 123 à 3 Air distribution p. 12 - 124 à 4 Setting the fan p. 12 - 123 à 5 Setting the temperature p. 12 - 124 Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 11...
  • Page 322 4 – Switching on p. 12 - 129 à – Switching off p. 12 - 133 à 5 Input – p. 12 - 130 à 6 Input + p. 12 - 130 10 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 323 5 – Switching on p. 12 - 134 à – Switching off p. 12 - 135 à 6 Input – p. 12 - 135 à 7 Input + p. 12 - 135 Operating instructions GMK 4100 3 112 343 en 10 - 13...

  • Page 324: Control Panels

    6 Slewing gear on / off p. 10 - 71 à 7 Auxiliary hoist on / off p. 10 - 70 à 8 Inclining the crane cab p. 10 - 81 Additional equipment 10 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 325 10 - 73 à 8 Telescoping mechanism on / off p. 10 - 74 1), 2) 9 Derrick lattice extension on / off Additional equipment à Operating Instructions Lattice Extension Operating instructions GMK 4100 3 112 343 en 10 - 15...

  • Page 326: Control Lever Assignment

    Version 1 ing . Left-hand control lever Right-hand control lever Slewing to the left Raising Slewing to the right Lowering Extending Lowering the main hoist Retracting Raising the main hoist 10 - 16 3 112 343 en Operating instructions GMK 4100...
  • Page 327 Lowering / extending Lowering the auxiliary hoist Lowering the main hoist Raising the auxiliary hoist Raising the main hoist Additional equipment à Derricking the lattice extension; Operating Instructions Lattice Extension Operating instructions GMK 4100 3 112 343 en 10 - 17...

  • Page 328: Ecos Control Unit

    Operating elements for crane operation 10.1 Overview of the operating elements 10.1.7 ECOS control unit 10 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 329 The functions of the buttons in the displayed menu correspond to the symbols next to or above the buttons; à p. 10 - 55. Operating instructions GMK 4100 3 112 343 en 10 - 19...

  • Page 330: Ecos Display - Main Menu

    Operating elements for crane operation 10.1 Overview of the operating elements 10.1.8 ECOS display – main menu The main menu displays symbols for further submenus and symbols for current displays. 10 - 20 3 112 343 en Operating instructions GMK 4100...
  • Page 331 14 Serial number and program version displays p. 10 - 57 à 15 Driving submenu p. 10 - 38 Additional equipment à Operating Instructions Lattice Extension à Separate operating instructions Operating instructions GMK 4100 3 112 343 en 10 - 21...

  • Page 332: Ecos Display - Submenus

    7 Pre-tensioning pressure display p. 10 - 67 à 8 Extending / Retracting the lifting cylinders p. 10 - 67 à 9 Lifting cylinder position display p. 10 - 67 10 - 22 3 112 343 en Operating instructions GMK 4100...
  • Page 333 3 Slewing gear display p. 10 - 72 à 4 Current slewing angle display p. 10 - 72 à 5 Stop at 0° / 180° p. 10 - 72 Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 23...
  • Page 334 Operating elements for crane operation 10.1 Overview of the operating elements Outriggers submenu 10 - 24 3 112 343 en Operating instructions GMK 4100...
  • Page 335 10 - 53 à 19 Display for engine for driving on / off p. 10 - 53 à 20 Start engine for driving p. 10 - 53 Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 25...
  • Page 336 Operating elements for crane operation 10.1 Overview of the operating elements Telescoping submenu 10 - 26 3 112 343 en Operating instructions GMK 4100...
  • Page 337 10 - 76 à 14 Teleautomation direction display p. 10 - 79 à 15 Entering the nominal value for teleautomation p. 10 - 78 à Separate operating instructions Operating instructions GMK 4100 3 112 343 en 10 - 27...
  • Page 338 12 - 96 à 6 Displays of entered speed p. 12 - 96 7 Enter speed for derricking gear of lattice extension 8 Display for input mode on Additional equipment 10 - 28 3 112 343 en Operating instructions GMK 4100...
  • Page 339 11 - 15 à 3 Voltage monitoring display p. 11 - 15 à 4 Engine speed display p. 11 - 15 à 5 Coolant temperature display p. 11 - 15 Operating instructions GMK 4100 3 112 343 en 10 - 29...
  • Page 340 Operating elements for crane operation 10.1 Overview of the operating elements Settings submenu 10 - 30 3 112 343 en Operating instructions GMK 4100...
  • Page 341 11 Current telescoping mechanism status display p. 10 - 80 à 12 Adjusting the wiper stroke interval p. 10 - 91 à 13 Entering the current telescoping p. 15 - 49 Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 31...
  • Page 342 4 Engine for crane operation 5 Derricking gear 6 Locking system 7 Main hoist 8 Auxiliary hoist 9 Slewing gear 10 Lattice extension 11 ECOS – carrier 12 Engine for driving Additional equipment 10 - 32 3 112 343 en Operating instructions GMK 4100...
  • Page 343 10 Supply pressure in the brake circuit too low 11 Prompt to brake 12 Hydraulic oil too hot 13 Replacing the hydraulic oil filter 14 Supply pressure in secondary consumers too low Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 33...
  • Page 344 Operating elements for crane operation 10.1 Overview of the operating elements Blank page 10 - 34 3 112 343 en Operating instructions GMK 4100...
  • Page 345 1 Display of current error / total errors p. 15 - 33 à 2 Next error p. 15 - 33 à 3 Previous error p. 15 - 33 à 4 Error display p. 15 - 33 Operating instructions GMK 4100 3 112 343 en 10 - 35...
  • Page 346 8 Slewing angle monitoring on / off p. 12 - 118 à 9 Working radius monitoring on / off p. 12 - 118 à 10 Overall height monitoring on / off p. 12 - 118 10 - 36 3 112 343 en Operating instructions GMK 4100...
  • Page 347 5 Select Previous point 6 Select next point 7 Select angle / working radius 8 Delete selected point data 9 Delete all point data à Entering objects , p. 12 - 113. Operating instructions GMK 4100 3 112 343 en 10 - 37...
  • Page 348 Operating elements for crane operation 10.1 Overview of the operating elements Driving submenu 10 - 38 3 112 343 en Operating instructions GMK 4100...
  • Page 349 10 - 105 à Separate steering on / off p. 10 - 105 à 14 Warning for steering circuit 1 and steering circuit 2 p. 10 - 104 Operating instructions GMK 4100 3 112 343 en 10 - 39...

  • Page 350: Sli Control Unit

    Operating elements for crane operation 10.1 Overview of the operating elements 10.1.10 SLI control unit 10 - 40 3 112 343 en Operating instructions GMK 4100...
  • Page 351 9 Acknowledge p. 10 - 84 à 10 Confirming an entry p. 10 - 84 à 11 Displaying and entering the time and date p. 12 - 39 Additional equipment Operating instructions GMK 4100 3 112 343 en 10 - 41...
  • Page 352 11 Additional function F2 on p. 10 - 88 à 12 Lamp test (as additional function F2) p. 10 - 88 à 13 F3 and F4 service buttons p. 10 - 88 10 - 42 3 112 343 en Operating instructions GMK 4100...
  • Page 353 8 Additional function F5 on p. 12 - 34 à 9 Additional function F6 on p. 12 - 34 à 10 Displaying the current main boom length p. 12 - 33 Operating instructions GMK 4100 3 112 343 en 10 - 43...

  • Page 354: Hand-Held Control

    4 Outriggers control panel p. 10 - 93 5 No function à 6 Horn p. 10 - 93 à Required connections for the various operations; p. 10 - 92. 10 - 44 3 112 343 en Operating instructions GMK 4100...
  • Page 355 10 - 58 (as additional function F1) à 8 Pre-select high-speed / normal speed mode p. 10 - 58 à 9 Additional function F1 on p. 10 - 58 Operating instructions GMK 4100 3 112 343 en 10 - 45...

  • Page 356: Outrigger Control Units

    Operating elements for crane operation 10.1 Overview of the operating elements 10.1.12 Outrigger control units 10 - 46 3 112 343 en Operating instructions GMK 4100...
  • Page 357 10 - 64 ger, opposite side Additional equipment Inclination display à 10 Switching over the measuring range p. 10 - 63 à 11 Display of current inclination p. 10 - 63 Operating instructions GMK 4100 3 112 343 en 10 - 47...
  • Page 358 Operating elements for crane operation 10.1 Overview of the operating elements Blank page 10 - 48 3 112 343 en Operating instructions GMK 4100...

  • Page 359: Short Description Of The Operating Elements

    On the superstructure The main boom head is always at the front, which means that: 1: front 2: right 3: rear 4: left Operating instructions GMK 4100 3 112 343 en 10 - 49...

  • Page 360: General Rules For Buttons And Symbols On The Display

    – If it says in this section e.g. to “Press button 1...“, this always refers to the button (2) next to or below the symbol shown (1). Even when the button itself is not visible in the illustration. 10 - 50 3 112 343 en Operating instructions GMK 4100...

  • Page 361: Engine For Crane Operation

    Flame start system indicator lamp – On: engine not ready to start – is being warmed up – Off: engine is ready to start à p. 11 - 13 Operating instructions GMK 4100 3 112 343 en 10 - 51...
  • Page 362 ECOS display There is no short description of the displays in the submenus; à Monitoring submenu , p. 11 - 15, à Warning submenu , p. 12 - 102. 10 - 52 3 112 343 en Operating instructions GMK 4100...

  • Page 363: Engine For Driving

    1 Starting the engine: press button once button has function Pre-select all supporting 2 Motor running: cylinders Turning off the engine: switch off the carrier ignition à p. 13 - 23 Operating instructions GMK 4100 3 112 343 en 10 - 53...

  • Page 364: Seat Contact Switch And Dead Man's Switch

    The seat contact switch responds very sensitively. It is recommended that you also press the dead man's switch in order to avoid unintentional shut- down. à Seat contact switch , p. 12 - 11 10 - 54 3 112 343 en Operating instructions GMK 4100...

  • Page 365: Ecos Crane Control

    10.2.6 ECOS crane control The truck crane GMK 4100 is equipped with the ECOS electronic crane con- trol (Electronic Crane Operating System). ECOS includes a control unit in the crane cab, an operating unit in the driver's cab and several control units (ESX0, ESX1, ESX2 etc.) and I / 0 circuit boards (I/O 0, I/O 1 etc.), which are...
  • Page 366 Slow turning changes the value slowly. Fast turning changes the value fast. Other à 1 Slewing gear brake indicator lamp; p. 10 - 71 à 2 Lifting limit switch warning; p. 10 - 71 10 - 56 3 112 343 en Operating instructions GMK 4100...
  • Page 367 1 x. Serial number and program version displays 1 Serial number 2 Current ECOS program version – always state in the event of malfunc- à tions; p. 15 - 32. Operating instructions GMK 4100 3 112 343 en 10 - 57...

  • Page 368: Outriggers

    – press button once – lamp (1) lights up – high-speed mode pre-selection on – press button once – lamp (1) goes out – normal speed mode pre-selection on 10 - 58 3 112 343 en Operating instructions GMK 4100...
  • Page 369 Slewing gear / movements locked display – Red: slewing gear switched off – Green: slewing gear switched on – outrigger movement locked, symbol (1) appears after pre-selection of the outrigger Operating instructions GMK 4100 3 112 343 en 10 - 59...
  • Page 370 Outrigger control units on / off – To switch on: press button until symbol (1) appears – To switch off: press button until symbol (2) appears à p. 13 - 29 10 - 60 3 112 343 en Operating instructions GMK 4100...
  • Page 371 The movement stops after the button is released, and when an end position is reached. Operating the right-hand outriggers (next to control unit) Operation is the same as on the button unit for Outriggers to the left of display field . Operating instructions GMK 4100 3 112 343 en 10 - 61...
  • Page 372 10 seconds – Display field lighting on: press any button à p. 13 - 33 10 - 62 3 112 343 en Operating instructions GMK 4100...

  • Page 373: Inclination Displays

    B In the main menu In the Outriggers submenu C On the Outrigger control units Press button once – the current measur- ing range 1° or 5° is shown Operating instructions GMK 4100 3 112 343 en 10 - 63...

  • Page 374: Outrigger Pressure Displays

    This function is the same in all the menus. The anemometer is electrically connected. 1 Scale in meters per second (m/sec) 2 Beaufort scale (B) 3 Display of wind speed à p. 12 - 42 10 - 64 3 112 343 en Operating instructions GMK 4100...

  • Page 375: Counterweight Submenu

    Display of slewing direction for automatic mode The automatic mode is switched on. – Arrow lights up: move control lever for slewing gear in direction of arrow – automatic mode is executed Operating instructions GMK 4100 3 112 343 en 10 - 65...
  • Page 376 Move control lever for slewing gear in indicated direc- tion, automatically: – slewing in position Move lifting cylinders , – retract lifting cylinders, Automatic mode ends – symbol yellow à p. 13 - 75 10 - 66 3 112 343 en Operating instructions GMK 4100...
  • Page 377 à reached; p. 13 - 73. Pre-tensioning pressure display – Green: pre-tensioning pressure reached – Red: pre-tensioning pressure too low – pre-tension counterweight à p. 13 - 74 Operating instructions GMK 4100 3 112 343 en 10 - 67...

  • Page 378: Main Hoist

    Power units display – Green: main hoist on – Red: main hoist off Right-hand control lever – To the rear: lifting – To the front: lowering à p. 12 - 46 10 - 68 3 112 343 en Operating instructions GMK 4100...
  • Page 379 – On: lifting limit switch triggered – hoist stops – Flashing: lifting limit switch triggered – shutdown overridden – Off: lifting limit switch not triggered à p. 12 - 51 Operating instructions GMK 4100 3 112 343 en 10 - 69...

  • Page 380: Auxiliary Hoist

    Button and lamp for hoist high-speed mode à Short description with main hoist, p. 10 - 69 Warning lamp for lifting limit switch shutdown Short description with main hoist 10 - 70 3 112 343 en Operating instructions GMK 4100...

  • Page 381: Slewing Gear

    – To the right: slewing to the right à p. 12 - 88 Submenu Slewing gear / Houselock submenu – To open: press button once – submenu opens Operating instructions GMK 4100 3 112 343 en 10 - 71...
  • Page 382 Current position ± 20° in front of the 0° or 180° superstructure position. – Both arrows: 0° or 180° superstructure position reached – One arrow: Arrow direction = slewing direction to reach 0° or 180° à p. 12 - 90 10 - 72 3 112 343 en Operating instructions GMK 4100...

  • Page 383: Derricking Gear

    à p. 12 - 86 High-speed indicator lamp for derricking gear / telescoping mechanism – On: high-speed mode on – Off: high-speed mode off à p. 12 - 86 Operating instructions GMK 4100 3 112 343 en 10 - 73...

  • Page 384: Telescoping Mechanism

    – To the right: extending à p. 12 - 65 Button and lamp for derricking gear / telescoping mechanism high-speed mode à Short description with derricking gear; p. 10 - 73. 10 - 74 3 112 343 en Operating instructions GMK 4100...
  • Page 385 – distance to the locking point larger than 1 m (3.3 ft) teleautomation on – symbol is displayed à p. 12 - 69 Operating instructions GMK 4100 3 112 343 en 10 - 75...
  • Page 386 Unlock selected – is executed after moving the control lever – Telescopic section unlocked: Unlock not selected – symbol (1) flashes (yellow / grey) as a prompt to Lock telescopic section à p. 12 - 71 10 - 76 3 112 343 en Operating instructions GMK 4100...
  • Page 387 Telescoping cylinder length display – Display: current extended length of the telescoping cylinder – Unit of measure- displayed depending on setting, mm (millimetres) ment: or ft (feet) à p. 12 - 73 Operating instructions GMK 4100 3 112 343 en 10 - 77...
  • Page 388 – Green: teleautomation on 2 Press button first time – nominal value input on Press button once – nominal value to next fixed length à p. 12 - 80 10 - 78 3 112 343 en Operating instructions GMK 4100...
  • Page 389 Telescoping emergency program access Right-hand dead man's switch is pressed. – Press button once: after entering the keycode, the emergency pro- gram opens Telescoping à p. 15 - 39 Operating instructions GMK 4100 3 112 343 en 10 - 79...
  • Page 390 The current status is shown using different symbols: 1 Normal 2 Waiting 3 Emergency program access 4 Keycode input 5 Emergency program 6 Telescope status divergence 7 Not active à p. 15 - 18 10 - 80 3 112 343 en Operating instructions GMK 4100...

  • Page 391: Hydraulic System

    – To switch on: press button until the dot (1) turns green. – To switch off: press button until the dot (1) turns black. à p. 12 - 99 Operating instructions GMK 4100 3 112 343 en 10 - 81...

  • Page 392: Houselock

    Houselock on / off The slewing gear is switched off – Press up: switch on – pin extends – Press down: switch off – pin retracts à p. 12 - 14 10 - 82 3 112 343 en Operating instructions GMK 4100...

  • Page 393: Safe Load Indicator (Sli)

    1 Display: SLI code, four digits 2 Enter: In input mode – press button once – next SLI code – or enter via numerical pad à p. 12 - 22 Operating instructions GMK 4100 3 112 343 en 10 - 83...
  • Page 394 (m) or feet (ft) – for displayed SLI code 2 Enter: in input mode press button once – next length à p. 12 - 26 10 - 84 3 112 343 en Operating instructions GMK 4100...
  • Page 395 1 Telescoping of telescopic sections – fixed lengths as decimal values – two decimal places after the comma – intermediate lengths in percent Surplus displays have no function à p. 12 - 31 Operating instructions GMK 4100 3 112 343 en 10 - 85...
  • Page 396 Current load display Currently raised load in tons (t) or kilopounds (klbs) – precision ± 5% of actual load Signalling point behind the value = shutdown à p. 12 - 31 10 - 86 3 112 343 en Operating instructions GMK 4100...
  • Page 397 – I or II flashing: corresponding hoist switched on as well – displayed reeving applies to the other hoist – I or II off: corresponding hoist switched off à p. 12 - 30 Operating instructions GMK 4100 3 112 343 en 10 - 87...
  • Page 398 12 - 38 – Turn to the left: SLI shutdown and Lifting limit switch shutdown overridden – crane functions released, no more monitoring; à p. 12 - 52. 10 - 88 3 112 343 en Operating instructions GMK 4100...

  • Page 399: Electrical System

    13 - 108 Rotating beacon on / off – To switch on: press down – lamp in button on – To switch off: press up – lamp in button off Operating instructions GMK 4100 3 112 343 en 10 - 89...
  • Page 400 – To the front: press up à p. 12 - 100 Cab lighting 1 Permanently on 2 Permanently off 3 On / off via door contact Reading lamp 1 On 2 Off 10 - 90 3 112 343 en Operating instructions GMK 4100...
  • Page 401 Adjusting the wiper stroke interval In the Settings submenu 1 Display of interval 2 Press once – input mode on 3 Turn – change interval à p. 12 - 96 Operating instructions GMK 4100 3 112 343 en 10 - 91...

  • Page 402: Hand-Held Control

    – Emergency operation for crane movements (except for telescoping mechanism) – Derrick lattice extension – Operation of the outriggers – Emergency mode for crane operations – Derrick lattice extension Lattice extension – derricking 10 - 92 3 112 343 en Operating instructions GMK 4100...
  • Page 403 The ignition is switched on. – Press once: – hand-held control on the superstructure socket – superstructure horn on – hand-held control on the carrier socket – carrier horn on Operating instructions GMK 4100 3 112 343 en 10 - 93...
  • Page 404 – Pre-selected function off Release one or both of the buttons. Press a non-assigned button combination – pre-selection off. – Faster movement: press button harder – Slower movement: press button less hard 10 - 94 3 112 343 en Operating instructions GMK 4100...
  • Page 405 à Emergency operation with the hand-held control , p. 15 - 51 Operating instructions GMK 4100 3 112 343 en 10 - 95...

  • Page 406: Diagnostics

    The diagnostics connections may only be operated by the service staff. The following connections are below the cover (5). 1 ECOS diagnostics – (serial interface) 2 ECOS diagnostics – Can bus 3 SLI diagnostics 4 Engine diagnostics 10 - 96 3 112 343 en Operating instructions GMK 4100...

  • Page 407: Windows, Doors, Keys

    From outside Unlock • Turn the key in direction A Lock • Turn the key in direction B Open / Close • Pull the handle (1). • Push the door Operating instructions GMK 4100 3 112 343 en 10 - 97...
  • Page 408 2 Crane cab ignition lock 3 Key-operated override switch 4 Distribution box 5 Windscreen washing system reservoir 6 Boom floating position lock 7 Slewing gear freewheel lock 8 Covers Additional equipment 10 - 98 3 112 343 en Operating instructions GMK 4100...

  • Page 409: Short Description Of The Operating Elements - Driving From The Crane Cab

    – parking brake was released before the submenu was opened – impermissible shifting operation, e.g. accelerator and brake pedal actuated simultaneously à – tachograph malfunction – warning à p. 14 - 8 Operating instructions GMK 4100 3 112 343 en 10 - 99...

  • Page 410: Engine For Driving

    14 - 8 Accelerator – Carrier ignition on: regulates the engine speed for driving – Carrier ignition off: regulates the engine speed for crane operation à p. 14 - 8 10 - 100 3 112 343 en Operating instructions GMK 4100...

  • Page 411: Transmission

    Transmission mode R – To switch on: press button once – dot (1) green first reverse gear engaged – To switch off: switch to (D) or N – dot (1) black Operating instructions GMK 4100 3 112 343 en 10 - 101...

  • Page 412: Final Drive

    B Longitudinal differential locks display The current status is shown using different symbols: 1 Green – locks off 2 Red – locks on 3 Yellow – intermediate position 4 Violet – error 10 - 102 3 112 343 en Operating instructions GMK 4100...

  • Page 413: Brakes

    – Red: apply parking brake – Grey: release parking brake There is no short description of the displays in the Warning submenu; à Warning submenu , p. 12 - 102. Operating instructions GMK 4100 3 112 343 en 10 - 103...

  • Page 414: Steering

    Warning for steering circuit 1 and steering circuit 2 The function is identical with the displays on the ECOS display in the à driver's cab; p. 3 - 46. 10 - 104 3 112 343 en Operating instructions GMK 4100...
  • Page 415 The steering direction for the current superstructure position is switched on. – Press button on left: left-hand turn – Press button on right: right-hand turn à p. 14 - 14 Operating instructions GMK 4100 3 112 343 en 10 - 105...
  • Page 416 Operating elements for crane operation 10.3 Short description of the operating elements – driving from the crane cab Blank page 10 - 106 3 112 343 en Operating instructions GMK 4100...
  • Page 417 Air intake inhibitor..........11 - 21 Operating instructions GMK 4100...
  • Page 418 3 112 343 en Operating instructions GMK 4100...

  • Page 419: Starting / Turning Off The Engine - For Crane Operation

    11 - 7. à Maintenance manual . 2. Check the coolant level of the engine; à 3. Check the oil level in the hydraulic system; Maintenance manual . Operating instructions GMK 4100 3 112 343 en 11 - 1...
  • Page 420 7. Switch on the ignition and check the instruments and displays; à p. 11 - 8. à 8. Adjust the brightness of the ECOS display as required; p. 11 - 11. 11 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 421 12. Check the instruments and displays with the engine running; à p. 11 - 14. à CHECKLIST: If the temper- 13. In the event of low outside temperatures; ature is low , p. 11 - 4. Operating instructions GMK 4100 3 112 343 en 11 - 3...

  • Page 422: Checklist: If The Temperature Is Low

    4. The engine can be preheated with the auxiliary water heater if neces- à Auxiliary water heater , p. 12 - 127. sary; à Preheating the hydraulic oil , 5. The hydraulic oil must be preheated; p. 12 - 13. 11 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 423: Refuelling

    5 to 10% – 20 to 40 l (5.3 to 10.6 gal) Red: below 5% – less than 20 l (5.3 gal) à Refuelling , p. 4 - 7. Operating instructions GMK 4100 3 112 343 en 11 - 5...
  • Page 424 Screw the cap back onto the filler neck each time after refuelling. In this way you can prevent other vehicles from being endangered by the cap falling off or fuel escaping. 11 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 425: Inspections Before Starting The Engine

    You can only start the engine when the battery master switch is switched switch • Switch on the battery master switch (1). The battery master switch is switched on if you are unable to pull off the selector handle. Operating instructions GMK 4100 3 112 343 en 11 - 7...

  • Page 426: Switch On The Ignition

    Insert the ignition key into the ignition lock and turn the key to position 1. After switching on the ignition, a lamp test is carried out, and switching states are checked. 11 - 8 3 112 343 en Operating instructions GMK 4100...

  • Page 427: Lamp Test / Equalisation Of The Switching States

    Check whether the lamps (1) and (2) light up briefly Contact if one or more lamps do CraneCARE not go on. If the specified time is insufficient, you can carry out the lamp test again as follows. Operating instructions GMK 4100 3 112 343 en 11 - 9...
  • Page 428 If the display (2) does not show the symbol that corresponds to the switching process, you must actuate the steering so that the lock- ing processes are performed mechanically; à p. 14 - 15. 11 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 429: Set Brightness Of Display

    Apply the entered minimum brightness – 1 x button (2). The red bar below the display goes out. The brightness is automatically regulated between the newly set value and 100%. Operating instructions GMK 4100 3 112 343 en 11 - 11...

  • Page 430: To Start The Engine

    You can also start the engine by pressing button 1 down once with the igni- tion turned on. After starting, the idling speed corresponds to the standard à value. To set the idling speed; p. 11 - 16. 11 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 431 15 seconds and wait one minute before trying again. à Malfunctions on the If the engine does not go on after several attempts; engine , p. 15 - 13. Operating instructions GMK 4100 3 112 343 en 11 - 13...

  • Page 432: Inspections After Starting The Engine

    à Malfunctions on the engine , p. 7 - 23 à For more information please refer to the Monitoring submenu; p. 11 - 15. 11 - 14 3 112 343 en Operating instructions GMK 4100...

  • Page 433: Monitoring Submenu

    The colour of the bar below the values indicates in which area the value can be found. Green: value o. k. Yellow: limit value is almost reached Red: limit value exceeded (or not reached) – warning message; à p. 12 - 102. Operating instructions GMK 4100 3 112 343 en 11 - 15...

  • Page 434: Setting The Idling Speed

    Exceeding the idling speed You can exceed the idling speed at any time using the accelerator. The engine speed is reduced to the preset idling speed if you release the accelerator. 11 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 435: Starting The Engine - With The Hand-Held Control

    15 - 22. Press the button (3) once – the engine starts. If the hand-held control is connected to the superstructure, you cannot drive the power units from the crane cab. Operating instructions GMK 4100 3 112 343 en 11 - 17...
  • Page 436 Starting / turning off the engine – for crane operation 11.2 Starting the engine – with the hand-held control Blank page 11 - 18 3 112 343 en Operating instructions GMK 4100...

  • Page 437: Turning Off The Engine

    Observe the warnings in the appropriate sections; à Short work breaks , p. 12 - 121, à Work breaks of more than 8 hours , p. 12 - 122. Operating instructions GMK 4100 3 112 343 en 11 - 19...

  • Page 438: In Emergencies, With The Emergency-Stop Switches

    If air intake inhibitors are fitted, they must be released; à Releasing the air intake inhibitor , p. 11 - 21. à Releasing the air intake inhibitor , p. 4 - 23. 11 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 439: Air Intake Inhibitor

    (A) – The indicator (2) is in the closed position. (B) – Turn the indicator (2) clockwise until it engages into the Released position. You can close the air intake inhibitor manually with the lever (3). Operating instructions GMK 4100 3 112 343 en 11 - 21...
  • Page 440 Starting / turning off the engine – for crane operation 11.4 Air intake inhibitor Blank page 11 - 22 3 112 343 en Operating instructions GMK 4100...
  • Page 441 Error submenu ........... 12 - 106 Operating instructions GMK 4100...
  • Page 442 Auxiliary air heater ..........12 - 134 3 112 343 en Operating instructions GMK 4100...

  • Page 443: Crane Operation

    3. If you intend to drive from the crane cab: – in the driver's cab, turn the ignition key to position 1 and – secure the truck crane against unauthorised use. Operating instructions GMK 4100 3 112 343 en 12 - 1...
  • Page 444 à Crane cab seat , p. 12 - 7, à Front panel , p. 12 - 8. à 9. Start the engine for crane operation; p. 11 - 12. 12 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 445 à Inspections prior to starting operations , p. 12 - 64. 15. Check telescoping; à o ð a 16. Perform lamp test on the SLI; p. 12 - 20. Operating instructions GMK 4100 3 112 343 en 12 - 3...
  • Page 446 Additional information on inspections during crane operation, on permissi- ble working positions and on how to operate the individual power units; à Crane operation with main boom , p. 12 - 41. 12 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 447: Checking The Condition Of The Truck Crane

    Refill the fuel in due time, and close the tank (1) with the lid. • If a fuel tank is available on the superstruc- ture, then tank (1) is not applicable. Operating instructions GMK 4100 3 112 343 en 12 - 5...
  • Page 448 (0 to 0.08 in). – the cross-over points must be at an angle of about 180°. The top rope lines are laid over the next lower rope lines at the cross-over points. 12 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 449: Adjusting The Crane Cab Seat And Front Panel

    1 Control panel – height 2 Back rest – angle (on both sides) 3 Seat – length adjustment without control panels 4 Seat – height 5 Seat – length adjustment with control panels Operating instructions GMK 4100 3 112 343 en 12 - 7...
  • Page 450 (2). • Fold the pedal (1) upwards. • (B) – Adjust the front panel to the desired height. • Fold down the pedal (1) to lock the front panel. 12 - 8 3 112 343 en Operating instructions GMK 4100...

  • Page 451: Checking The Safety Devices

    Raise , Lower and Extend are switched off. If the lifting limit switch is not working correctly, do not begin to work with the crane but notify CraneCARE Operating instructions GMK 4100 3 112 343 en 12 - 9...
  • Page 452 Perform the same inspection for the emer- gency switches (1) and (2). If the emergency stop switches are not working correctly, do not begin to work with the crane but notify CraneCARE 12 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 453 3 seconds. If the dead man's switch system is not working correctly, do not begin to work with the crane but notify CraneCARE Operating instructions GMK 4100 3 112 343 en 12 - 11...

  • Page 454: Earthing The Load

    • Hold the metal rod by the insulated grip (1). • To earth, touch the load with the metal rod. 12 - 12 3 112 343 en Operating instructions GMK 4100...

  • Page 455: Preheating The Hydraulic Oil

    Operate all crane functions at least twice after preheating (hydraulic oil tem- perature above 10 °C (50 °F)) in order to remove the cold oil from all parts of the hydraulic system. Operating instructions GMK 4100 3 112 343 en 12 - 13...

  • Page 456: Switching The Houselock On / Off

    Risk of damage during slewing Always switch off the slewing gear before you operate the houselock. The system will be damaged when slewing the superstructure during the locking procedure. 12 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 457 Press the button (1) in at the top until the symbol (2) turns green. • If the symbol (3) is still displayed, you must correct the position of the superstructure once more. Operating instructions GMK 4100 3 112 343 en 12 - 15...
  • Page 458 Press the button (1) in at the bottom until the symbol (2) turns red. The display first shows the symbol yellow and when the houselock is switched on, it shows the symbol (2) in red. 12 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 459: Operation Of The Safe Load Indicator

    It is prohibited to work with the SLI if it is switched off, overridden, out of service or faulty. Danger of overturning in two-hook operation mode The safe load indicator only secures one-hook operations! Two-hook oper- ations are not permitted. Operating instructions GMK 4100 3 112 343 en 12 - 17...

  • Page 460: Switching On The Sli

    – and the lamps (2) and (3). • Check whether all digits flash on all displays • Notify and have the error elimi- CraneCARE nated in the event of faulty safety devices 12 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 461 You must re-enter the current rigging mode if the displayed values do not à correspond to the current rigging mode of the truck crane; Entering the rigging mode , p. 12 - 21. Operating instructions GMK 4100 3 112 343 en 12 - 19...
  • Page 462 The brightness of all displays and lamps is adjusted automatically to the displays ambient brightness after turning on the ignition. Do not cover the sensor (1) and keep it clean to avoid soiling affecting the adjustment of the brightness. 12 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 463: Entering The Rigging Mode

    The complete input procedure for the SLI code is described in the following section. To enter the rigging mode based on individual components; à Entering individual components , p. 12 - 26. Operating instructions GMK 4100 3 112 343 en 12 - 21...
  • Page 464 If an error occurs, the lamps in the button (2) flash. To display error codes, you must press the button (2). You can switch back to the display of the permissible slewing range by pressing the button (3). 12 - 22 3 112 343 en Operating instructions GMK 4100...
  • Page 465 – If the SLI code is not permissible, the lamps in the button (1) flash. à Press the button (1) once to display the error codes; p. 15 - 28. Operating instructions GMK 4100 3 112 343 en 12 - 23...
  • Page 466 If there are no more error messages and all error messages which have occurred have been acknowledged, the lamps (1) and (2) go out. The crane à Inspections prior to crane operation , movements are now enabled; p. 12 - 29. 12 - 24 3 112 343 en Operating instructions GMK 4100...
  • Page 467 The entry is confirmed and the signalling point displayed (1). Accepting the reeving value • Press button (2) once. The signalling point disappears and the reev- ing value is accepted. Operating instructions GMK 4100 3 112 343 en 12 - 25...
  • Page 468 SLI code display. Entries are made in four steps: – switch on input mode – select values – confirm SLI code and – accept SLI code. 12 - 26 3 112 343 en Operating instructions GMK 4100...
  • Page 469 (2). The values are displayed repeatedly in ascending order. The display (3) shows the corresponding SLI code for each newly selected value. Operating instructions GMK 4100 3 112 343 en 12 - 27...
  • Page 470 The entry is confirmed and you can accept the SLI code. Accepting the SLI code à Accepting the SLI code , p. 12 - 24. 12 - 28 3 112 343 en Operating instructions GMK 4100...

  • Page 471: Inspections Prior To Crane Operation

    , p. 12 - 30. You may only begin operating the crane once all displays show the current rigging mode of the truck crane. Correct any incorrect entries, as required. Operating instructions GMK 4100 3 112 343 en 12 - 29...
  • Page 472 In this way, you can prevent the SLI from making calculations based on an incorrect reeving value and the truck crane from becoming overloaded or overturning. 12 - 30 3 112 343 en Operating instructions GMK 4100...

  • Page 473: Displays During Crane Operation

    The value is displayed either in metres (m) or feet (ft), depending on the setting. Operating instructions GMK 4100 3 112 343 en 12 - 31...
  • Page 474 Green: 0 – 90% Yellow: approx. 90 -100% Red: greater than 100% The current degree of utilisation can also be displayed as a number; à p. 12 - 33. 12 - 32 3 112 343 en Operating instructions GMK 4100...
  • Page 475 The lamp (2) goes on and the current main boom length is displayed after pressing the button (1). The value is displayed either in metres (m) or feet (ft), depending on the setting. Operating instructions GMK 4100 3 112 343 en 12 - 33...
  • Page 476 Oil pressure in the derricking cylinder upper chamber: • Press button (2) once. • Press the button (1) once additionally. The lamps in the pressed buttons go on. The corresponding value is dis- played in bar. 12 - 34 3 112 343 en Operating instructions GMK 4100...

  • Page 477: Sli Early Warning

    The display (1) shows the current degree of utilisation, e.g. 91%. If the current crane movements continue to be carried out in the same direc- tion, an SLI shutdown occurs. Operating instructions GMK 4100 3 112 343 en 12 - 35...

  • Page 478: Sli Shutdown

    In some cases the SLI also switches off boom retracting. In this case, leave the shutdown range by raising the boom. If this is not possible, set down the load, telescope to the next fixed length and raise the load again. 12 - 36 3 112 343 en Operating instructions GMK 4100...

  • Page 479: Error Message

    – both lamps in the button (1) light up. Further displays depend on the type of error; à Error messages , p. 15 - 26. Operating instructions GMK 4100 3 112 343 en 12 - 37...

  • Page 480: Sli Override

    The key must not remain in the key-operated switch when operating the crane. In this way, you avoid accidentally overriding the SLI. The SLI can also be overridden together with the lifting limit switch; à p. 12 - 52. 12 - 38 3 112 343 en Operating instructions GMK 4100...

  • Page 481: Displaying And Entering The Time And Date

    – Display of the time, e.g. 8 minutes past 9 – Display of the seconds, e.g. 14 seconds – Display of the day and month, e.g. 10 May – Display of the year, e.g. 2004 Operating instructions GMK 4100 3 112 343 en 12 - 39...
  • Page 482 The entry is confirmed. The display no longer flashes but indicates the new entry, e.g. 9:08. Illogical values (77 seconds for example) are not saved and the display con- tinues to flash. 12 - 40 3 112 343 en Operating instructions GMK 4100...

  • Page 483: Crane Operation With Main Boom

    (e.g. scaffolding or gas containers). à Safe distance from electrical lines , Keep a safe distance to electrical lines; p. 13 - 14. Operating instructions GMK 4100 3 112 343 en 12 - 41...
  • Page 484 If the current wind speed is higher that the maximum permissible wind speed, stop crane operation immediately and establish the corresponding rigging mode Lifting capacity table . This prevents the truck crane from overturning due to overloading. 12 - 42 3 112 343 en Operating instructions GMK 4100...

  • Page 485: Permissible Slewing Ranges And Working Positions

    SLI code for the 360° slewing range. • Observe the additional information if the truck crane is free on wheels; à Free-on-wheels working position , p. 12 - 44. Operating instructions GMK 4100 3 112 343 en 12 - 43...
  • Page 486 – put the truck crane on the wheels. • Proceed as described in the section titled Rigging in free on wheels work- à ing position; p. 13 - 111. 12 - 44 3 112 343 en Operating instructions GMK 4100...

  • Page 487: Main Hoist

    This can result in the load slipping during subsequent lifting pro- cedures. à You can have the operating hours of the hoist displayed; p. 12 - 101. Operating instructions GMK 4100 3 112 343 en 12 - 45...
  • Page 488 Never turn off the engine with a load suspended. You must have the control levers at hand in order to intervene at any time. Always set down the load before you leave the crane cab. 12 - 46 3 112 343 en Operating instructions GMK 4100...
  • Page 489 • Press button (1) once. – The lamp in the button (1) lights up dimly. – Symbol (2) is red when the main hoist is switched off. Operating instructions GMK 4100 3 112 343 en 12 - 47...

  • Page 490: Auxiliary Hoist

    – The symbol (2) must be red. • Press button (1) once. – The lamp in button (1) lights up brightly. – Symbol (2) is green when the auxiliary hoist is switched on. 12 - 48 3 112 343 en Operating instructions GMK 4100...
  • Page 491 You can regulate the speed by moving the control lever and changing the engine speed with the accelerator. You can set the desired engine speed (idling speed) with the button (1); à p. 11 - 16. Operating instructions GMK 4100 3 112 343 en 12 - 49...
  • Page 492 • Press button (1) once. – The lamp in the button (1) lights up dimly. – Symbol (2) is red when the auxiliary hoist is switched off. 12 - 50 3 112 343 en Operating instructions GMK 4100...

  • Page 493: Lifting Limit Switch And Lowering Limit Switch

    , lowering, extending and derricking the lattice extension . To cancel the shutdown, leave the shutdown range by performing a differ- ent crane movement or setting down the load. Operating instructions GMK 4100 3 112 343 en 12 - 51...
  • Page 494 This crane movement will now not be stopped again. The lamp (1) goes out – if you let go of the key-operated switch (override cancelled) or – if you leave the shutdown range. 12 - 52 3 112 343 en Operating instructions GMK 4100...
  • Page 495 In this way you avoid the lowering limit switch switching off too late or not at all, the hoist rope being damaged and the load being dropped. Operating instructions GMK 4100 3 112 343 en 12 - 53...

  • Page 496: Derricking Gear

    If the control lever is assigned more than one function, all other power units which are assigned the same control lever operation are switched off; à Control lever assignment , p. 10 - 16. 12 - 54 3 112 343 en Operating instructions GMK 4100...
  • Page 497 11 - 16. à You can limit the maximum derricking speed; p. 12 - 96. à For higher speeds, you can also switch to high-speed mode; p. 12 - 86. Operating instructions GMK 4100 3 112 343 en 12 - 55...
  • Page 498 (e.g. retracting, setting down the load, other superstructure position). All rigging modes for which rigging tables exist can be found in the Lifting capacity tables . 12 - 56 3 112 343 en Operating instructions GMK 4100...

  • Page 499: Telescoping Mechanism

    The ECOS display shows various sectional views of the main boom. To make you familiar with these representations more quickly, the following section begins with an overview of the telescoping mechanism and a tele- scoping process. Operating instructions GMK 4100 3 112 343 en 12 - 57...
  • Page 500 – then the mechanism (10) engages into the locking pins (7) and can retract them – the telescopic section is unlocked. Telescoping This condition should be the starting point for a telescoping process. Tele- process scoping processes consist of 4 steps: 12 - 58 3 112 343 en Operating instructions GMK 4100...
  • Page 501 3. Unlocking the telescopic section The telescoping cylinder extends until the locking pins (7) are clear. The mechanism (10) retracts the locking pins (7) – the telescopic section is unlocked. Operating instructions GMK 4100 3 112 343 en 12 - 59...
  • Page 502 The Telescoping submenu of the ECOS display shows two sectional views of Assignment for display the main boom. 1 Sectional view from the rear 2 Sectional view from the front The following elements are displayed. 12 - 60 3 112 343 en Operating instructions GMK 4100...
  • Page 503 3 Telescopic section III 4 Cutouts 5 Locking pins on the telescoping cylinder 6 Cutouts 7 Locking pins on the telescopic section 8 Telescoping cylinder (piston rod) 9 Basic section 10 Mechanism Operating instructions GMK 4100 3 112 343 en 12 - 61...
  • Page 504 The size of the load that can be telescoped depends on the angle of inclination and on the degree of lubrication of the main boom. 12 - 62 3 112 343 en Operating instructions GMK 4100...
  • Page 505 (e.g. V, IV, III , II , I ). The telescopic sections are always retracted in the reverse order of extend- ing. Operating instructions GMK 4100 3 112 343 en 12 - 63...
  • Page 506 ECOS display with the current telescoping. You must enter the current telescoping if the current telescoping is not dis- à Entering the current telescoping , p. 15 - 49. played correctly; 12 - 64 3 112 343 en Operating instructions GMK 4100...
  • Page 507 The rope can become slack if the hook block touches the ground during retraction operations. Rope loops form, which can cause the load to slip and destroy the hoist rope. Operating instructions GMK 4100 3 112 343 en 12 - 65...
  • Page 508 With certain telescoping statuses, the SLI switches telescoping off, e.g. when you leave the telescoping lengths or when the working range limit has à SLI shutdown , p. 12 - 36. been reached; 12 - 66 3 112 343 en Operating instructions GMK 4100...
  • Page 509 à Control lever assignment , is assigned the same control lever movement; p. 10 - 16. Operating instructions GMK 4100 3 112 343 en 12 - 67...
  • Page 510 (1) once. The Telescoping submenu opens. If an error message (1) is pending, all operating elements are disabled; à Telescoping mechanism error messages , p. 15 - 18. 12 - 68 3 112 343 en Operating instructions GMK 4100...
  • Page 511 – number green – the display (5) shows one or two arrows, depending on the distance to the locking point The display (1) shows a top view of the current position. Operating instructions GMK 4100 3 112 343 en 12 - 69...
  • Page 512 1 Locking pins on the telescoping cylinder 2 Locking pins on the telescopic sections The positions are shown as follows: – Green: locked – No display: unlocked or intermediate position 12 - 70 3 112 343 en Operating instructions GMK 4100...
  • Page 513 The locking pins(3) retract. – Yellow: intermediate position – Red: unlocked In the Unlocked position the symbol (1) is yel- low. If the control lever is moved, the telescoping cylinder moves immediately. Operating instructions GMK 4100 3 112 343 en 12 - 71...
  • Page 514 If removing the load does not cause unlocking, you must lock the telescop- à ing cylinder ( p. 12 - 74) and start unlocking anew. 12 - 72 3 112 343 en Operating instructions GMK 4100...
  • Page 515 1 m (3.3 ft) B Yellow: smaller than 1 m (3.3 ft) C Green: at the locking point – the direction of travel to the locking point: 1 Extending 2 Retracting Operating instructions GMK 4100 3 112 343 en 12 - 73...
  • Page 516 – Yellow: intermediate position – Green: locked In Locked position – the symbol (1) is yellow – the symbol (2) is grey – the locking pins (4) are green. 12 - 74 3 112 343 en Operating instructions GMK 4100...
  • Page 517 – Yellow: intermediate position – Red: unlocked In the Unlocked position the symbol (1) is yel- low. If the control lever is moved, the telescopic section is telescoped immediately. Operating instructions GMK 4100 3 112 343 en 12 - 75...
  • Page 518 If removing the load does not cause unlocking, you must lock the telescopic à section ( p. 12 - 78) and start unlocking anew. 12 - 76 3 112 343 en Operating instructions GMK 4100...
  • Page 519 Move the control lever in the desired tele- scoping direction. The display (2) shows the currently extended length (telescoping), e.g. 55% for telescopic section III . The current telescope diagram on the display (1) changes continually. Operating instructions GMK 4100 3 112 343 en 12 - 77...
  • Page 520 – Green: locked The telescopic section is set down; à p. 12 - 60. In Locked position – the symbol (1) is yellow – the symbol (2) is grey 12 - 78 3 112 343 en Operating instructions GMK 4100...
  • Page 521 12 - 71 à – move the telescoping cylinder into telescopic section I ; p. 12 - 73 and à – lock the telescoping cylinder; p. 12 - 74. Operating instructions GMK 4100 3 112 343 en 12 - 79...
  • Page 522 • Enter the desired set values for all telescopic sections, e.g. 0%, 100%, 100%, 100%, 100%. • Ö Press the button once. The entered set values are confirmed. 12 - 80 3 112 343 en Operating instructions GMK 4100...
  • Page 523 Empty trips are automatically per- formed in both directions, irrespective of the control lever movement. You can regulate the speed for telescoping in the same way as for manual telescoping. Operating instructions GMK 4100 3 112 343 en 12 - 81...
  • Page 524 The telescoping process is stopped: – the display (5) goes out. – the display (4) appears. – the values in the display (6) are red. Teleautomation is now switched off. 12 - 82 3 112 343 en Operating instructions GMK 4100...
  • Page 525 Move the control lever to retract and hold it there. • Telescopic section I will be fully retracted. For this to be done, the following processes are carried out automatically. Operating instructions GMK 4100 3 112 343 en 12 - 83...
  • Page 526 – The display (3) shows the current telescoping procedure. Teleautomation is switched off. To extend telescopic section I to 60%, for example, you can now further extend this telescopic section manually. 12 - 84 3 112 343 en Operating instructions GMK 4100...
  • Page 527 If you continue to extend the main boom after an SLI shutdown, you may enter ranges in which you can neither perform retraction operations nor raise the boom. Operating instructions GMK 4100 3 112 343 en 12 - 85...

  • Page 528: High Speed

    The derricking speed is not increased in high-speed mode. High-speed mode is disabled for raising when performing operations with the lattice extension. 12 - 86 3 112 343 en Operating instructions GMK 4100...
  • Page 529 The speed of the hoists will only be significantly increased by switching to high-speed mode if you have extended the control lever by more than 70%. Operating instructions GMK 4100 3 112 343 en 12 - 87...

  • Page 530: Slewing Gear

    Therefore always check before slewing whether the SLI code valid for the current rigging mode is displayed. This prevents slewing operations from being released within impermissi- ble ranges, which would cause the truck crane to overturn. 12 - 88 3 112 343 en Operating instructions GMK 4100...
  • Page 531 You can set the desired engine speed (idling speed) with the button (1); à p. 11 - 16. à You can limit the maximum slewing speed; p. 12 - 96. Operating instructions GMK 4100 3 112 343 en 12 - 89...
  • Page 532 – both arrows (1) are shown. If you have stopped too late, an arrow (1) indicates in which direction you need to slew in order to reach the slewing angle. 12 - 90 3 112 343 en Operating instructions GMK 4100...
  • Page 533 • Switch on the slewing gear. The slewing gear brake is released – lamp (1) lights up. • Shift the control lever (2) to zero position. Operating instructions GMK 4100 3 112 343 en 12 - 91...

  • Page 534: Possible Movement Combinations

    – Lattice extension derricking gear The lattice extension derricking gear cannot be operated in combination with the Extending movement. Certain movement combinations can reduce the speed in high-speed mode. 12 - 92 3 112 343 en Operating instructions GMK 4100...

  • Page 535: Hydraulic Oil Cooling

    Warning submenu , p. 12 - 102. When the hydraulic oil temperature reaches 80 °C (176 °F): • Stop crane operation. • Let the hydraulic oil cool down while the engine is running. Operating instructions GMK 4100 3 112 343 en 12 - 93...
  • Page 536 Crane operation 12.3 Crane operation with main boom Blank page 12 - 94 3 112 343 en Operating instructions GMK 4100...

  • Page 537: Settings And Displays For Crane Operation

    The crane cab is inclined as long as you hold the button down or the end position is reached. 12.4.2 Setting the idling speed à Setting the idling speed , p. 11 - 16. Operating instructions GMK 4100 3 112 343 en 12 - 95...

  • Page 538: Adjusting The Stroke Interval Of The Windscreen Wiper

    You can enter how many percent of the maximum speed shall be enabled for each power unit. • ö If necessary, open the main menu and press the button (1) once. The Power unit speeds submenu opens. 12 - 96 3 112 343 en Operating instructions GMK 4100...
  • Page 539 • If necessary, change the values for other power units in the same way. • Confirm the changed values – press button (6) once. All changed values are applied. Operating instructions GMK 4100 3 112 343 en 12 - 97...

  • Page 540: Setting The Characteristic Curve For The Control Levers

    The higher the number of the characteristic curve, the further the control lever must be moved to instigate a clear increase in speed. With characteristic curve (5), you work particularly sensitively with the con- trol lever. 12 - 98 3 112 343 en Operating instructions GMK 4100...

  • Page 541: Critical Load Control

    • Press the button (1) repeatedly until dot (2) is black. To switch on the critical load control • Press the button (1) repeatedly until dot (2) is green. Operating instructions GMK 4100 3 112 343 en 12 - 99...

  • Page 542: Operation Of The Directional Spotlights

    To direct the spotlights backwards • Press button (2) down. The direction of the spotlights is adjusted until you let go of the button or they reach their end position. 12 - 100 3 112 343 en Operating instructions GMK 4100...

  • Page 543: Displaying The Operating Hours

    Exception: the value below the symbol (3) indicates how often the cycle Unlock telescopic section has been operated, e.g. 13,750 times. Auxiliary power units (1) include: – counterweight hoist unit, – crane cab inclination. Operating instructions GMK 4100 3 112 343 en 12 - 101...

  • Page 544: Warning Submenu

    Symbols which are present in both submenus are only explained once. Follow the cross-references for continued procedures in part 1 or part 2, depending on the submenu opened. 12 - 102 3 112 343 en Operating instructions GMK 4100...
  • Page 545 11 - 5, p. 4 - 7. When the fuel tank is almost empty, air is sucked in and you must bleed the à Maintenance manual . fuel system; Operating instructions GMK 4100 3 112 343 en 12 - 103...
  • Page 546 11 - 21, p. 4 - 23. Pre-tensioning the counterweight The pre-tensioning pressure on the counterweight has dropped too much. à • Pre-tension the counterweight; p. 13 - 74. 12 - 104 3 112 343 en Operating instructions GMK 4100...
  • Page 547 If the same warning messages are still present, the lamps (1) and (2) light If no warning message is present, both lamps will have gone out. Both lamps start to flash again as soon as a new warning message occurs. Operating instructions GMK 4100 3 112 343 en 12 - 105...

  • Page 548: Error Submenu

    12 - 102). In the event of an error message the lamps (1) and (2) flash. à Error messages , p. 15 - 33. More information on error messages; 12 - 106 3 112 343 en Operating instructions GMK 4100...

  • Page 549: Working Range Limiter

    Risk of accidents due to insufficient safety distances Always observe all safety distances in accordance with the national legal regulations (e.g. concerning electrical cables) even if the working range limiter is switched on. Operating instructions GMK 4100 3 112 343 en 12 - 107...

  • Page 550: Opening The Working Range Limiter Submenu

    3 Slewing angle monitoring 4 Object monitoring – Dot is black: monitoring switched off – Dot is green: monitoring switched on, the monitored area à is displayed; p. 12 - 118. 12 - 108 3 112 343 en Operating instructions GMK 4100...
  • Page 551 (0° to +180.0°). – Angles in the left-hand semi-circle are displayed as negative values (0° to –179.9°). à Objects , p. 12 - 117. Viewing the limit values for object monitoring; Operating instructions GMK 4100 3 112 343 en 12 - 109...

  • Page 552: Entering Limit Values

    (B) – Press the button once. – The current value (6) is accepted as the limit value (7). – The bar (5) goes out. à • Switch on monitoring; p. 12 - 118. 12 - 110 3 112 343 en Operating instructions GMK 4100...
  • Page 553 – The slewing angle B limits slewing to the right. The permissible slewing range is represented by the angle stretching clock- wise from A to B. Approx. 270° in this illustration – arrow (1). Operating instructions GMK 4100 3 112 343 en 12 - 111...
  • Page 554 • Ö Press button once. – The slewing angle B is displayed. – The value (2) is accepted as the limit value (3). – The bar (1) goes out. 12 - 112 3 112 343 en Operating instructions GMK 4100...
  • Page 555 Only those points are displayed that are located within the entered, maxi- mum working radius. You may need to enlarge the maximum working à radius in order to display the point; p. 12 - 116. Operating instructions GMK 4100 3 112 343 en 12 - 113...
  • Page 556 Enter the next point, e.g. point (5) at -160° and 20 m. This point (5) is the first point for the new object. The following point is added to this object, e.g. point (6). 12 - 114 3 112 343 en Operating instructions GMK 4100...
  • Page 557 • Press the button (2) once – symbol (3) appears. ö You can cancel the process with the button • Ö Press button once – all points are deleted. Operating instructions GMK 4100 3 112 343 en 12 - 115...

  • Page 558: Entering Limit Values / Objects Manually

    (B) – Press button once. – Display (5) = new limit value – Display (4) = current value, e.g. 3.0 – Bar (3) goes out – Dot (2) black, manual input off 12 - 116 3 112 343 en Operating instructions GMK 4100...
  • Page 559 To end your input, press the button once. – Bar (9) or (10) goes out – display = current main boom position – Dot (11) black – manual input off Operating instructions GMK 4100 3 112 343 en 12 - 117...

  • Page 560: Switching Monitoring Functions On / Off

    – Overall height No display. The current main boom position (7) is always displayed. It is impossible to move behind a defined object whenever a monitoring function is switched on. 12 - 118 3 112 343 en Operating instructions GMK 4100...

  • Page 561: Shutdown By Working Range Limiter

    Bear in mind that, due to the boom bending for exam- ple, the overall height is increased if you set down the load. If you override the SLI, the shutdown is overridden and all movements are enabled. Operating instructions GMK 4100 3 112 343 en 12 - 119...
  • Page 562 Crane operation 12.5 Working range limiter Blank page 12 - 120 3 112 343 en Operating instructions GMK 4100...

  • Page 563: Work Break

    Switch the engine off, turn the ignition key to position 0 and remove it. Ensure that no unauthorised persons can operate the truck crane; à To secure the truck crane , p. 12 - 122. Operating instructions GMK 4100 3 112 343 en 12 - 121...

  • Page 564: Work Breaks Of More Than 8 Hours

    Danger due to unauthorised use Close the hand-held control before you leave the truck crane. In this way you can prevent unauthorised persons from starting the engine with the hand-held control. 12 - 122 3 112 343 en Operating instructions GMK 4100...

  • Page 565: Heating And Air-Conditioning System

    C Mixed air – outer air and air is sucked in from the driver's cab. The percentage of the corresponding air type is increased continu- ously by turning the switch in the direction (B) or (A). Operating instructions GMK 4100 3 112 343 en 12 - 123...
  • Page 566 1 – To open: press in and position lengthwise – To close: position crosswise – To direct the air flow: in intermediate position 2 – To direct the air flow: turn 12 - 124 3 112 343 en Operating instructions GMK 4100...

  • Page 567: Air-Conditioning System

    If the air-conditioning system is operated continuously, close the windows and doors to ensure sufficient cooling. Set the fan to a lower level once the inside temperature has reached the desired temperature. Operating instructions GMK 4100 3 112 343 en 12 - 125...
  • Page 568 Set the air distribution with switch (3) – open the air vents if necessary. • If switch (2) is set to recirculated air, cooling will be quicker. There will be no oxygen sup- plied, however. 12 - 126 3 112 343 en Operating instructions GMK 4100...

  • Page 569: Auxiliary Water Heater

    You can use the auxiliary water heater to: – either preheat the engine or – preheat the engine and crane cab simultaneously. à The auxiliary heater is supplied from a separate tank; p. 12 - 5. Operating instructions GMK 4100 3 112 343 en 12 - 127...
  • Page 570 Turn the switch (2) to the required fan level. à • Open the air vents; p. 12 - 124. The amount of time required to preheat the engine is increased significantly by simultaneously heating the crane cab. 12 - 128 3 112 343 en Operating instructions GMK 4100...
  • Page 571 In this way, you prevent the auxiliary heater from restarting and running down the batteries after the engine has cooled down. Operating instructions GMK 4100 3 112 343 en 12 - 129...
  • Page 572 The display stops flashing after five seconds and the current time is dis- played. The day of the week disappears. The time and day of the week have been set. 12 - 130 3 112 343 en Operating instructions GMK 4100...
  • Page 573 If you wish to store one or two further heating starts, retrieve a new storage location using the button and repeat the procedure. After you have stored the heating start, you can also set the heating period; à p. 12 - 132. Operating instructions GMK 4100 3 112 343 en 12 - 131...
  • Page 574 This heating start is activated as soon as the display stops flashing. To deactivate the automatic heating start, press the button repeatedly until no storage location is displayed any longer. 12 - 132 3 112 343 en Operating instructions GMK 4100...
  • Page 575 Set the required remaining run time on the flashing display. You can set a remaining run time of 1 to 120 minutes. • Wait for 5 seconds until the current time is shown. The remaining run time is now set. Operating instructions GMK 4100 3 112 343 en 12 - 133...

  • Page 576: Auxiliary Air Heater

    Turn on the ignition; Switch on the ignition , p. 11 - 8. • Press button (1) once. The auxiliary heating switches itself on – the control field lights up. 12 - 134 3 112 343 en Operating instructions GMK 4100...
  • Page 577 – Switching heating start on / off p. 12 - 132 à – Setting the heating period p. 12 - 132 à – Setting the remaining time p. 12 - 133 Operating instructions GMK 4100 3 112 343 en 12 - 135...
  • Page 578 Crane operation 12.7 Heating and air-conditioning system Blank page 12 - 136 3 112 343 en Operating instructions GMK 4100...
  • Page 579 Removing / installing the counterweight on the turntable ....13 - 77 13.7.9 Setting down counterweight for driving the truck crane ....13 - 80 Operating instructions GMK 4100 3 112 343 en...
  • Page 580 Mirror for crane operation ......... 13 - 114 3 112 343 en Operating instructions GMK 4100...

  • Page 581: Rigging Work

    13 - 18, à – If necessary, switch off boom pre-tensioning; p. 13 - 19. à 4. Folding out the tread grid on the turntable; p. 13 - 113 Operating instructions GMK 4100 3 112 343 en 13 - 1...
  • Page 582 Lifting capacity table and raise until none of the wheels à Outriggers , p. 13 - 25. touches the ground; à 9. Align the truck crane horizontally; p. 13 - 46. 13 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 583 Hook block on a separate vehicle , p. 13 - 87, à Hook block on the bumper , p. 13 - 85, à Reeving and unreeving the hoist rope , p. 13 - 90. Operating instructions GMK 4100 3 112 343 en 13 - 3...
  • Page 584 21. With the SLI adjusted accordingly, rig the counterweight version required for the operation according to the Lifting capacity table ; à CHECKLIST: Rigging counterweight , p. 13 - 59. 13 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 585: Checklist: Unrigging

    à CHECKLIST: Unrigging counterweight , p. 13 - 60. 3. Enter the current rigging mode with the newly rigged counterweight à version on the SLI; p. 12 - 21. Operating instructions GMK 4100 3 112 343 en 13 - 5...
  • Page 586 12 - 14. à 8. Turn off the engine for crane operation; p. 11 - 19. à 9. Remove anemometer and the air traffic control light; p. 13 - 108. 13 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 587 14. Fold in the tread grid on the turntable; p. 13 - 113 à 15. When the truck crane is no longer being used; Work breaks of more than 8 hours , p. 12 - 122. Operating instructions GMK 4100 3 112 343 en 13 - 7...
  • Page 588 Rigging work 13.1 Rigging work checklists for crane operation with the main boom Blank page 13 - 8 3 112 343 en Operating instructions GMK 4100...

  • Page 589: Choosing A Suitable Site

    ⎞ ⎜ ⎟ -------- - loadbearing capacity of the ground ⎝ ⎠ Outrigger pressure • Determine the outrigger pressure for the operation planned using the Outrigger pressure table . Operating instructions GMK 4100 3 112 343 en 13 - 9...
  • Page 590 In massive or columnar for- (61 400) mation If you are unsure about the load bearing capacity of the ground, please have the ground tested. 13 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 591 If the outrigger pad has a surface of 2 000 cm , you would need to enlarge the à ground bearing area by packing the outrigger pads; p. 13 - 39. Operating instructions GMK 4100 3 112 343 en 13 - 11...

  • Page 592: Safe Distance From Slopes And Pits

    The safe distance is measured from the base of the pit (c). In addition to this the safe distance (d) between the pads and the pit border must always be more than 2.00 m (6.6 ft). 13 - 12 3 112 343 en Operating instructions GMK 4100...

  • Page 593: Earthing The Truck Crane

    Do not attach the clamp to parts that are screwed on, such as valves, covers or similar parts. • Attach the clamp to the main boom or to the superstructure. Operating instructions GMK 4100 3 112 343 en 13 - 13...

  • Page 594: Safe Distance From Electrical Lines

    If this is not possible, you must at least observe the prescribed safe dis- tance (A). Different safe distances are recommended by the respective national regu- lations: 13 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 595 Do not leave the crane cab. • Tell anyone standing outside not to touch the crane, the load or the lifting tackle. • Move the main boom out of the danger area. Operating instructions GMK 4100 3 112 343 en 13 - 15...
  • Page 596 Rigging work 13.2 Choosing a suitable site Blank page 13 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 597: Rigging Work After Driving With A Trailer

    Switch the valve I over – lever (1) positioned • vertically pointing outwards or inwards, depending on its fitting position. • Secure the lever (1) with the padlock (2) The boom floating position is now switched off. Operating instructions GMK 4100 3 112 343 en 13 - 17...

  • Page 598: Switching Off The Slewing Gear Freewheel

    Before slewing Support the truck crane with the necessary outrigger span, enter the corre- sponding SLI code and derrick the main boom to an angle permissible within the working range. 13 - 18 3 112 343 en Operating instructions GMK 4100...

  • Page 599: Switching Off Boom Pre-Tensioning

    The pressure accumulator is emptied. The pressure on the pressure gauge (1) must drop to 0 bar (0 psi). Valve II stays closed – the lever (3) points downwards. Operating instructions GMK 4100 3 112 343 en 13 - 19...

  • Page 600: Connecting / Disconnecting The Hand-Held Control

    Insert the bridging plug (3) into the socket (1) and secure it with the cap (2.) The ignition is turned off, unless it is switched on at an ignition lock. 13 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 601: Starting The Engine For Driving For Rigging Work

    In that case you cannot start the engine for driving since the ignition in the crane cab is still switched Operating instructions GMK 4100 3 112 343 en 13 - 21...
  • Page 602 You cannot turn off the engine with the ignition lock in the driver's cab if it engine was started with the hand-held control. • Press the button (1) once – the engine goes off. 13 - 22 3 112 343 en Operating instructions GMK 4100...

  • Page 603: Starting / Turning Off The Engine From The Crane Cab

    Press the button (5) once. The engine starts. When the engine is running – The symbols (3) and (4) are displayed. – The lamp in the button (1) lights up. Operating instructions GMK 4100 3 112 343 en 13 - 23...
  • Page 604 The carrier ignition is turned off and the engine is switched off. – The lamp in the button (1) goes out. – The symbol (2) turns red. – The symbols (3) and (4) are displayed. 13 - 24 3 112 343 en Operating instructions GMK 4100...

  • Page 605: Outriggers

    Setting the spans , p. 13 - 30 à Extending / retracting outriggers , p. 13 - 32. 4. Move the outrigger pads into working position and secure them; à p. 13 - 38. Operating instructions GMK 4100 3 112 343 en 13 - 25...
  • Page 606 13 - 22, à – After operating it from the control units; p. 4 - 21, à – After operating it from the crane cab; p. 13 - 24. 13 - 26 3 112 343 en Operating instructions GMK 4100...

  • Page 607: Checklist: Retracting The Outriggers

    Extending / retracting outriggers , p. 13 - 32. 4. Stow away packing material safely, if applicable. 5. Activate (unlock) the suspension. à The symbol must be green (suspension on); p. 5 - 15. Operating instructions GMK 4100 3 112 343 en 13 - 27...

  • Page 608: Permissible Outrigger Spans

    The second value specifies the required out- rigger span (2), e.g. 7.00 m (23.0 ft). In addition, there is a lifting capacity table for the Free on wheels work position. 13 - 28 3 112 343 en Operating instructions GMK 4100...

  • Page 609: Preparing The Truck Crane

    – Symbol (2) – operating units on, buttons enabled – Symbol (3) – operating units off, buttons dis- abled • To switch on or off, press the button next to the symbol (1) once. Operating instructions GMK 4100 3 112 343 en 13 - 29...

  • Page 610: Setting The Spans

    Plug the pin with the peg (1) with the peg (2) through the cutout (3). • Turn the pin in such a way that the handle (4) points downwards. 13 - 30 3 112 343 en Operating instructions GMK 4100...
  • Page 611 Danger of accidents due to outrigger beams moving out Completely retract all outriggers and secure them. This prevents the outrig- ger beams from swaying out in curves and causing serious accidents. Operating instructions GMK 4100 3 112 343 en 13 - 31...

  • Page 612: Extending / Retracting Outriggers

    – On the Outriggers control units; p. 13 - 36 à – On the hand-held control; p. 13 - 34 à – In the crane cab; p. 13 - 36 13 - 32 3 112 343 en Operating instructions GMK 4100...
  • Page 613 1 + 4 Extend both 2 + 3 Retract both The outriggers move until you let go of the respective button or until the respective end position has been reached. Operating instructions GMK 4100 3 112 343 en 13 - 33...
  • Page 614 Pre-select high-speed mode / normal speed • Press the button (2). – Lamp (1) lights up – high-speed mode pre-selected, – Lamp (1) goes out – normal speed pre-selected. 13 - 34 3 112 343 en Operating instructions GMK 4100...
  • Page 615 Press the button combination for the desired movement: 1 Extend 2 Retract The pre-selected supporting cylinders move until you let go of the respec- tive button or until the respective end position has been reached. Operating instructions GMK 4100 3 112 343 en 13 - 35...
  • Page 616 – The dot in the symbol turns green, e.g. in symbol (5). – The symbols (1) and (2) turn black. After about 10 seconds the pre-selection is switched off. 13 - 36 3 112 343 en Operating instructions GMK 4100...
  • Page 617 Press the button below the symbol for the desired movement: 1 Retract 2 Extend The pre-selected outrigger beams move until you let go of the respective button or until the respective end position has been reached. Operating instructions GMK 4100 3 112 343 en 13 - 37...

  • Page 618: Moving The Outrigger Pads Into Working / Driving Position

    (3). • Secure the outrigger pad with the pin (1). • Secure the pin (1). • Move the other outrigger pads into driving position in the same way. 13 - 38 3 112 343 en Operating instructions GMK 4100...

  • Page 619: Enlarging The Ground Bearing Area

    – The outrigger pad must cover all the wooden planks. – If the packing has several layers, each layer must be placed below the other offset by 90°. Consult your supervisor if you are in doubt. Operating instructions GMK 4100 3 112 343 en 13 - 39...
  • Page 620 Rigging work 13.6 Outriggers Blank page 13 - 40 3 112 343 en Operating instructions GMK 4100...

  • Page 621: Extending / Retracting Supporting Cylinders

    – On the Outriggers control units; p. 13 - 42 à – On the hand-held control; p. 13 - 43 à – In the crane cab; p. 13 - 44 Operating instructions GMK 4100 3 112 343 en 13 - 41...
  • Page 622 You can also operate several supporting cylin- ders at the same time. The outriggers move until you let go of the respective button or until the respective end position has been reached. 13 - 42 3 112 343 en Operating instructions GMK 4100...
  • Page 623 After about 10 seconds the pre-selection is switched off. Combinations of the buttons (1) to (4) are also possible, e.g. buttons (1) and (2), in order to lift the truck crane at the front. Operating instructions GMK 4100 3 112 343 en 13 - 43...
  • Page 624 The Outriggers submenu opens. To start the engine • Switch the carrier ignition on and start the engine for driving; à p. 13 - 23. • Switch off the slewing gear 13 - 44 3 112 343 en Operating instructions GMK 4100...
  • Page 625 Press the button below the symbol for the desired movement: 1 Retract 2 Extend The pre-selected supporting cylinders move until you let go of the respec- tive button or until the respective end position has been reached. Operating instructions GMK 4100 3 112 343 en 13 - 45...

  • Page 626: Levelling The Truck Crane On Outriggers

    The assignment to the carrier is given by the directional indicator (1). In this example, the carrier would be stand- ing higher to the rear on the right hand side. 13 - 46 3 112 343 en Operating instructions GMK 4100...
  • Page 627 In other positions the deformation of the carrier will create incorrect results for the inclination and the truck crane will be at an angle. This could cause the outrigger beam to become overloaded during crane operation. Operating instructions GMK 4100 3 112 343 en 13 - 47...
  • Page 628 If slewing is permissible with the current rigging mode: • Slew the superstructure within the permissible slewing range. • Perform the specified checks again. • Check the horizontal alignment on the inclination display. 13 - 48 3 112 343 en Operating instructions GMK 4100...
  • Page 629 Press the button combination (3) for automatic alignment. The procedure begins. – On the control units • Press the button (1). • Additionally, press the button (2). The procedure begins. Operating instructions GMK 4100 3 112 343 en 13 - 49...
  • Page 630 Danger of overturning if the truck crane is not level When ECOS ends the automatic alignment procedure, the truck crane is not necessarily level. Always check the horizontal alignment on the inclination display after auto- matic levelling. 13 - 50 3 112 343 en Operating instructions GMK 4100...

  • Page 631: Levelling The Free-Standing Truck Crane

    In the driver's cab, open the Level adjustment system submenu – button • Press the button (2) once – dot green. The symbol 1 is green if the suspension is switched on. Operating instructions GMK 4100 3 112 343 en 13 - 51...
  • Page 632 To secure the truck crane • Retract the supporting cylinders until the outrigger pads are about 5 to 10 cm (2 to 4 in) above the ground. Leave the outrigger beams extended. 13 - 52 3 112 343 en Operating instructions GMK 4100...

  • Page 633: Outrigger Pressure Display

    1 Display for the outrigger cylinder 1.1 2 Display for the outrigger cylinder 2.1 3 Display for the outrigger cylinder 3.1 4 Display for the outrigger cylinder 4.1 Operating instructions GMK 4100 3 112 343 en 13 - 53...
  • Page 634 Rigging work 13.6 Outriggers Blank page 13 - 54 3 112 343 en Operating instructions GMK 4100...

  • Page 635: Rigging / Unrigging The Counterweight

    13.7 Rigging / unrigging the counterweight 13.7 Rigging / unrigging the counterweight There are counterweight masses of 4.1 t (9,000 lbs) to 26.1 t (57,540 lbs) available for the GMK 4100. 13.7.1 Counterweight parts There are various counterweight parts, depending on the truck crane's ver- sion and additional equipment.
  • Page 636 Can be mounted on the turntable This version contains a different 2.2 t base plate than versions A and B in order to enable slewing with mounted 4.4 t plate. 13 - 56 3 112 343 en Operating instructions GMK 4100...

  • Page 637: Identification

    Other or additional counterweight sections may not be rigged. The serial number (1) of all sections is either on the back or indicated together with the weight. Operating instructions GMK 4100 3 112 343 en 13 - 57...

  • Page 638: Slinging Points

    Do not sling the plate (3) at the points (5). With some plates in version C, the slinging points (1) are only designed for the dead weight of the plates. 13 - 58 3 112 343 en Operating instructions GMK 4100...

  • Page 639: Checklist: Rigging Counterweight

    (automatic) and pre-charge; p. 13 - 74. 6. Enter the current rigging mode with the newly rigged counterweight à version on the SLI; p. 12 - 21. Operating instructions GMK 4100 3 112 343 en 13 - 59...

  • Page 640: Checklist: Unrigging Counterweight

    6. Lift the counterweight sections off the counterweight platform, as required by the respective driving mode; à Slinging points , p. 13 - 58, à Driving modes , p. 6 - 1. 13 - 60 3 112 343 en Operating instructions GMK 4100...

  • Page 641: Assembling Counterweight Versions

    Can only be mounted on the turntable with à version C; p. 13 - 77. 10.7 t (23,500 lbs) Can only be mounted on the turntable with à version C; p. 13 - 77. Operating instructions GMK 4100 3 112 343 en 13 - 61...
  • Page 642 (57,500 lbs) two 2.2 t plates (2) must always lie at the top so that the lifting cylinders within the cutouts (3) can be turned into the 2.2 t base plate (1). 13 - 62 3 112 343 en Operating instructions GMK 4100...
  • Page 643 The 2.2 t plate (4) is positioned correctly when its weight (3) is shown at the front. Otherwise, this plate protrudes out from the other plates at the rear. Operating instructions GMK 4100 3 112 343 en 13 - 63...
  • Page 644 The tables specify what counterweight sections are needed for the respec- tive counterweight versions. à • Slinging points , Lift the counterweight sections onto the base plate; p. 13 - 58. 13 - 64 3 112 343 en Operating instructions GMK 4100...
  • Page 645 (47 800) (52 600) (57 500) 6.3 t on the turntable 4,4 t section 2.2 t section – – 2.2 t base plate For 1 x can also be used Operating instructions GMK 4100 3 112 343 en 13 - 65...
  • Page 646 The tables specify what counterweight sections are needed for the respec- tive counterweight versions. à • Slinging points , Lift the counterweight sections onto the base plate; p. 13 - 58. 13 - 66 3 112 343 en Operating instructions GMK 4100...
  • Page 647 (47 800) (52 600) (57 500) 4.1 t on the turntable 4.4 t section 2.2 t section – 2.2 t base plate For 1 x can also be used Operating instructions GMK 4100 3 112 343 en 13 - 67...
  • Page 648 The tables specify what counterweight sections are needed for the respec- tive counterweight versions. à • Slinging points , Lift the counterweight sections onto the base plate; p. 13 - 58. 13 - 68 3 112 343 en Operating instructions GMK 4100...
  • Page 649 2.2 t section – – – – 2.2 t base plate – – – can also be used can be used can be used can also be used can be used Operating instructions GMK 4100 3 112 343 en 13 - 69...
  • Page 650 Rigging work 13.7 Rigging / unrigging the counterweight 13 - 70 3 112 343 en Operating instructions GMK 4100...
  • Page 651 – – 78 78 78 78 78 78 78 3.3 to plates 20 920 2.2 t section – 2.2 t base plate can also be used can be used Operating instructions GMK 4100 3 112 343 en 13 - 71...

  • Page 652: Counterweight Hoist Unit

    If necessary, open the main menu and press the button (1) once. The Counterweight submenu opens. If an error symbol (1) is displayed with subse- quent operation, please contact CraneCARE 13 - 72 3 112 343 en Operating instructions GMK 4100...
  • Page 653 Let go of the key-operated switch (5). • (B) – Fully retract the lifting cylinders – but- ton (3). The symbol (2) turns yellow – counterweight unrigged. You can now use the automatic mode. Operating instructions GMK 4100 3 112 343 en 13 - 73...
  • Page 654 (2) or (3) – the automatic process starts. – The superstructure turns into position (A). – The lifting cylinders are extended (B). • Let go of the control lever. 13 - 74 3 112 343 en Operating instructions GMK 4100...
  • Page 655 – The lifting cylinders are fully retracted – dis- play (3). – The slewing gear is switched on – symbol (4) green. – The superstructure is in the rigging range – one display (5) green. Operating instructions GMK 4100 3 112 343 en 13 - 75...
  • Page 656 Press the button not used (1), (2) or a button (3) The automatic process is cancelled. If the symbol (1) or (2) is yellow, you can re-activate the automatic process. 13 - 76 3 112 343 en Operating instructions GMK 4100...

  • Page 657: Removing / Installing The Counterweight On The Turntable

    (1). – Two brackets (2) are also provided for the plate (3). In order to lift the plates, you will require suit- able lifting gear, e.g. a forklift truck. Operating instructions GMK 4100 3 112 343 en 13 - 77...
  • Page 658 • Tighten the nuts (5) with 100 Nm (74 lbf ft) and secure them with the counternuts. • Secure the clamp on the other side in the same way. 13 - 78 3 112 343 en Operating instructions GMK 4100...
  • Page 659 (B) – 2.2 t plate: Unscrew the nuts and remove the clamp (4). • Remove the clamp on the other side as well. • Lift the plate (1) or (2) off the turntable. Operating instructions GMK 4100 3 112 343 en 13 - 79...

  • Page 660: Setting Down Counterweight For Driving The Truck Crane

    Always check whether the specifications in this section apply before setting down the main boom. In this way you can prevent the derricking cylinder from being pushed against an incorrectly assembled counterweight combination and becom- ing damaged. 13 - 80 3 112 343 en Operating instructions GMK 4100...
  • Page 661 – the 2.2 t base plate (1) and – one 2.2 t plate (2) down. You can also set the die 3.3 t plates (3) and (4) onto the plate (2). Operating instructions GMK 4100 3 112 343 en 13 - 81...

  • Page 662: Slewing With Rigged Counterweight

    When operating with the hand-held control, there is no monitoring by the SLI. Before slewing, always check using the following table whether slew- ing is permissible. This prevents the truck crane from overturning while rotating. 13 - 82 3 112 343 en Operating instructions GMK 4100...
  • Page 663 Slewing only permitted if the radius permitted in the working range is à observed(at least 3.0 m (9.8 ft)); Lifting capacity table Only 0° working range to the rear permitted, Operating instructions GMK 4100 3 112 343 en 13 - 83...
  • Page 664 Rigging work 13.7 Rigging / unrigging the counterweight Blank page 13 - 84 3 112 343 en Operating instructions GMK 4100...

  • Page 665: Rigging Work On The Main Boom

    • Raise the main boom until the boom head is in a vertical position above the hook block. • Detach the hook block from the retaining rope (1). Operating instructions GMK 4100 3 112 343 en 13 - 85...
  • Page 666 If the lifting limit switch is deactivated while you tighten the hoist rope, you à can override the deactivation of the lifting limit switch; p. 12 - 52. 13 - 86 3 112 343 en Operating instructions GMK 4100...

  • Page 667: Hook Block On A Separate Vehicle

    To prevent slack rope, do not ease down too much hoist rope when picking up and reeving the hook block. Slack rope causes rope loops on the hoist drum, which can result in the load slipping and the hoist rope being destroyed. Operating instructions GMK 4100 3 112 343 en 13 - 87...
  • Page 668 Raise the hook block until it is about 1 m (3.3 ft) below the main boom. • Lower the main boom and set the hook block (1) down on the separate vehicle. 13 - 88 3 112 343 en Operating instructions GMK 4100...
  • Page 669 Pull the hoist rope slightly taut. • Fasten the lifting limit switch weight to the hoist rope. The hoist rope and lifting limit switch weight are now secured for driving. Operating instructions GMK 4100 3 112 343 en 13 - 89...

  • Page 670: Reeving And Unreeving The Hoist Rope

    (2) and protrude from the rope end clamp at point (3). Under a load, the load-bearing rope (1) runs along the pulling axis (X-X) and is not kinked. 13 - 90 3 112 343 en Operating instructions GMK 4100...
  • Page 671 Fasten the rope clamp (1) to the loose end of the hoist rope. • Pull the hoist rope (4) taut until the rope wedge and the hoist rope sit tightly in the rope end clamp. Operating instructions GMK 4100 3 112 343 en 13 - 91...
  • Page 672 Feed the main hoist rope to the head sheave (3). • Feed the auxiliary hoist rope to the head sheave (2). Use the rope grab also when operating the lat- tice extension. 13 - 92 3 112 343 en Operating instructions GMK 4100...
  • Page 673 (1) with 2-fall, 4-fall, 6-fall etc. reev- ings. – Fixed point for an odd number of lines The rope end clamp is fastened to the fixed point (1) with 2-fall, 3-fall, 5-fall etc. reev- ings. Operating instructions GMK 4100 3 112 343 en 13 - 93...
  • Page 674 Secure all rods using the retaining pins. Closing the hook block • Fold up the plates (1) on both sides. • Insert the rope pins (2) and secure them with the linchpins. 13 - 94 3 112 343 en Operating instructions GMK 4100...
  • Page 675 – fasten the hoist rope to the bumper; à p. 13 - 89 or – pull out the rods (4) and (5) and roll the hoist rope onto the drum. Operating instructions GMK 4100 3 112 343 en 13 - 95...

  • Page 676: Possible Reeving Methods On The Main Boom

    GMK 4100 together with this hook block. The lifting capacity of the GMK 4100 depends on the rope pull, the reeving and friction force. It is lower than the lifting capacity of the hook block.
  • Page 677 13.8 Rigging work on the main boom 5 sheave hook block Max. lifting capacity of the hook block 63 t (138,900) Max. lifting capacity with the GMK 4100: A With 11-fall reeving 60.9 t (134,300 lbs) B With 10-fall reeving 55.5 t (122,400 lbs)
  • Page 678 13.8 Rigging work on the main boom 1 sheave hook block Max. lifting capacity of the hook block 20 t (44,100 lbs) Max. lifting capacity with the GMK 4100: A With 3-fall reeving 17.0 t (37,500 lbs) B With 2-fall reeving 11.3 t (24,900 lbs)
  • Page 679 13 - 96. 9 sheave hook block Max. lifting capacity of the hook block 125 t (255,600 lbs) Max. lifting capacity with the GMK 4100: A With 16-fall reeving 85.0 t (187,400 lbs) 7 sheave hook block Max. lifting capacity of the hook block 100 t (220,500 lbs) Max.
  • Page 680 13.8 Rigging work on the main boom 5 sheave hook block Max. lifting capacity of the hook block 63 t (138,900) Max. lifting capacity with the GMK 4100: A With 11-fall reeving 60.9 t (134,300 lbs) B With 10-fall reeving 55.5 t (122,400 lbs)
  • Page 681 13.8 Rigging work on the main boom 1 sheave hook block Max. lifting capacity of the hook block 20 t (44,090 lbs) Max. lifting capacity with the GMK 4100: A With 3-fall reeving 17.0 t (37,500 lbs) B With 2-fall reeving 11.3 t (24,900 lbs)

  • Page 682: Installing / Removing The Lifting Limit Switch

    Lay the cable (5) in such a way that it will not be damaged during crane operation, and insert the lifting limit switch into the socket (1). à Operating Instructions Lat- Connections (6), tice Extension . 13 - 102 3 112 343 en Operating instructions GMK 4100...
  • Page 683 If two hoist ropes are reeved, you must also use two lifting limit switch weights. In this case, both lifting limit switches must be unlocked; à Unlocking , p. 13 - 107. Operating instructions GMK 4100 3 112 343 en 13 - 103...
  • Page 684 This allows you to reduce the wear of the hoist rope and lifting limit switch weight and prevent unintentional deactivation procedures that may be caused by the running hoist rope lifting the lifting limit switch weight. 13 - 104 3 112 343 en Operating instructions GMK 4100...
  • Page 685 (5) and plug it into the socket (1). • Remove the lifting limit switch (4) from the clamp (3). • Attach the retaining pin to the lifting limit switch. Operating instructions GMK 4100 3 112 343 en 13 - 105...

  • Page 686: Locking / Unlocking The Lifting Limit Switch

    If the lifting limit switch is blocked, release the locking system. This prevents the hook block from hitting the main boom head, causing damage to the hook block, main boom head and hoist rope. 13 - 106 3 112 343 en Operating instructions GMK 4100...
  • Page 687 (A) – Pull the rope (2) down and take off the cap (1) – the lock is removed. • (B) – Fit the cap (1) onto the lifting limit switch. Operating instructions GMK 4100 3 112 343 en 13 - 107...

  • Page 688: Anemometer And Air Traffic Control Light

    Switching the air traffic control light on and off: To switch on: Press the switch (1) in at the bottom. To switch off: Press switch (1) in at the top. 13 - 108 3 112 343 en Operating instructions GMK 4100...
  • Page 689 • Wind the cables onto the holders (2). • Take the rod (1) out of the holder (3). • For transportation, attach the retaining pins to the rod (1). Operating instructions GMK 4100 3 112 343 en 13 - 109...
  • Page 690 Rigging work 13.8 Rigging work on the main boom Blank page 13 - 110 3 112 343 en Operating instructions GMK 4100...

  • Page 691: Other Rigging Work

    In the driver's cab, open the Level adjustment system submenu – button • Press the button (2) once – dot green. The symbol 1 is green if the suspension is switched on. Operating instructions GMK 4100 3 112 343 en 13 - 111...
  • Page 692 Always leave the outriggers extended and the outrigger pads just above the ground to secure the truck crane against overturning. Setting the SLI à • Enter the current rigging mode on the SLI; p. 12 - 21. 13 - 112 3 112 343 en Operating instructions GMK 4100...

  • Page 693: Railings On The Turntable

    Fold the railings (3) up until the bolts (1) and (2) latch into place. (B) – Folding in • Loosen the bolts (2) and (1). • Fold the railings (3) down until the bolt (1) latches into place. Operating instructions GMK 4100 3 112 343 en 13 - 113...

  • Page 694: Mirror For Crane Operation

    For driving • Fold the mirrors (1) downwards. • Remove the mirror (2) to avoid dazzling other drivers on the road. • Stow away the mirror (2). 13 - 114 3 112 343 en Operating instructions GMK 4100...
  • Page 695 After driving ........... . . 14 - 21 Operating instructions GMK 4100...
  • Page 696 3 112 343 en Operating instructions GMK 4100...

  • Page 697: Driving The Rigged Truck Crane

    CHECKLIST: inspections before on-road driving are met; p. 5 - 1. Driving from the crane cab and driving with the truck crane rigged is not permissible on public roads. Operating instructions GMK 4100 3 112 343 en 14 - 1...

  • Page 698: Route

    To drive without a load • Bring the main boom to an inclination permitted within the working range. • Tie down the hook block so that it cannot swing back and forth. 14 - 2 3 112 343 en Operating instructions GMK 4100...

  • Page 699: To Drive With A Load

    The axle loads do not exceed 25.0 t (55,100 lbs), if the main boom is within the permissible working range in a permissible Lifting capacity table Free-on- wheels working position. Operating instructions GMK 4100 3 112 343 en 14 - 3...

  • Page 700: Before Driving The Rigged Truck Crane

    You may not drive the rigged truck crane if the wind speed exceeds the maximum permissible values specified in the Lifting capacity table . In this case you must bring the truck crane into a safe condition. 14 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 701: Driving From The Driver's Cab

    The symbol (2) is displayed in red if the separate steering is switched on. Connections If necessary, you can connect the longitudinal and transverse differential à locks; p. 5 - 63. Operating instructions GMK 4100 3 112 343 en 14 - 5...

  • Page 702: While Driving

    In this case you must raise the truck crane with the outrigger cyl- à Levelling the free-standing truck crane , inders, level it and then re-lower it; p. 13 - 51. 14 - 6 3 112 343 en Operating instructions GMK 4100...

  • Page 703: Driving From The Crane Cab

    If necessary, reset the idling speed to the default value. Do not drive with increased idling speed. You may only drive the truck crane from the crane cab at the lowest speed possible. Operating instructions GMK 4100 3 112 343 en 14 - 7...

  • Page 704: Preparing To Drive

    Press the button (1) down once. – The carrier ignition is turned on. – The lamp in button (1) flashes. – The transmission shifts to neutral position. – The Driving mode submenu opens automatically. 14 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 705 11 - 16. If you now turn off the carrier ignition, the same state is established as after à manual opening; Manually , p. 14 - 10. Operating instructions GMK 4100 3 112 343 en 14 - 9...
  • Page 706 – The lamp in the button (1) goes out. – The transmission shifts to neutral position. The same state is established as after opening the submenu manually. The lamp (1) lights up. • Press button (2) once. 14 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 707: Starting / Turning Off The Engine For Driving

    When the symbol (4) is displayed, you might be actuating the accelerator and the brake pedal at the same time – otherwise; à Warning messages , p. 14 - 18. Operating instructions GMK 4100 3 112 343 en 14 - 11...

  • Page 708: Steering

    You can adjust the function of the buttons in the control levers to the super- direction structure position. • To switch over the steering direction, press the button (2). The display (1) shows the current setting: 14 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 709 (1). The following applies when the steering direc- tion is set correctly: • Right-hand turn: Push the button to the right. • Left-hand turn: Push the button to the left. Operating instructions GMK 4100 3 112 343 en 14 - 13...
  • Page 710 The axle line is steered as long as you keep the button pressed or until an end position is reached. You can move the third and fourth axle lines for turning corners (A) or for à crab travel (B); p. 5 - 72. 14 - 14 3 112 343 en Operating instructions GMK 4100...

  • Page 711: Operating The Transmission

    Operating the transmission After the submenu has opened automatically, the buttons next to the sym- bols have no function. The transmission is in neutral position – dot (1) green. Operating instructions GMK 4100 3 112 343 en 14 - 15...
  • Page 712 Switch to the required transmission mode R or D. • Take your foot off the brake pedal only after the starting gear is engaged – dot (1) green, e.g. in transmission mode R. 14 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 713: Starting

    Do not steer the truck crane when it is stationary. Risk of damage to the steering linkage The steering linkage can be damaged if the steering is operated while the vehicle is stationary. Operating instructions GMK 4100 3 112 343 en 14 - 17...

  • Page 714: Warning Messages

    To start the engine , p. 14 - 11. symbols grey; You can speed up the process by stepping on the accelerator. When other symbols are red à Warning submenu , p. 12 - 102. 14 - 18 3 112 343 en Operating instructions GMK 4100...

  • Page 715: Possible Connections

    After automatic opening, the buttons (1) and (2) are active. The displays (3) and (4) indicate the current switching state. If the error symbol is shown during the following gear changes, contact CraneCARE Operating instructions GMK 4100 3 112 343 en 14 - 19...
  • Page 716 Display: – initially symbol (3) – yellow, – then symbol (2) – green, differential locks off. If symbol (2) is not displayed, then drive back and forth slowly. 14 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 717: After Driving

    Remove the ignition key from the ignition lock in the driver's cab and lock the driver's cab to prevent unauthorised access. Put the truck crane on outriggers if you do not intend to work in the Free-on- wheels working position. Operating instructions GMK 4100 3 112 343 en 14 - 21...
  • Page 718 Driving the rigged truck crane 14.5 Driving from the crane cab Blank page 14 - 22 3 112 343 en Operating instructions GMK 4100...
  • Page 719 Emergency supply of another crane ....... . . 15 - 67 Operating instructions GMK 4100...
  • Page 720 3 112 343 en Operating instructions GMK 4100...

  • Page 721: Malfunctions During Crane Operation

    The battery master switch cannot be used as an emergency stop switch for the engine. The engine continues to run after the battery master switch has been switched off. Operating instructions GMK 4100 3 112 343 en 15 - 1...
  • Page 722 Malfunctions during crane operation 15.1 Emergency stop switch Blank page 15 - 2 3 112 343 en Operating instructions GMK 4100...

  • Page 723: What To Do When A Malfunction Occurs During Crane Operation

    Try to eliminate the malfunction. Inform if you cannot elimi- CraneCARE nate the malfunction. • Load cannot be Secure the danger zone using cordons and warning signs. lowered • Notify CraneCARE Operating instructions GMK 4100 3 112 343 en 15 - 3...
  • Page 724 Malfunctions during crane operation 15.2 What to do when a malfunction occurs during crane operation Blank page 15 - 4 3 112 343 en Operating instructions GMK 4100...

  • Page 725: Fuses

    Notify if a fuse of the same amperage blows again after turning CraneCARE on the ignition. Danger of fire Never repair a blown fuse with other electrically conductive materials. Operating instructions GMK 4100 3 112 343 en 15 - 5...

  • Page 726: Fuses On The Turntable

    F1/3 lattice extension Alternator, F1/4 rotating beacon of the superstructure F1/5 Air intake inhibitor F1/6 Air intake inhibitor I/O-3 circuit board, F1/7 I/O-4 circuit board F1/8 Engine E-control (PLD) 15 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 727 Arrangement of the fuses Pos. Designation Amperage ESX 1 D+ ESX 1 UE ESX 1 8.5 V ESX 0 D+ ESX 0 UE ESX 0 8.5 V Operating instructions GMK 4100 3 112 343 en 15 - 7...

  • Page 728: Fuses In The Crane Cab

    Controlling the crane cab seat – F3/4 version 2 ESX2 control unit F3/5 Parking brake ESX2 control unit F3/6 ECOS control unit supply F3/7 Control lever supply F3/8 Engine electronics (ADM) 15 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 729 Windscreen wiping and washing sys- F5/3 tem, cigarette lighter F5/4 Heating system F5/5 Instrument panel lighting Voltage indicator lamp F5/6 Engine electronics diagnostics plug F5/7 Heater fan F5/8 – Free Operating instructions GMK 4100 3 112 343 en 15 - 9...
  • Page 730 4 Fuse F13 • Observe the instructions regarding fuse à changes; p. 15 - 5. Designation Amperage (A) Function Free Superstructure central fuse Free Preliminary fuse for auxiliary heater timer 15 - 10 3 112 343 en Operating instructions GMK 4100...

  • Page 731: Sli Fuses

    15 - 5 Arrangement of the fuses on the SLI control unit. Pos. Designation Amperage (A) Fuse F1 Fuse F2 Fuse F3 Fuse F11 Fuse F12 Fuse F6 Operating instructions GMK 4100 3 112 343 en 15 - 11...
  • Page 732 Malfunctions during crane operation 15.3 Fuses Blank page 15 - 12 3 112 343 en Operating instructions GMK 4100...

  • Page 733: Finding And Eliminating Malfunctions

    2. Bleed the fuel system; à Maintenance manual à Separate engine operating instructions, provided by the manufacturer à Releasing the air intake inhib- Air intake inhibitor closed itor , p. 11 - 21 Operating instructions GMK 4100 3 112 343 en 15 - 13...
  • Page 734 – the perform- to ensure the load can be low- ance will increase again ered and the truck crane can be unrigged. Other malfunction: must be notified CraneCARE 15 - 14 3 112 343 en Operating instructions GMK 4100...

  • Page 735: Malfunctions On The Main Hoist / Auxiliary Hoist

    15 - 1 No response to control lever ECOS malfunction concerning Unrig using hand-held con- à movements operating elements in the trol; p. 15 - 51 crane cab Operating instructions GMK 4100 3 112 343 en 15 - 15...

  • Page 736: Malfunctions On The Derricking Gear

    15 - 1 No response to control lever ECOS malfunction concerning Unrig using hand-held con- à movements operating elements in the trol; p. 15 - 51 crane cab 15 - 16 3 112 343 en Operating instructions GMK 4100...

  • Page 737: Malfunctions In The Telescoping Mechanism

    Fault in hydraulics / electrical Note down error codes à à ing cylinder locking function system p. 15 - 18, p. 15 - 32 not working and notify CraneCARE Operating instructions GMK 4100 3 112 343 en 15 - 17...
  • Page 738 – The display (1) appears. – An error code(2) is indicated. • Always note down this error codes before contacting CraneCARE The display (1) shows the symbol for the cur- rent status: 15 - 18 3 112 343 en Operating instructions GMK 4100...
  • Page 739 Emergency program à The Telescoping emergency program is open; p. 15 - 39. Not active Contact if this status is still displayed after repeatedly switching CraneCARE on the ignition. Operating instructions GMK 4100 3 112 343 en 15 - 19...

  • Page 740: Malfunctions On The Slewing Gear

    15 - 1 No response to control lever ECOS malfunction concerning Unrig using hand-held con- à movements operating elements in the trol; p. 15 - 51 crane cab 15 - 20 3 112 343 en Operating instructions GMK 4100...

  • Page 741: Malfunctions On The Counterweight Hoist Unit

    Lift / lower counterweight posi- position tion reached Retract / extend lifting cylin- Automatic mode cancelled Meet requirements for auto- à der and slewing not working matic mode; p. 13 - 76 Operating instructions GMK 4100 3 112 343 en 15 - 21...

  • Page 742: Malfunctions In The Hydraulic System / Hydraulic Oil Cooler

    4 - 21 Pre-selected function cannot Another function has been Pre-select the desired function be performed pre-selected Operation not possible Malfunction in the control sys- must be notified CraneCARE 15 - 22 3 112 343 en Operating instructions GMK 4100...

  • Page 743: Malfunctions When Driving From The Crane Cab

    à Malfunctions in the differential locks , p. 7 - 28, à Steering malfunctions , p. 7 - 27, à Malfunctions on the engine , p. 7 - 23. Operating instructions GMK 4100 3 112 343 en 15 - 23...

  • Page 744: Malfunctions On The Outriggers

    à bridging plug not inserted p. 13 - 20 None of the specified causes Solenoid valves are not must be notified CraneCARE apply switching electrically 15 - 24 3 112 343 en Operating instructions GMK 4100...

  • Page 745: Troubleshooting On The Sli

    Fuse F3/3 blown Replace the blown fuse; à p. 15 - 6. Fuse SLI F6 blown Replace the blown fuse; à p. 15 - 11. Operating instructions GMK 4100 3 112 343 en 15 - 25...
  • Page 746 If the error is displayed again, check whether the error code is contained in the Error codes tables. These tables contain information on how to remedy à errors; p. 15 - 28. 15 - 26 3 112 343 en Operating instructions GMK 4100...
  • Page 747 When values flash, the difference between the calculated and measured value is too large. If the error message 3033 is displayed; à Table of error codes , p. 15 - 28. Operating instructions GMK 4100 3 112 343 en 15 - 27...
  • Page 748 Accept the telescoping data from the crane control if incorrect telescoping is displayed on the SLI: Press the buttons once. The SLI shows the new values. Acknowledge the error 15 - 28 3 112 343 en Operating instructions GMK 4100...
  • Page 749 CraneCARE be acknowledged. Fuse F1 blown Fuse F2 blown Replace the blown fuse; à Fuse F3 blown p. 15 - 11. Fuse F11 blown Fuse F12 blown Operating instructions GMK 4100 3 112 343 en 15 - 29...
  • Page 750 Slew into a permissible working overall slewing range range. exceeded Shutdown area of a moni- Move into a permissible working tored object reached range. with working range limiter switched on 15 - 30 3 112 343 en Operating instructions GMK 4100...
  • Page 751 16 - 2. Checking the angle sensor function • Set down the main boom on the boom rest. • Check whether the display (1) shows an angle of 0°. Operating instructions GMK 4100 3 112 343 en 15 - 31...

  • Page 752: Malfunctions Ecos - Superstructure

    15 - 5. F3/6 faulty switched on Fuses on the circuit board Replace the blown fuse; à blown p. 15 - 7. Other malfunctions on the ECOS generate corresponding error messages. 15 - 32 3 112 343 en Operating instructions GMK 4100...
  • Page 753 When you keep a button held down, all errors are shown one after the other continuously. If not all errors have been acknowledged, the buttons have no func- tion – the symbols are grey. Operating instructions GMK 4100 3 112 343 en 15 - 33...
  • Page 754 All errors remain saved until you switch off the ignition, even those errors of which the cause has been eliminated in the meantime. All existing errors are treated as new errors and displayed again after turning on the ignition. 15 - 34 3 112 343 en Operating instructions GMK 4100...

  • Page 755: Emergency Operations And Programs

    – a mechanical emergency operation for retracting, – the Telescoping emergency program submenu, – the entering of the telescoping after an emergency operation and – the operation of the power units with the hand-held control. Operating instructions GMK 4100 3 112 343 en 15 - 35...

  • Page 756: Mechanical Emergency Operation For Retracting

    Which of the retracting procedures is best in your particular case depends on the conditions on site and on the crane functions that can still be oper- ated. Select the procedure best suited to your particular case and consult CraneCARE 15 - 36 3 112 343 en Operating instructions GMK 4100...
  • Page 757 (1). Pins located further inside are reached through the bore holes (2). You will need a suitable socket wrench (3), at least 200 mm (7.9 in) long. Operating instructions GMK 4100 3 112 343 en 15 - 37...
  • Page 758 • Take the set screw out of the bore hole. • (B) – Retract further until the telescopic sec- tion is set down. 15 - 38 3 112 343 en Operating instructions GMK 4100...

  • Page 759: Telescoping Emergency Program

    After correct input, the symbol (1) is displayed – the emergency program Telescoping starts. • ö If necessary, open the main menu and press the button (1) once. The Telescoping submenu opens. Operating instructions GMK 4100 3 112 343 en 15 - 39...
  • Page 760 After pressing the button, locking or unlocking is performed immediately. • Note down the error code (4) first if you intend to contact before carrying CraneCARE out the emergency program. 15 - 40 3 112 343 en Operating instructions GMK 4100...
  • Page 761 (1) and (2). • Check whether the display (3) shows the SLI measured value for the extended length of the telescoping cylinder. • Check the telescoping on the SLI. Operating instructions GMK 4100 3 112 343 en 15 - 41...
  • Page 762 If you select Lock during telescoping, the locking pins on the telescopic sec- tion are slid out immediately and they can damage or tear the electrical or hydraulic components in the main boom. 15 - 42 3 112 343 en Operating instructions GMK 4100...
  • Page 763 – the locking pins (3) are red – the symbol (1) is yellow, – the symbol (2) is grey. You can now move the telescoping cylinder into the next telescopic section. Operating instructions GMK 4100 3 112 343 en 15 - 43...
  • Page 764 – the locking pins (3) are green, – the symbol (1) is grey, – the symbol (2) is yellow. à • You can now retract this telescopic section; p. 15 - 42. 15 - 44 3 112 343 en Operating instructions GMK 4100...
  • Page 765 – Display (A) – telescoping cylinder locked 6 Locked left 7 Unlocked left 8 Unlocked right 9 Locked right For fault-free proximity switches, the following applies: – Green: position reached – Red: position not reached Operating instructions GMK 4100 3 112 343 en 15 - 45...
  • Page 766 ECOS if the Telescoping emergency program was open. You must enter the current telescoping after terminating the emergency à Entering the current telescoping , p. 15 - 49. program; 15 - 46 3 112 343 en Operating instructions GMK 4100...
  • Page 767 4 745 (15,57) 8 875 (29,12) 900 ( 3,01) Telescopic section IV 4 888 (16,04) 8 875 (29,12) 1 175 ( 3,85) Telescopic section V 5 025 (16,49) 8 875 (29,12) Operating instructions GMK 4100 3 112 343 en 15 - 47...
  • Page 768 4 780 (15,68) 8 910 (29,12) 935 ( 3,07) Telescopic section IV 4 923 (16,15) 8 910 (29,23) 1 210( 3,97) Telescopic section V 5 060 (16,60) 8 910 (29,23) 15 - 48 3 112 343 en Operating instructions GMK 4100...

  • Page 769: Entering The Current Telescoping

    100%. You can cancel the entry at any time using button (1). • Confirm the entered required values – press button (2) once. You must now accept the values. Operating instructions GMK 4100 3 112 343 en 15 - 49...
  • Page 770 Before working with the crane, check whether ECOS now indicates the cor- rect telescoping and correct the input, if necessary. Entering incorrect values causes malfunctions and may cause damage to the telescoping mechanism. 15 - 50 3 112 343 en Operating instructions GMK 4100...

  • Page 771: Emergency Operation With The Hand-Held Control

    All power units can be operated from this con- nection. à Information on connecting; p. 13 - 20. To start the engine à • Press the button (1) once – the engine starts; p. 11 - 17. Operating instructions GMK 4100 3 112 343 en 15 - 51...
  • Page 772 , press button (1) first, and then also button (2). The further you press button (2), the quicker the movement is. The maxi- mum speed is limited to about 50% for all power units. 15 - 52 3 112 343 en Operating instructions GMK 4100...
  • Page 773 If the telescoping cylinder is extended, it will extend. Operating instructions GMK 4100 3 112 343 en 15 - 53...
  • Page 774 In this case it is not possible to turn off the engine via the ignition lock. • Stop all crane movements. • Press the button (1) – the engine shuts down. 15 - 54 3 112 343 en Operating instructions GMK 4100...

  • Page 775: Switching On Emergency Operation In Coolant Circuit

    When the fan wheel is blocked, the engine can be operated for a maximum of 20 hours. Operating instructions GMK 4100 3 112 343 en 15 - 55...
  • Page 776 Malfunctions during crane operation 15.5 Emergency operations and programs Blank page 15 - 56 3 112 343 en Operating instructions GMK 4100...

  • Page 777: Hydraulic Emergency Operation

    The hydraulic circuits are triggered with the valves (3). The control lever (2) regulates the direction of movement and the speed. Operating instructions GMK 4100 3 112 343 en 15 - 57...

  • Page 778: Connecting/Disconnecting Hoses

    Connect the thicker hose (6) to the connec- tion (3). • Connect the thinner hose (5) to the connec- tion (4). • Connect the hoses (7) to the connections (2). 15 - 58 3 112 343 en Operating instructions GMK 4100...

  • Page 779: Activating/Deactivating Emergency Operation

    • Remove the cover (1). • Start the engine for driving. Switching on • Press switch (2) down. Switching off • Press switch (2) up. Operating instructions GMK 4100 3 112 343 en 15 - 59...

  • Page 780: Establishing The Required Hydraulic Circuits

    Danger due to mutual interference of the power units For crane operation, always switch all the valves 1 to 5 down. This prevents the power units from suddenly starting to move. 15 - 60 3 112 343 en Operating instructions GMK 4100...
  • Page 781 1, 2, 4, 5 none Lowering (Derricking 1, 2, 3, 4 none gear) à Slewing 2, 4 1, 3, 5 Valve 6, 7, 8 closed; p. 15 - 63 Operating instructions GMK 4100 3 112 343 en 15 - 61...
  • Page 782 • Remove the cap (3) from the actuated valve (1), (2). • Screw on the cap so that the pin (4) can be seen. • Insert the plug (5). 15 - 62 3 112 343 en Operating instructions GMK 4100...
  • Page 783 Close the valves 6, 7, and 8 – lever at right angles to the line. (B) – Crane operation position • Open the valves 6, 7, and 8 – lever parallel to the line. Operating instructions GMK 4100 3 112 343 en 15 - 63...

  • Page 784: Carrying Out Emergency Operation

    Make sure the hoses do not get caught and torn off while performing slewing operations. • Slowly move the control lever (1) in the required direction: Slewing to the right Slewing to the left 15 - 64 3 112 343 en Operating instructions GMK 4100...
  • Page 785 • Move the control lever (1) in the required direction: Lowering Raising Lifting/lowering • Move the control lever (1) in the required direction: Lowering Lifting Operating instructions GMK 4100 3 112 343 en 15 - 65...

  • Page 786: After Emergency Operation

    15 - 63. à • Disconnecting the Disconnect the hoses; p. 15 - 59. hoses • Close all the connections and hoses with the caps. • Remove the transformer. 15 - 66 3 112 343 en Operating instructions GMK 4100...

  • Page 787: Emergency Supply Of Another Crane

    Attach the transformer (3). à • Operating manual of Attach the hoses (4); the other crane . On the GMK 4100 • Turn off the engine for driving. • Connect the hoses (2) to the connections (1). • Switch on hydraulic emergency operation;...
  • Page 788 Malfunctions during crane operation 15.6 Hydraulic emergency operation Blank page 15 - 68 3 112 343 en Operating instructions GMK 4100...
  • Page 789 Superstructure ........... 16 - Operating instructions GMK 4100...
  • Page 790 3 112 343 en Operating instructions GMK 4100...
  • Page 791 Technical information for the superstructure 16.1 Technical data Technical information for the superstructure 16.1 Technical data GROVE truck crane GMK 4100 Permissible temperature range: –25 °C to +40 °C (–13 °F to +104 °F) Crane designation: Truck crane in accordance with...
  • Page 792 (660) Hook tackle 0.90 x 0.35 x 0.35 (2.95 x 1.15 x 1.15) (440) Single or double hook à Lifting capacity of the hook blocks; p. 13 - 96. 16 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 793 There may be deviations of up to ± 3% due to the manufacturing proce- dure. The stability of the crane rigged with the delivered counterweight parts has been tested. à Assembling counterweight versions , p. 13 - 61. Counterweight versions Operating instructions GMK 4100 3 112 343 en 16 - 3...
  • Page 794 M2 (in accordance with ISO 4301 - 2) Derricking gear Adjusting angle –3° to + 83° from horizontal position (main boom): Power unit group M2 (in accordance with ISO 4301 - 2) 16 - 4 3 112 343 en Operating instructions GMK 4100...
  • Page 795 In automatic mode during uninter- rupted locking and telescoping processes Derricking gear: Derricking between – 3° and 83° Normal speed: raising approx. 90 s High speed: raising approx. 50 s Operating instructions GMK 4100 3 112 343 en 16 - 5...
  • Page 796 Technical information for the superstructure 16.1 Technical data Blank page 16 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 797 Index Operating instructions GMK 4100 3 112 343 en...
  • Page 798 3 112 343 en Operating instructions GMK 4100...
  • Page 799 3 and chapter 10, Description of the truck crane . You are referred to more detailed descriptions of these elements from there as usual. Operating instructions GMK 4100 3 112 343 en 17 - 1...
  • Page 800 Index Blank page 17 - 2 3 112 343 en Operating instructions GMK 4100...
  • Page 801 ........5 - 90 Operating instructions GMK 4100...
  • Page 802 ............12 - 95 operating elements 17 - 4 3 112 343 en Operating instructions GMK 4100...
  • Page 803 Diagnostics plug ........... . 10 - 96 Operating instructions GMK 4100...
  • Page 804 ........... . 5 - 43 17 - 6 3 112 343 en Operating instructions GMK 4100...
  • Page 805 SLI fuses ............15 - 11 Operating instructions GMK 4100...
  • Page 806 / equalisation of the switching states ..... 4 - 10 17 - 8 3 112 343 en Operating instructions GMK 4100...
  • Page 807 ..........12 - 86 Operating instructions GMK 4100...
  • Page 808 Installing / removing the anemometer ....... . . 13 - 108 17 - 10 3 112 343 en Operating instructions GMK 4100...
  • Page 809 ..........7 - 28 Operating instructions GMK 4100...
  • Page 810 / retracting outriggers ........13 - 32 17 - 12 3 112 343 en Operating instructions GMK 4100...
  • Page 811 ......6 - 8 switching the superstructure driving lights on / off ....6 - 12 Operating instructions GMK 4100 3 112 343 en...
  • Page 812 ............12 - 88 17 - 14 3 112 343 en Operating instructions GMK 4100...
  • Page 813 ......... . 16 - 1 Operating instructions GMK 4100...
  • Page 814 ..........5 - 31 17 - 16 3 112 343 en Operating instructions GMK 4100...
  • Page 815 Windscreen wiper / washing system ........10 - 89 Operating instructions GMK 4100...
  • Page 816 ..........12 - 108 17 - 18 3 112 343 en Operating instructions GMK 4100...

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