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Böcker AHK 30/1400 Operating Instructions Manual

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Operating instructions
Trailer Crane
AHK 30/1400
02/2008
BWA000223

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  • Page 1 Operating instructions Trailer Crane AHK 30/1400 02/2008 BWA000223...
  • Page 2 Trailer Crane AHK 30/1400 © Böcker Kran- und Aufzugstechnik Lippestr. 69 D-59368 Werne Tel.: +49 (0) 2389 / 7989-0 Fax: +49 (0) 2389 / 532204 E-Mail: boecker@boecker-group.com Internet: www.boecker-group.com Dok-ID: 00985 02/2008...

  • Page 3: Table Of Contents

    Trailer Crane AHK 30/1400 Introduction.......................... 7 1 General ..........................8 1.1 Information about the Operating Manual............... 8 1.2 Applicable Documents ....................8 1.3 Explanation of symbols ....................9 1.4 Safety Signs and Labels on the Device............... 10 1.5 Liability and Guarantee ....................19 1.6 Copyright ........................
  • Page 4 Trailer Crane AHK 30/1400 3.2 Maximum Slewing Range Crane Mode ..............42 3.3 Telescoping Dimensions..................... 43 4 Device Structure and Function ..................46 4.1 General description..................... 46 4.2 Description of modules ....................47 4.3 Telescoping System....................48 4.4 Load Moment Device ....................49 4.5 Control Cabinet......................
  • Page 5 Trailer Crane AHK 30/1400 7.4 Movement of load ..................... 117 7.5 Remote Control ......................119 7.6 Maneuvering Drive (optional) ................... 122 7.6.1 Activating Maneuvering Drive ................122 7.6.2 Operating maneuvering drive................125 7.6.3 Deactivate maneuvering drive ................126 8 Dismantling ........................129 8.1 Dismounting the Device ....................
  • Page 6 Trailer Crane AHK 30/1400 11.4.1 Emergency Operation - Crane Mode ..............168 11.4.2 Electrical-hydraulic methods ................172 11.4.3 Hydraulic Method....................175 11.4.4 Emergency Activation - Hydraulic Outriggers............ 178 12 Accessories......................... 180 13 Appendix ........................183 13.1 Troubleshooting ...................... 183 13.1.1 Motor does not Start ..................183 13.1.2 Motor does not Start (only Mitsubishi model ) ...........

  • Page 7: Introduction

    Trailer Crane AHK 30/1400 Introduction Introduction Pos: 1.2 /Kothes! Network/Boeker/Allgemeines/Vorwort AHK EU Böcker (0985) @ 10\mod_1147355937552_1.doc @ 98408 We are pleased that you have selected a high-quality, technical product from Böcker. This operating manual contains detailed information about operation, maintenance, and care, and rectification of malfunctions.

  • Page 8: General

    Trailer Crane AHK 30/1400 General Pos : 1.4 /F I/Allgemei nes /1 Allgemeines Ti tel @ 0\mod155_1.doc @ 2732 1 General Pos : 1.5 /Kothes! Networ k/Boeker/Allgemei nes/Infor mationen z ur Betriebsanl eitung Böc ker @ 7\mod_1140875004052_1.doc @ 71243 1.1 Information about the Operating Manual This operating manual describes operation and maintenance of the device.

  • Page 9: Explanation Of Symbols

    Trailer Crane AHK 30/1400 General 1.3 Explanation of symbols Pos : 1.10 /Kothes! Networ k/Boeker/Allgemei nes /Er kl ärung Symbole Boec ker @ 8\mod_1142324961701_1.doc @ 76201 Important safety and technical device instructions are identified by warning notices in this operating manual. The warnings must be strictly heeded to prevent accidents, personal injury, and property damage.

  • Page 10: Safety Signs And Labels On The Device

    Trailer Crane AHK 30/1400 General 1.4 Safety Signs and Labels on the Device Pos : 1.15 /Kothes! Networ k/Boeker/Allgemei nes /Kennz eic hnung en am Gerät AH K EU Böc ker ( 0985) @ 10\mod_1147356114954_1.doc @ 98415 Check the warnings and instruction notices affixed to the device for completeness and damage prior to each start-up, and when executing maintenance work.
  • Page 11 Trailer Crane AHK 30/1400 General • The sign provides a summary description of the operating functions. Abb. 5: Control block The sign is mounted on the valve plate for emergency activation. • Warning sign "Risk of tipping". The sign shows the maximum permissible support load.
  • Page 12 Trailer Crane AHK 30/1400 General • Sign "Manoeuvring drive". The sign provides brief operating instructions. The sign is on the left of the chassis. Abb. 10: Control block for travel • Warning "Maneuvering drive". The sign is mounted on the right and left sides of the chassis (only for versions with maneuvering drive).
  • Page 13 Trailer Crane AHK 30/1400 General • Sign "Folding luffing boom in and out". The sign is mounted on the right of the Abb. 13: Folding luffing boom in and out superstructure. • Sign „Stop cock“. The sign is on the left of the superstructure.
  • Page 14 Trailer Crane AHK 30/1400 General • Warning "Swinging of the load is prohibited". The sign warns of dangers if the instructions are not heeded. The sign is on the right of the superstructure. Abb. 18: Swinging of the load is prohibited •...
  • Page 15 Trailer Crane AHK 30/1400 General • Sign „Operation diagram“.For more detailed information, see "Operating diagram". The sign is mounted on the right of the superstructure. Abb. 21: Operation diagram • Warning sign "Locking tab". The sign shows the maximum permissible loads for the respective configuration.
  • Page 16 Trailer Crane AHK 30/1400 General • Warning„Danger of tipping limit“.The sign warns of dangers if the instructions are not heeded. The sign is located behind the panelling at the rear of the superstructure. Abb. 25: Danger of tipping limit •...
  • Page 17 Trailer Crane AHK 30/1400 General • Warning sign "Travel on slope". The sign contains a work instruction. The sign is attached near the control unit of the manoeuvring drive. Abb. 28: Travel on slope • Sign "Activate manoeuvring drive". The sign contains a work instruction.
  • Page 18 Trailer Crane AHK 30/1400 General • Specification of maximum permissible tongue load. The sign is mounted on the drawbar. Abb. 32: Specification of tongue load • Warning „Rivolta“. The sign warns of dangers if the instructions are not heeded. The sign is mounted on the hydraulic oil tank.

  • Page 19: Liability And Guarantee

    Trailer Crane AHK 30/1400 General 1.5 Liability and Guarantee All information and instructions in this operating manual have been provided under due consideration of applicable guidelines, the current state of engineering development, as well as our many years of experience.

  • Page 20: Spare Parts

    Trailer Crane AHK 30/1400 General os: 1.22 /F I/(---------- 1 Leerzeil e ----------) @ 0\mod796_1.doc @ 1527 1.7 Spare parts Pos : 1.24 /Kothes! Networ k/Boeker/Allgemei nes /Ers atz teil e EU Böc ker @ 8\mod_1142937690388_1.doc @ 79660 ATTENTION! Incorrect or defective replacement parts can cause damage, malfunction or total device failure.

  • Page 21: Disposal

    Trailer Crane AHK 30/1400 General 1.9 Disposal If a return or disposal agreement has not been concluded, then recycle dismantled components: • Scrap metal material residue. • Take plastic elements to plastic recycling points. • Sort and dispose of all other components according to material condition.

  • Page 22: Safety

    Trailer Crane AHK 30/1400 Safety Pos : 2.2 /F I/Sic herheit/1 Sicherheit Titel @ 4\mod_1123592830376_1.doc @ 19886 2 Safety Pos : 2.3 /Kothes! Networ k/Boeker/Sic her heit/Allgemeiner T ext Sic her hei t Boec ker @ 8\mod_1141813939045_1.doc @ 74731 This section provides an overview of all the important safety aspects for optimal protection of personnel, as well as for safe and trouble-free device operation.

  • Page 23: Responsibility Of The Customer

    Always keep safety devices freely accessible and inspect them regularly. Pos: 2.7 /Kothes! Network/Boeker/Sicherheit/Bestimmungsgemäße Verwendung AHK 30_1400 EU @ 26\mod_1166629858952_1.doc @ 287061 The AHK 30/1400 mobile crane manufactured by Boecker is designed exclusively for material transport. Deviating crane implementation must be must be approved by the manufacturer in writing.

  • Page 24: Possible Misuse

    Trailer Crane AHK 30/1400 Safety 2.3 Possible misuse Pos : 2.10 /Kothes! Networ k/Boeker/Sicherheit/M öglicher Miss brauch AH K EU Böc ker ( 00985) @ 10\mod_1147358349645_1.doc @ 98429 WARNING! Danger to life! Misoperation and abuse can cause life-threatening injuries. The following uses of the device are prohibited: –...

  • Page 25: Work Safety

    Trailer Crane AHK 30/1400 Safety 2.5 Work safety Compliance with the notes on safety can help to avoid personal injury and material damage when working on the machine. Failure to comply with these notes will cause a considerably risk of injury for persons and danger of damage or destruction of the machine Non-compliance with the safety regulations causes the exclusion of any liability or compensation claims against the manufacturer or his representative.

  • Page 26: Hazards That Can Be Associated With The Device

    Trailer Crane AHK 30/1400 Safety 2.7 Hazards that Can be Associated with the Device The device has been subjected to a hazard analysis. The design and execution of the device derived from this analysis represents the current state of the art.
  • Page 27 Trailer Crane AHK 30/1400 Safety ATTENTION! Sharp-edged housing parts, points, and corners can scrape the skin. Always wear protective gloves when working on the device! Pos : 2.26 /Kothes! Networ k/Boeker/Sicherheit/Warnung hydraulisc he Energien EU @ 8\mod_1142939317251_1.doc @ 79751 WARNING! Hydraulic energy can cause the most serious injuries.
  • Page 28 Trailer Crane AHK 30/1400 Safety WARNING! Danger to life! If the machine is operated while the view is obstructed by objects, or if the machine is operated in the dark, there is a serious risk of damage to property, serious injury or even death! –...

  • Page 29: Safety Instructions In Accordance With Bgv D6

    Trailer Crane AHK 30/1400 Safety 2.8 Safety Instructions in Accordance with BGV D6 Pos : 2.34 /Kothes! Networ k/Boeker/Sicherheit/Sic her heitshi nweis e i n Anl ehnung an BGV D6 AH K Böc ker @ 10\mod_1146735618365_1.doc @ 96828 2.8.1 Inspections Inspection before commissioning and after significant modifications Article 25.
  • Page 30 Trailer Crane AHK 30/1400 Safety (5) The crane operator must ensure that 1. Prior to releasing the energy supply to the drive aggregates, all control devices are placed in zero or idle position, 2. Prior to leaving the control station the control devices must be brought into zero or idle position.
  • Page 31 Trailer Crane AHK 30/1400 Safety Work Involving Multiple Cranes § 33. (1) If the work ranges of multiple cranes overlap, then the customer, or his authorized representative must previously specify the work sequence and ensure trouble-free communication among the crane operators.
  • Page 32 Trailer Crane AHK 30/1400 Safety Approaching Operating Limit Positions § 39. Operational approach to limit positions that are limited by emergency restraint devices is only permitted if these devices are switched in front of operational limit devices. Setup, dismounting, and retrofitting mobile cranes §...

  • Page 33: Special Instructions

    Trailer Crane AHK 30/1400 Safety 2.8.2 Special Instructions Customer must ensure that when working with cranes in the vicinity of live components, electrical systems and equipment, personnel are not endangered by electrical current. Minimum distances (safety distances) to overhead lines are cited in the chapter "Safety Distance to Power Lines".

  • Page 34: Operating Personnel

    Trailer Crane AHK 30/1400 Safety 2.10 Operating Personnel 2.10.1 General The device should only be operated and maintained by instructed personnel. Such personnel must have had special instruction relative to the dangers that can occur. Instructed personnel are personnel who have been instructed and taught concerning the...

  • Page 35: Physical Qualifications

    Trailer Crane AHK 30/1400 Safety 2.10.3 Physical Qualifications Der Bediener muss über – Visual acuity of at least 0,7 Dioptrien, with or without optical aid; – Ability to differentiate colors, regardless of their position when color differentiation is required for operation;...

  • Page 36: Behavior Of Operating Personnel

    Trailer Crane AHK 30/1400 Safety 2.10.4 Behavior of Operating Personnel The crane operator should not pursue any other activity during hoist operation. Each operator is responsible for the operating procedures that are initiated under his direct operation. If there is a question of safety then the device must be switched off immediately.

  • Page 37: Behavior In The Event Of Danger Or Accident

    Trailer Crane AHK 30/1400 Safety 2.11 Behavior in the Event of Danger or Accident In the event of danger or accident stop the device immediately by activating an EMERGENCY-STOP switch. Only activate safety devices with EMERGENCY-STOP function in appropriate emergency situations.

  • Page 38: Technical Data

    Trailer Crane AHK 30/1400 Technical data Pos : 3.3 /F I/T echnisc he Daten/1 T ec hni sche D aten Titel @ 0\mod253_1.doc @ 2907 3 Technical data Pos : 3.4 /Kothes! Networ k/Boeker/T ec hnische D aten/T abelle techn. D aten AHK EU Böc ker (00985) @ 10\mod_1147419842387_1.doc @ 98491...
  • Page 39 Trailer Crane AHK 30/1400 Technical data Designation Description Dimensions Center Line of the Rotational Point - the horizontal distance parallel to the longitudinal center line of the 0,2 m chassis, between the rear axles of the chassis and the center line of the pivot point of the mast...
  • Page 40 Trailer Crane AHK 30/1400 Technical data Crane Superstructure Max setup angle - telescoping mast 85° Flying job boom length - retracted 4,8 m Flying jib boom length - extended 9,1 m Fly jib boom can be pegged at 135° /150° /165°...

  • Page 41: Rating Plate

    Trailer Crane AHK 30/1400 Technical data Pos : 3.6 /Kothes! Networ k/Boeker/T ec hnische D aten/1.1 T ypensc hild Junior Titel @ 8\mod_1141305657331_1.doc @ 72415 3.1 Rating Plate Pos : 3.7 /Kothes! Networ k/Boeker/T ec hnische D aten/1.1.1 T ypensc hild Kranaufbau Titel @ 11\mod_1149500718130_1.doc @ 115169 3.1.1 Rating Plate Crane- Superstructure...

  • Page 42: Maximum Slewing Range Crane Mode

    Trailer Crane AHK 30/1400 Technical data 3.2 Maximum Slewing Range Crane Mode WARNING! Danger to life! Overturning the device can result in serious injury and property damage! Always heed the load sign on the device for the maximum slewing range.

  • Page 43: Telescoping Dimensions

    If there is a defect contact the manufacturer or service personnel who have been trained by the manufacturer. Pos : 3.17 /Kothes! Networ k/Boeker/T ec hnisc he D aten/Tel es kopi erabmessungen AHK 30/1400 EU Böc ker @ 10\mod_1147430557528_1.doc @ 98518 02/2008...
  • Page 44 Trailer Crane AHK 30/1400 Technical data Designation Description Dimensions Hook height, maximum retraction: fly jib boom 165° swung out - the height of the anchoring surface of the base plate of the unit, the center line of the hook bolt on the boom tip...
  • Page 45 Trailer Crane AHK 30/1400 Technical data Designation Description Dimensions Horizontal extension, main boom 50% extension; fly jib boom 165° swung out - the distance between the center 16,9 m line of the fulcrum and the center line of the crane hook of the boom tip.

  • Page 46: Device Structure And Function

    Pos : 4.4 /Kothes! Networ k/Boeker/Aufbau und F unkti on/Allgemeine Bes chr eibung AHK EU Böc ker (00985) @ 10\mod_1147431759666_1.doc @ 98532 The Boecker AHK 30/1400 is a mobile telescoping trailer crane. With suitable load suspension gear, such as brick carriers, pallet forks, rubbish buckets, rubbish troughs, holding straps, and corrugated sheet handlers, loads of up to 1400 kg can be lifted with the load winch.

  • Page 47: Description Of Modules

    Trailer Crane AHK 30/1400 Device Structure and Function Pos : 4.6 /F I/Aufbau und F unktion/1.1 Baugruppenbesc hrei bung Titel @ 2\mod1625_1.doc @ 2952 4.2 Description of modules Pos : 4.7 /Kothes! Networ k/Boeker/Aufbau und F unkti on/Gesamtansic ht AH K Böc ker ( 00980) @ 10\mod_1146149536436_1.doc @ 95151 Abb.

  • Page 48: Telescoping System

    Trailer Crane AHK 30/1400 Device Structure and Function Pos : 4.9 /Kothes! Networ k/Boeker/Aufbau und F unkti on/1.1 Tel es kops ystem Titel @ 10\mod_1146219371021_1.doc @ 95459 4.3 Telescoping System Pos : 4.10 /Kothes! Networ k/Boeker/Aufbau und F unktion/T eles kops ystem AH K EU Böc ker ( 00985) @ 10\mod_1147431878948_1.doc @ 98539 Abb.

  • Page 49: Load Moment Device

    Trailer Crane AHK 30/1400 Device Structure and Function Pos : 4.12 /Kothes! Networ k/Boeker/Aufbau und F unktion/1.1 Lastmomentbegrenz ung Ti tel @ 10\mod_1146219394187_1.doc @ 95466 4.4 Load Moment Device Pos : 4.13 /Kothes! Networ k/Boeker/Aufbau und F unktion/Lastmomentbegrenz ung AHK Böc ker (00980) @ 10\mod_1146219958566_1.doc @ 95480 Abb.
  • Page 50 Trailer Crane AHK 30/1400 Device Structure and Function The warning light will be continuously illuminated when the load limit has been reached. When the load torque limit has been reached the load winch can still lift and lower loads, the crane can be turned as long you do not swing into a poorer support range.

  • Page 51: Control Cabinet

    Trailer Crane AHK 30/1400 Device Structure and Function Pos : 4.15 /Kothes! Networ k/Boeker/Aufbau und F unktion/1.1 Steuersc hrank Titel @ 10\mod_1146241706929_1.doc @ 95681 4.5 Control Cabinet Pos : 4.16 /Kothes! Networ k/Boeker/Aufbau und F unktion/Sc haltschr ank AH K Böc ker (00980) @ 10\mod_1146241736487_1.doc @ 95688 Abb.

  • Page 52: Transport

    Trailer Crane AHK 30/1400 Transport Pos : 5.2 /Kothes! Networ k/Boeker/Tr ansport, Lager ung und Verpac kung/1 Tr ans port Titel @ 8\mod_1141315582153_1.doc @ 72492 5 Transport Pos : 5.3 /Kothes! Networ k/Boeker/Tr ansport, Lager ung und Verpac kung/1.1 Ü bergabe/Lieferung Titel @ 8\mod_1141469802404_1.doc @ 73420 5.1 Transfer/Delivery...
  • Page 53 Trailer Crane AHK 30/1400 Transport Check that the telescoping mast (1) is completely secured in the receptacle (arrow). Abb. 44: Check the position of the telescoping mast Ensure that the telescoping mast is completely retracted until the stop (arrow). Retract the telescoping mast if necessary (see "Dismounting").
  • Page 54 Trailer Crane AHK 30/1400 Transport Check maneuvering drive (optional): ATTENTION! Property damage! There is a risk of serious damage to the machine, if the manoeuvring drive is engaged during transportation. – Before moving the machine, ensure that the two drives are not connected to the wheels.
  • Page 55 Trailer Crane AHK 30/1400 Transport Check outriggers ATTENTION! Property damage! Outriggers that are not fully retracted can cause significant property damage! – Ensure that the outriggers are in the correct position before starting transport! Ensure that all outrigger cylinders (arrow) are completely retracted. If necessary retract outrigger cylinders, see "Dismounting Outriggers".
  • Page 56 Trailer Crane AHK 30/1400 Transport Ensure that the tenter hooks (1) correctly hook into the outriggers (arrow) and that the outriggers are secured. Abb. 51: Check outriggers Check the motor hood Ensure that the motor hood (1) is correctly seated.
  • Page 57 Trailer Crane AHK 30/1400 Transport Additional Check Points: Ensure that the remote control is in the tool box (arrow). Abb. 54: Check tool box Ensure that the outrigger pads (arrow) are correctly placed in the holders (1). Repeat work step on the opposite side of the vehicle.

  • Page 58: Coupling

    Trailer Crane AHK 30/1400 Transport Pos : 5.9 /Kothes! Networ k/Boeker/Tr ansport, Lager ung und Verpac kung/1.1 Ankuppeln Titel @ 8\mod_1141476565946_1.doc @ 73456 5.3 Coupling Pos : 5.10 /Kothes! Networ k/Boeker/Trans port, Lagerung und Ver pac kung/Ankuppeln AH K EU Böc ker (00985) @ 10\mod_1147432504771_1.doc @ 98560...
  • Page 59 Trailer Crane AHK 30/1400 Transport Only for models with ball coupling: NOTE! See the supplier documentation for the operating instructions for the height-adjustable drawbar. Attach the trailer to the towing vehicle. Push the lever (1) down to the stop. Abb. 58: Coupling...
  • Page 60 Trailer Crane AHK 30/1400 Transport Check the brake cable (1) for damage. If required, have the trailer repaired in a specialist workshop. Attach the brake cable (1) to the towing vehicle. Abb. 60: Brake cable of overrun brake NOTE! Ensure that the hook of the brake cable is fully closed.
  • Page 61 Trailer Crane AHK 30/1400 Transport Press button (1) Swing the support wheel (2) up to the stop. Ensure that the support wheel is properly engaged. Abb. 62: Swing up the support wheel Swing support wheel around to the rear. Use the crank to crank up the support wheel until the lock tab engages in the aperture (arrow).
  • Page 62 Trailer Crane AHK 30/1400 Transport Check that the mobile crane is aligned horizontally to the ground. If necessary adjust the optional adjustable drawbar, see the supplier documentation, "Appendix". Plug the connecting cable (1) into the socket (arrow) on the trailer.
  • Page 63 Trailer Crane AHK 30/1400 Transport Check tires (arrows) for damage and sufficient tread. Check pressure and correct as needed, see "Technical data". Repeat the work steps on the opposite side of the vehicle. Abb. 67: Check the tire condition Insert stop block (1) in the holder..
  • Page 64 Trailer Crane AHK 30/1400 Transport Ensure that the brake lever (1) is completely pressed down. Abb. 70: Check the hand brake Pos : 5.11 /FI/(---------- 1 Leerz eile ----------) @ 0\mod796_1.doc @ 1527 Pos : 5.12 /Kothes! Networ k/Boeker/Trans port, Lagerung und Ver pac kung/1.1 Während des Transports Titel @ 8\mod_1141476735924_1.doc @ 73494...

  • Page 65: During Transport

    Trailer Crane AHK 30/1400 Transport 5.4 During Transport Pos : 5.13 /Kothes! Networ k/Boeker/Trans port, Lagerung und Ver pac kung/Während der F Ahrt AHK EU Böc ker (00985) @ 10\mod_1147433079527_1.doc @ 98567 WARNING! Risk of damage to persons and property!

  • Page 66: Uncoupling, Parking

    Trailer Crane AHK 30/1400 Transport 5.5 Uncoupling, parking Pos : 5.16 /Kothes! Networ k/Boeker/Trans port, Lagerung und Ver pac kung/Abkuppeln/Abstellen AHK EU Böc ker (00985) @ 10\mod_1147433362268_1.doc @ 98594 WARNING! Risk of damage to persons and property! Uncontrolled rolling of the device can result in serious injury and property...
  • Page 67 Trailer Crane AHK 30/1400 Transport Carefully pull the retaining bracket (arrow) towards you and hold. Pull stop block (1) out of the holder. Abb. 72: Pull out stop block ATTENTION! Property damage! Uncontrolled movement of the machine results in damage to the equipment.
  • Page 68 Trailer Crane AHK 30/1400 Transport Pull the connecting cable (1) out of the socket (arrow) on the trailer. Pull the connecting cable out of the socket on the tow vehicle. Keep the connecting cable where it will not get lost or stolen.
  • Page 69 Trailer Crane AHK 30/1400 Transport Only for models with ball coupling: Disconnect the brake cable (1) from the towing vehicle. Abb. 77: Brake cable of overrun brake NOTE! Follow the instructions for the height adjustable drawbar, see supplier documentation. Push down the safety lock (arrow) and lift the lever (1).

  • Page 70: Setup

    Trailer Crane AHK 30/1400 Setup 6 Setup Pos : 6.3 /Kothes! Networ k/Boeker/Ins tall ati on und Inbetriebnahme/1.1 Sic herheits hinweise Titel @ 8\mod_1141485072352_1.doc @ 73530 6.1 Safety instructions Pos : 6.4 /Kothes! Networ k/Boeker/Ins tall ati on und Inbetriebnahme/Sic herheits hinweis e allgemei n AH K EU Böc ker ( 00985) @ 10\mod_1147433757089_1.doc @ 98608...

  • Page 71: Warning: Suspended Loads

    Trailer Crane AHK 30/1400 Setup 6.2 Warning: suspended loads Pos : 6.6 /Kothes! Networ k/Boeker/Ins tall ati on und Inbetriebnahme/Sic herheits hinweis s chwebenden Las ten AHK EU Böc ker (00985) @ 10\mod_1147433867376_1.doc @ 98615 WARNING! Danger to life! Suspended loads can fall and cause severe or fatal injuries.

  • Page 72: Site Inspection

    Trailer Crane AHK 30/1400 Setup 6.3 Site Inspection Pos : 6.9 /Kothes! Networ k/Boeker/Ins tall ati on und Inbetriebnahme/Standortprüfung AHK EU Böc ker (00985) @ 10\mod_1147434055667_1.doc @ 98622 The ground composition and the vicinity must be checked prior to setting up the device.
  • Page 73 Trailer Crane AHK 30/1400 Setup ATTENTION! Property damage! Working with the device can cause damage. – Impacts with obstacles when maneuvering and telescoping can cause property damage. If necessary remove obstacles prior to using the device. Take the necessary spatial requirements into consideration prior to determining the site.

  • Page 74: Safety Distance To Power Lines

    Trailer Crane AHK 30/1400 Setup 6.4 Safety distance to power lines Pos : 6.13 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Sc hutz abs tand z u Oberleitungen AH K EU Böc ker @ 26\mod_1166633453542_1.doc @ 287147 • Exercise caution when working in the vicinity of overhead lines. Due to wind effects overhead lines can swing vertically and horizontally.
  • Page 75 Trailer Crane AHK 30/1400 Setup Required minimum clearance Standard voltage, kV (voltage between phases) When operating in the vicinity of high voltage lines over 50 over 200 over 350 over 500 11,0 over 750 1000 14,0 During transport operation without load with...

  • Page 76: Setup

    Trailer Crane AHK 30/1400 Setup 6.5 Setup Pos : 6.17 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Aufs tell en AH K EU Böc ker (00985) @ 10\mod_1147434921067_1.doc @ 98646 NOTE! When selecting the setup location, ensure that the device is not an obstacle to pedestrians.
  • Page 77 Trailer Crane AHK 30/1400 Setup WARNING! Danger to life! Inhaling escaping gases and fumes can cause death by suffocation and long- term health problems! – Only use the device outdoors and in well ventilated locations. ATTENTION! Risk of injury! Escaping process chemicals or fuels can cause injury! Please note that the tank might be under pressure! –...
  • Page 78 Trailer Crane AHK 30/1400 Setup Only for models with petrol or diesel engine Open the seal (1) of the fuel tank. Check the fuel level, top off if necessary. NOTE! Only add petrol with an octane number of minimum 91.
  • Page 79 Trailer Crane AHK 30/1400 Setup ATTENTION! Risk of burns! Hot surfaces can cause burns. – Do not touch hot components. Check the level of the motor oil, see supplier documentation "Appendix". Abb. 86: Dip stick for motor oil Mount the motor cover (1).
  • Page 80 Trailer Crane AHK 30/1400 Setup Only for models with Mitsubishi diesel engine Open the seal (1) of the fuel tank. Check the fuel level, top off if necessary. NOTE! Diesel engines must be run only with diesel. Ensure that the fuel tank is sealed correctly.
  • Page 81 Trailer Crane AHK 30/1400 Setup ATTENTION! Risk of burns! Hot surfaces can cause burns. – Do not touch hot components. Check the level of the motor oil (arrow), see supplier documentation "Appendix". Abb. 91: Dip stick for motor oil Swivel the engine flap down.
  • Page 82 Trailer Crane AHK 30/1400 Setup Additional steps for all models Remove the safety lock (1) on the main switch (2). Turn main switch (2) to "ON". Abb. 93: Remove safety lock If necessary insert chargeable batteries on the bottom of the remote control unit (arrow).
  • Page 83 Trailer Crane AHK 30/1400 Setup If necessary take chargeable batteries out of the control cabinet. Open lock (arrow). Open control cabinet door (1). Abb. 95: Open control cabinet door Take chargeable batteries (2) out of the transportable charger (1). Insert chargeable batteries in the remote control unit.
  • Page 84 Trailer Crane AHK 30/1400 Setup Insert the key (1) to activate the remote control in the lock. Insert key (1) to activate the remote control and turn clockwise until the stop. Abb. 98: Activate remote control WARNING! Personal injury! Motor noise can cause hearing damage.
  • Page 85 Trailer Crane AHK 30/1400 Setup To start the motor, briefly push switch (1) forward. If after several attempts the motor does not start up, execute troubleshooting, see supplier documentation "Appendix". Press the EMERGENCY-STOP switch (arrow) for function test. The motor must stop immediately.
  • Page 86 Trailer Crane AHK 30/1400 Setup Switch off motor: Push the switch (1) for shutting off the motor in the direction of the operator. Abb. 102: Shutting off the motor Turn the key (1) to deactivate the remote control counter-clockwise until the stop.

  • Page 87: Setting Up And Aligning The Outriggers

    Trailer Crane AHK 30/1400 Setup 6.6 Setting up and Aligning the Outriggers Pos : 6.23 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Stützen aufbauen AHK EU Böc ker (00985) @ 10\mod_1147435293861_1.doc @ 98660 WARNING! Danger to life! Overturning the device can result in severe or fatal injuries and extensive property damage.
  • Page 88 Trailer Crane AHK 30/1400 Setup The mobile crane's bracing system enables different bracing widths that are coupled to different slewing ranges. This enables 4 different arrangements of the bracing system. Completely braced - crane work is possible without limitation Braced on one side, left - crane work is possible to the front, rear and to the left Braced on one side, right - crane work is possible to the front, rear and to the right One outrigger, braced on one side - slewing range of 210°...
  • Page 89 Trailer Crane AHK 30/1400 Setup WARNING! Danger to life! An incorrectly setup device can overturn and cause life-threatening injuries! – Outrigger pads must be placed under the outrigger cylinders. – Check outrigger pads for damage prior to use. – Do not use defective outrigger pads! –...
  • Page 90 Trailer Crane AHK 30/1400 Setup Release the spring-loaded latch (1). Ensure that the spring-loaded latch is fully engaged (arrow). Repeat work steps on the other outrigger cylinders. Abb. 107: Check the spring-loaded latches Take the outrigger pads (arrow) out of the holder (1).
  • Page 91 Trailer Crane AHK 30/1400 Setup To extend the respective outrigger cylinder, pull the operating lever (arrow) towards you and hold. For initial lowering of the outrigger cylinder always operate the levers in pairs. Abb. 109: Lowering the outrigger cylinders To extend the front outrigger cylinders pull levers (3+4) towards you and hold.
  • Page 92 Trailer Crane AHK 30/1400 Setup To extend the rear outrigger cylinders pull levers (1+2) towards you and hold. Press the operating lever down and hold until the wheels lose ground contact. Extend all outrigger cylinders (1-4) to the maximum height.
  • Page 93 Trailer Crane AHK 30/1400 Setup If necessary lower outrigger cylinders (1-4) slightly until the box level is aligned in the middle. Ensure that the air bubble is centered in the box level. Ensure that no vehicle tire has ground contact.

  • Page 94: Setup , Extend

    Trailer Crane AHK 30/1400 Setup 6.6.1 Setup , Extend Pos : 6.26 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Aufrichten, Ausfahren AHK EU Böc ker (00985) @ 10\mod_1147679145095_1.doc @ 99061 WARNING! Danger to life! High wind or wind gusts overturning the device can result in severe injuries and property damage! –...
  • Page 95 Trailer Crane AHK 30/1400 Setup Turn the switch (arrow) to "Assembly" position. Abb. 116: Activation of the slack cable function NOTE! See "Remote Control" for instructions and explanations on controlling the device via remote control. Carefully lift the telescoping mast (1) out of the support (arrow) until the fly jib boom can be swung out.
  • Page 96 Trailer Crane AHK 30/1400 Setup ATTENTION! Risk of damage to persons and property! The boom colliding with persons or objects can result in injuries or property damage! – Prior to unreeling the carrying cable ensure that no one is in the work area.
  • Page 97 Trailer Crane AHK 30/1400 Setup ATTENTION! Severe injuries! A falling crane hook can cause low-severity to medium- severity injuries! – Before releasing the crane hook, safeguard it from falling. Carefully remove the hook (1) from the cable loop (arrow) on the telescoping mast.
  • Page 98 Trailer Crane AHK 30/1400 Setup Hook the crane hook (1) into the holder (2). Hook the cable cut-off (3) into the holder (arrow). Abb. 120: Hook in the crane hook Ensure that the cable runs correctly in the pulleys and guides (arrows).
  • Page 99 Trailer Crane AHK 30/1400 Setup ATTENTION! Risk of damage to persons and property! Uncontrolled swinging of the boom can result in severe bodily injury and property damage! – Always tension the cable carefully. – Avoid incorrect operation of the remote control unit.
  • Page 100 Trailer Crane AHK 30/1400 Setup Use the "Lift load" and "Lower load" function on the remote control to carefully move the boom until the desired bore (arrow) is in line with the passage in the boom. Remove the safety pin (1) from the bolt.
  • Page 101 Trailer Crane AHK 30/1400 Setup Insert bolt (1) into the desired bore (arrow) until the stop. Abb. 126: Insert bolt Insert safety pin (1) in the bolt (2) and lock the ring. Abb. 127: Insert safety pin Use the "Lower load" function on the remote control to slightly loosen the carrying cable.
  • Page 102 Trailer Crane AHK 30/1400 Setup Ensure that the cable is correctly seated in the pulleys and guides (arrows). If necessary extend the fly jib boom, see "Adjusting the Fly Jib Boom". Hook in the supplemental hook weight, see "Supplemental Hook Weight".

  • Page 103: Adjusting The Fly Jib Boom

    Pos : 6.29 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Wi ppausleg er Las tbegrenzung AH K 30/1400 EU Böc ker (00985) @ 10\mod_1147680168566_1.doc @ 99068 The fly jib boom of the AHK 30/1400 consists of three concentric telescoping tubes pushed into each other. Thus the boom length can be extended from 4,5 m to .
  • Page 104 Trailer Crane AHK 30/1400 Setup Load capacity to 300 kg: Abb. 131: Telescoping tube 1 extended If the telescoping tube (R1) is extended then the maximum load capacity is 300 kg. Load capacity to 250 kg: Abb. 132: Telescoping tube 0 and 1 extended If both telescoping tubes (R0 + R1) are extended then the max.
  • Page 105 Trailer Crane AHK 30/1400 Setup ATTENTION! Property damage! Extension while the luffing boom is not folded out can cause serious damage to the machine! – Only telescope out if the fly jib boom has already been swung out. – The unlocked boom extension must be safeguarded from self-activated falling.
  • Page 106 Trailer Crane AHK 30/1400 Setup Pull out the bolt (1). Fig. 135: Remove bolt Pull the fly jib boom out to the stop using the handle bars. Ensure that the bores are aligned. Fig. 136: Pull out fly jib boom Insert bolt (1).
  • Page 107 Trailer Crane AHK 30/1400 Setup Insert safety pin (1) in the bolt and throw over the retaining ring. If boom length is not sufficient then repeat work steps 3-8 on the second telescoping element. Fig. 138: Insert safety pin Ensure that the cable is correctly positioned in the cable pulleys and guides (arrows).

  • Page 108: Supplemental Hook Weight

    Trailer Crane AHK 30/1400 Setup 6.8 Supplemental Hook Weight Pos : 6.33 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Hakenzusatzgewic ht AHK EU Böc ker (00985) @ 10\mod_1147685608321_1.doc @ 99088 ATTENTION! Property damage! Incorrectly wound cable can result in damage to the cable and to the cable drum! Use supplemental hook weight.
  • Page 109 Trailer Crane AHK 30/1400 Setup Hook the supplemental hook weight (1) onto the crane hook (2). Ensure that the safety device (arrow) is completely closed. Dismounting is executed in the reverse sequence. Fig. 141: Mount supplemental hook weight Pos : 6.35 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/1.1 Belas tungsdi agramm Titel @ 10\mod_1146666708742_1.doc @ 96578...

  • Page 110: Load Diagram

    Trailer Crane AHK 30/1400 Setup 6.9 Load Diagram Pos : 6.36 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Belas tungsdi agramm AHK EU 30/1400 Böc ker ( 00985) @ 10\mod_1147685990565_1.doc @ 99095 Abb. 142: Load diagram Distance between center line, slewing ring, and hook Example of load in kg with retracted boom (dotted line), Distance 5,50 m, height 9 m, represents a max.

  • Page 111: Beaufort Scale

    Trailer Crane AHK 30/1400 Setup 6.10 Beaufort Scale Pos : 6.39 /Kothes! Networ k/Boeker/Installation und Inbetriebnahme/Beaufort-Skal a EU Boec ker @ 8\mod_1141319064841_1.doc @ 72749 Name according to Speed Effect inland Beaufort km/h / kn <0,6 /<1 Smoke rises in a straight line...

  • Page 112: Operation

    Trailer Crane AHK 30/1400 Operation Pos : 7.2 /Kothes! Networ k/Boeker/Bedi enung/1 Bedi enung Titel @ 8\mod_1141490120797_1.doc @ 73746 7 Operation Pos : 7.3 /Kothes! Networ k/Boeker/Bedi enung/Verhalten des Bedi enpers onals AH K Böc ker ( 00980) @ 10\mod_1146667831923_1.doc @ 96592 The crane operator should not pursue any other activity during crane operation.

  • Page 113: User/Loader Instruction

    Trailer Crane AHK 30/1400 Operation 7.1 User/Loader Instruction Pos : 7.6 /Kothes! Networ k/Boeker/Bedi enung/Ei nweis ung der Benutzer AH K Böc ker ( 00980) @ 10\mod_1146667989520_1.doc @ 96599 Hazards for objects and persons can occur when operating the crane, particularly if the guidelines in the operating manual are not heeded.

  • Page 114: End Of Work Measures

    Trailer Crane AHK 30/1400 Operation 7.2.2 End of Work Measures Pos : 7.15 /Kothes! Networ k/Boeker/Bedienung/M aßnahmen Arbeits ende AHK allg. Böc ker ( 00980) @ 10\mod_1146668512805_1.doc @ 96690 The following activities must be executed prior to ending work: –...

  • Page 115: Crane Operation

    Trailer Crane AHK 30/1400 Operation 7.3 Crane Operation Pos : 7.21 /Kothes! Networ k/Boeker/Bedienung/Warnung s chwebende LAsten AH K EU Böc ker ( 00985) @ 10\mod_1147686408915_1.doc @ 99109 Check warning and instruction stickers for legibility and completeness. WARNING! Danger to life! Suspended loads can fall and cause severe or fatal injuries.
  • Page 116 Trailer Crane AHK 30/1400 Operation Switch switch (arrow) to "Operation". Fig. 143: Slack cable switch Push switch (1) for crane mode forward. See "Remote Control" for explanations of the switch functions for operating the crane via remote control. Fig. 144: Switch - crane mode/outrigger Pos : 7.22 /FI/(---------- 1 Leerz eile ----------) @ 0\mod796_1.doc @ 1527...

  • Page 117: Movement Of Load

    Trailer Crane AHK 30/1400 Operation 7.4 Movement of load Pos : 7.24 /Kothes! Networ k/Boeker/Bedienung/Bewegen der Last AH K EU Böc ker @ 26\mod_1166701583000_1.doc @ 287282 The person guiding the lifting procedure must ensure that the crane is in a proper upright position and locked, if required.
  • Page 118 Trailer Crane AHK 30/1400 Operation a number of additional measures are taken when the crane transports a load: The boom must be transported in the direction of movement. The superstructure must be secured against rotation (alternatively, position the boom on the boom rest mounted to the vehicle), unless it is to be rotated, the operator is in the cab or the boom is secured in a bracket.

  • Page 119: Remote Control

    Trailer Crane AHK 30/1400 Operation 7.5 Remote Control Pos : 7.27 /Kothes! Networ k/Boeker/Bedienung/F ernbedi enung Aufbau AHK Böc ker (00980) @ 10\mod_1146219279654_1.doc @ 95452 Control lever telescoping mast and rotation. Control lever winch and telescope. Indicator light battery status...
  • Page 120 Trailer Crane AHK 30/1400 Operation Abb. 147: Function diagram 02/2008...
  • Page 121 Trailer Crane AHK 30/1400 Operation Lower mast Lift mast Rotate left Rotate right (in the direction of travel) (in the direction of travel) Crane mode Support mode Telescope in Telescope out Lower load Lift load Motor start Motor stop Key switch...

  • Page 122: Maneuvering Drive (Optional)

    Trailer Crane AHK 30/1400 Operation 7.6 Maneuvering Drive (optional) Pos : 7.30 /Kothes! Networ k/Boeker/Bedienung/R angi erantrieb AHK EU Böc ker (00985) @ 10\mod_1147686605024_1.doc @ 99116 Brief movement of the device is possible without the tow vehicle, using the maneuvering drive.
  • Page 123 Trailer Crane AHK 30/1400 Operation Insert the safety pin into the bolt. Swing up the safety bracket. Repeat the work step on the opposite side of the vehicle. Start the motor and let it warm up, See "Starting the Motor"...
  • Page 124 Trailer Crane AHK 30/1400 Operation Start motor, see "Starting the Motor". Flip switch (1) towards the operator to "Support mode". Abb. 151: Activate support mode If present remove stop block from the tires, see "Uncoupling, Parking". Press the hand brake lever (arrow) in the direction of the ball coupling until the stop.

  • Page 125: Operating Maneuvering Drive

    Trailer Crane AHK 30/1400 Operation 7.6.2 Operating maneuvering drive ATTENTION! Risk of damage to persons and property! Swing-out of the device in curves can result in severe injury and property damage! – Pay attention to onlookers and objects when using maneuvering drive! –...

  • Page 126: Deactivate Maneuvering Drive

    Trailer Crane AHK 30/1400 Operation 7.6.3 Deactivate maneuvering drive Pull hand lever (arrow) in the direction of the device. Switch off the motor. Abb. 154: Hand brake lever Pull the retaining bracket carefully towards you and hold. Pull the stop block (1) out of the holder.
  • Page 127 Trailer Crane AHK 30/1400 Operation Wedge the stop block under the tire from the side. Repeat the work step on the opposite side of the vehicle. Abb. 156: Place stop block under the tire Swing up the safety ring (arrow) and remove the safety pin.
  • Page 128 Trailer Crane AHK 30/1400 Operation Insert safety pin and swing over the safety ring. Repeat work step on the other side of the vehicle. Abb. 159: Pin the bolt lock Pos : 8.1 /F I/..Seitenumbr uch ..@ 0\mod272_1.doc @ 1522...

  • Page 129: Dismantling

    Trailer Crane AHK 30/1400 Dismantling Pos : 8.2 /Kothes! Networ k/Boeker/Abbau/1 Abbau Titel @ 8\mod_1141490412413_1.doc @ 73791 8 Dismantling Pos : 8.3 /Kothes! Networ k/Boeker/Abbau/1.1 Gerät abbauen Titel @ 8\mod_1141827093869_1.doc @ 74857 8.1 Dismounting the Device Pos : 8.4 /Kothes! Networ k/Boeker/Abbau/Abbau AHK EU Böc ker (00985) @ 10\mod_1147698297101_1.doc @ 99371...
  • Page 130 Trailer Crane AHK 30/1400 Dismantling Start motor, see "Starting the motor". Press the switch (arrow) forward for crane mode. Abb. 160: Switch over to crane mode Turn switch (arrow) to the "Assembly" position. Remove load suspension gear. Take off supplemental hook weight, see "Supplemental Hook Weight".
  • Page 131 Trailer Crane AHK 30/1400 Dismantling Hook the crane hook (2) into the holder (3). Hook the cable cut-off (1) into the holder (arrow). Fig. 162: Hook in the crane hook Check that the cable is seated correctly in the cable pulleys and guides (arrows).
  • Page 132 Trailer Crane AHK 30/1400 Dismantling ATTENTION! Risk of damage to persons and property! Uncontrolled swinging of the boom can result in severe bodily injury and property damage! – Always tension the cable carefully. – Avoid incorrect operation of the remote control unit.
  • Page 133 Trailer Crane AHK 30/1400 Dismantling Place the safety pin (1) on the bolt. Fig. 167: Insert safety pin ATTENTION! Risk of damage to persons and property! The boom colliding with persons or objects can cause injuries or property damage! –...
  • Page 134 Trailer Crane AHK 30/1400 Dismantling Raise the telescoping mast high enough that the fly jib boom can be swung in. Turn the telescoping mast so that it is not in the range of the drawbar or an outrigger. Carefully unreel the carrying cable until the boom (1) is perpendicular to the ground.
  • Page 135 Trailer Crane AHK 30/1400 Dismantling Take the cable cut-off (3) out of the holder (arrow). Carefully unhook the crane hook (1) from the holder (2). Fig. 169: Unhook the crane hook Use the "Lower load" function on the remote control to unreel the carrying...
  • Page 136 Trailer Crane AHK 30/1400 Dismantling Swing the fly jib boom under the telescoping mast. To do this execute the following work step: Activate the function "Lift load" on the remote control until the fly jib boom(1) rests completely against the end position buffer.

  • Page 137: Dismounting The Outriggers

    Trailer Crane AHK 30/1400 Dismantling 8.2 Dismounting the Outriggers Pos : 8.7 /Kothes! Networ k/Boeker/Abbau/Stützen abbauen AHK EU Böc ker (00985) @ 10\mod_1147698598425_1.doc @ 99378 ATTENTION! Property damage! Non-compliance to the sequence of disassembly steps can cause damage to the...
  • Page 138 Trailer Crane AHK 30/1400 Dismantling Use the crank (1) to lower the support wheel (2) to medium height. Abb. 175: Use the crank to lower the support wheel To retract the rear outrigger cylinders pull levers 1+2 towards you and hold.
  • Page 139 Trailer Crane AHK 30/1400 Dismantling Unscrew the spring-loaded latch (1) and hold. Swing the outrigger arms forward to the stop in the direction of travel. Abb. 178: Swing out the outrigger cylinders Release the spring-loaded latch (1). Ensure that the spring-loaded latch (1) is completely engaged (arrow).
  • Page 140 Trailer Crane AHK 30/1400 Dismantling Check the position of the stop block (arrow). If necessary wedge the stop block in place again. Repeat work step on the opposite side of the vehicle. Abb. 181: Position stop block Pos : 9.1 /F I/..Seitenumbr uch ..@ 0\mod272_1.doc @ 1522...

  • Page 141: Storage

    Trailer Crane AHK 30/1400 Storage Pos : 9.2 /Kothes! Networ k/Boeker/Lagerung/1 Lager ung Ti tel @ 8\mod_1141317872905_1.doc @ 72658 9 Storage Pos : 9.3 /Kothes! Networ k/Boeker/Lagerung/Lager ung bei Nichtbenutzung AHK EU Böc ker @ 11\mod_1149545731042_1.doc @ 115205 Execute the following work steps if the device will not be used for a longer period of time: –...
  • Page 142 Trailer Crane AHK 30/1400 Storage For storage periods longer than 1 year: – Complete all tasks that must be carried out every three months for prolonged storage (see list) and also complete the tasks listed below. – The crane must be inspected and released by a crane expert prior to first use.

  • Page 143: Maintenance

    Trailer Crane AHK 30/1400 Maintenance Pos : 10.2 /Kothes! Networ k/Boeker/War tung/1 Wartung Titel @ 8\mod_1141316819821_1.doc @ 72567 10 Maintenance Pos : 10.3 /Kothes! Networ k/Boeker/War tung/1.1 Allgemeines Ti tel @ 8\mod_1141316843964_1.doc @ 72576 10.1 General Pos : 10.4 /Kothes! Networ k/Boeker/War tung/Allgemeines Wartung AHK EU Böc ker (00985) @ 10\mod_1147687026627_1.doc @ 99130 Boecker cranes are designed to be low-maintenance and user friendly.
  • Page 144 Trailer Crane AHK 30/1400 Maintenance General Note: – Cleaning the device increases safety and and prolongs service life. – Immediately repair minor paint damage to prevent rust. – Sheet metal and accident damage should only be repaired by specialized work shops..

  • Page 145: Regular Operator Checks

    Trailer Crane AHK 30/1400 Maintenance 10.2 Regular Operator Checks Pos : 10.7 /Kothes! Networ k/Boeker/War tung/1.1.1 Vor jeder Fahrt im Str aß enver kehr Ti tel @ 8\mod_1141394725443_1.doc @ 72983 10.2.1 Prior to Each Transport in Road Traffic Pos : 10.8 /Kothes! Networ k/Boeker/War tung/Wartung - vor jeder F ahrt i m Str ass enver kehr EU Böc ker @ 9\mod_1144156757785_1.doc @ 85440 NOTE! You will find a detailed description of activities in "Prior to Transport".

  • Page 146: Prior To Each Use

    Trailer Crane AHK 30/1400 Maintenance 10.2.2 Prior to Each Use Pos : 10.11 /Kothes! N etwor k/Boeker/Wartung/Wartung vor j edem Eins atz AH K EU Böc ker ( 00985) @ 10\mod_1147687346070_1.doc @ 99137 WARNING! Danger to life! Cable break can result in serious injury and property damage! –...

  • Page 147: Operating Hour Meter

    Trailer Crane AHK 30/1400 Maintenance 10.3 Operating Hour Meter Pos : 10.14 /Kothes! N etwor k/Boeker/Wartung/Betriebsstundenzähl er AH K Böc ker @ 10\mod_1147099525755_1.doc @ 97550 There is an operating hour meter in the switch cabinet. Use the operating hour meter to ensure that the instructions in the maintenance table are executed in a timely manner.

  • Page 148: Regular Maintenance By Qualified Personnel

    Trailer Crane AHK 30/1400 Maintenance 10.4 Regular Maintenance by Qualified Personnel Pos : 10.17 /Kothes! N etwor k/Boeker/Wartung/Warnung Manipulation T eles kopier abmess ungen AH K EU Böc ker @ 11\mod_1150213325053_1.doc @ 119386 WARNING! Danger to life! Incorrectly maintained or manipulated components can cause the mobile crane to overturn! Only use manufacturer's original replacement parts.

  • Page 149: General Inspections

    Trailer Crane AHK 30/1400 Maintenance 10.4.1 General Inspections Pos : 10.21 /Kothes! N etwor k/Boeker/Wartung/Allgemeine Prüfung en AH K EU Böc ker ( 00985) @ 10\mod_1147687612189_1.doc @ 99151 Measure Signage on the mobile crane Check for legibility and (legibility, completeness)
  • Page 150 Trailer Crane AHK 30/1400 Maintenance Measure Initially after Check the wheel bearings 500 km, Check, see supplier on the wheels documentation thereafter every 2500 km Check the hub cap on the wheels for firm Every Check, see supplier seat 2500 km...

  • Page 151: Engine Tests

    Trailer Crane AHK 30/1400 Maintenance 10.4.2 Engine tests Pos : 10.24 /Kothes! N etwor k/Boeker/Wartung/M otorentec hnis che Prüfungen AH K 30/1400 Böc ker @ 26\mod_1166703461387_1.doc @ 287293 Visual inspection Checking engine level Check fuel level Check coolant level Check air filter...

  • Page 152: Mechanical Inspections

    Trailer Crane AHK 30/1400 Maintenance 10.4.3 Mechanical Inspections Pos : 10.27 /Kothes! N etwor k/Boeker/Wartung/M ec hanisc he Pr üfung en AH K Böc ker ( 00980) @ 10\mod_1147092279825_1.doc @ 97468 Measure Condition - chassis frame Check Connection base-frame support...
  • Page 153 Trailer Crane AHK 30/1400 Maintenance Measure Visual inspection of the running gear (deformation, cracks, weld seams) Flyer chains, initial tension, damage, Re-tension, clean, grease, lubricate corrosion) Check, grease, Deflection pulleys (damage, lubrication) lubricate Hydraulic hose drum (anchoring, corrosion) Check Load winch including cable drum (anchoring,...
  • Page 154 Trailer Crane AHK 30/1400 Maintenance Check the gear mesh and the track of the slewing ring monthly, lubricate with "Vosimex VM". Use the lubrication nipple on the circumference of the slewing ring for this. Extend the telescoping tubes horizontally until the stop. Clean all sliding surfaces and grease with "Vosimex VM.

  • Page 155: Hydraulic Inspections

    Trailer Crane AHK 30/1400 Maintenance 10.4.4 Hydraulic Inspections Pos : 10.30 /Kothes! N etwor k/Boeker/Wartung/H ydr aulisc he Pr üfung en AH K EU Böc ker ( 00985) @ 10\mod_1147688044237_1.doc @ 99158 Measure After Hydraulic oil 2400 OH, min. every Change (only Rivolta S.B.H.
  • Page 156 Trailer Crane AHK 30/1400 Maintenance Annotation: ATTENTION! Property damage! Improper handling can cause property damage! – Only change the hydraulic oil when it is warm. – Never let the hydraulic pump run without oil – Pump and pump housing must be filled with oil.

  • Page 157: Electrical Inspections

    Trailer Crane AHK 30/1400 Maintenance 10.4.5 Electrical Inspections Pos : 10.33 /Kothes! N etwor k/Boeker/Wartung/Elektrisc he Prüfungen AHK Böc ker ( 00980) @ 10\mod_1147092701505_1.doc @ 97492 Measure Switch box on the superstructure (damage, water penetration, corrosion, Check fuses, plug connectors)

  • Page 158: Verification Of Theoretical Service Life

    Trailer Crane AHK 30/1400 Maintenance 10.6 Verification of Theoretical Service Life Pos : 10.39 /Kothes! N etwor k/Boeker/Wartung/Ü berpr üfung der theor. N utz ungs dauer EU AH K Böc ker ( 00985) @ 10\mod_1147688319066_1.doc @ 99165 Operating hours are recorded by the operating hour meter. The operating hour meter is mounted in the switch box.

  • Page 159: Fuels And Lubricants

    Trailer Crane AHK 30/1400 Maintenance 10.8 Fuels and lubricants Pos : 10.44 /Kothes! N etwor k/Boeker/Wartung/Betriebs- und Sc hmierstoffe AH K EU Böc ker ( 00985) @ 10\mod_1147688437567_1.doc @ 99172 ATTENTION! Risk of damage to property and the environment! If process chemicals reach the soil, there is a risk of serious damage to the environment or property! –...

  • Page 160: Tightening Torques

    Trailer Crane AHK 30/1400 Maintenance 10.9 Tightening Torques Pos : 10.47 /Kothes! N etwor k/Boeker/Wartung/Anziehdrehmomente AH K EU Böc ker ( 00985) @ 10\mod_1147693431105_1.doc @ 99179 ATTENTION! Property damage! Bolts that loosen on their own can cause property damage. Follow the instructions listed below: –...

  • Page 161: Malfunctions

    Trailer Crane AHK 30/1400 Malfunctions Pos : 11.2 /FI/Störungen/1 Störungen Titel @ 0\mod295_1.doc @ 3327 11 Malfunctions Pos : 11.3 /Kothes! Networ k/Boeker/Stör ung/Sic her hei tshi nweis Stör ung EU Böc ker @ 8\mod_1143716830852_1.doc @ 83213 11.1 Safety Instructions...

  • Page 162: Major Malfunction

    Trailer Crane AHK 30/1400 Malfunctions Press the "I" button on the remote control unit briefly to acknowledge the error message. Fig. 185: Error acknowledgement button 11.1.2 Major Malfunction In the case of major device malfunctions a distinction is made between electrical and hydraulic malfunctions.
  • Page 163 Trailer Crane AHK 30/1400 Malfunctions Count the flash code. Wait for the short flash pause, then count the flash sequence. Start the troubleshooting process based on the error code, see Appendix, "Troubleshooting". Fig. 187: Error light Are the indicator lights on the control cabinet active? If not check fuse F2.
  • Page 164 Trailer Crane AHK 30/1400 Malfunctions Check the required fuse (arrow) for continuity. Fig. 189: Fuses If the error cannot be rectified based on the error table then contact the manufacturer or the service organization. If necessary dismount the device manually (transport position), see "Emergency Activation".

  • Page 165: Malfunction Table

    Trailer Crane AHK 30/1400 Malfunctions Pos : 11.6 /Kothes! Networ k/Boeker/Stör ung/1.1. Stör ungstabell e Titel @ 8\mod_1142436634715_1.doc @ 77430 11.2 Malfunction Table Pos : 11.7 /Kothes! Networ k/Boeker/Stör ung/Störungstabelle AH K Böc ker ( 00980) @ 10\mod_1146740500944_1.doc @ 96872...

  • Page 166: Mitsubishi Engine Fault Indicator

    Trailer Crane AHK 30/1400 Malfunctions 11.3 Mitsubishi engine fault indicator In models equipped with a Mitsubishi diesel engine, the engine is monitored and protected by special Mitsubishi engine electronics. They make fault detection more user-friendly and help prolong the service life of the equipment. The system constantly monitors the water temperature, oil pressure and minimum engine speed.

  • Page 167: Emergency Activation

    Trailer Crane AHK 30/1400 Malfunctions Fault code table: Fault Oil-related fault Generator or pickup defective. CAUTION! Certain generators only produce pulses at a higher speed and after excitation. Temperature-related fault Overspeed fault. In pump mode, the system detects an overspeed fault as soon as the entered generator frequency is exceeded.

  • Page 168: Emergency Operation - Crane Mode

    Trailer Crane AHK 30/1400 Malfunctions 11.4.1 Emergency Operation - Crane Mode Pos : 11.15 /Kothes! N etwor k/Boeker/Stör ung/N otbetätigung Kranbedienung AHK EU Böc ker (00985) @ 10\mod_1146741296793_1.doc @ 96907 If the drive motor or the electrical system fails, then the device can be retracted and dismounted via hydraulic hand pumps in an emergency situation.
  • Page 169 Trailer Crane AHK 30/1400 Malfunctions Hold cover (1) securely and safeguard it from falling. Unscrew screws (arrow). Take off cover (1). Start motor if possible, see "Starting the Motor". Fig. 191: Cover - control valves Abb. 192: Warning on the device Abb.
  • Page 170 Trailer Crane AHK 30/1400 Malfunctions Abb. 194: Sign on the device Throw lever on the mechanical hydraulic pump over to "Crane mode position. Abb. 195: Valve for crane mode 02/2008...
  • Page 171 Trailer Crane AHK 30/1400 Malfunctions Abb. 196: Valve control Level: Function: Swivel Lever up swivel to the left Lever down swivel to the right Telescope arm Lever up lower mast Lower down raise mast Cable winch Lever up lower load...

  • Page 172: Electrical-Hydraulic Methods

    Trailer Crane AHK 30/1400 Malfunctions 11.4.2 Electrical-hydraulic methods If the motor or the hydraulic system is out of order, then the device must be retracted via the "Electrical-Hydraulic Method". The procedure sequence must be complied with, see "Dismounting the Device".
  • Page 173 Trailer Crane AHK 30/1400 Malfunctions WARNING! Danger to life! Overturning the device due to misoperation can cause life-threatening and fatal injuries! Always heed the following in the event of malfunction: In order to obtain the greatest possible stability, always follow the sequence below: –...
  • Page 174 Trailer Crane AHK 30/1400 Malfunctions Insert key in the key switch (1). Turn the key to "|" and hold. Press the mushroom button and hold. Fig. 200: Key switch If the motor does not function, remove extension lever from the tool box.

  • Page 175: Hydraulic Method

    Trailer Crane AHK 30/1400 Malfunctions 11.4.3 Hydraulic Method Switch on the main switch (1). Ensure that no battery voltage is applied (arrow). If in the event of electronic problems there is no voltage, or if there is an electrical problem, proceed as follows to dismount the device: Fig.
  • Page 176 Trailer Crane AHK 30/1400 Malfunctions Take the retaining strip (1) out of the tool box. Operate the required lever for valve activation (arrow) and put retaining strip (1) in place. Fig. 203: Put retaining strip in place WARNING! Danger to life! Misoperation of the device can cause life-threatening and fatal injuries! –...
  • Page 177 Trailer Crane AHK 30/1400 Malfunctions NOTE! Diagram of the valve (arrow) located at the rear of the valve block. Abb. 205: Emergency activation - valve button If the motor is not working, take the extension lever out of the tool box.

  • Page 178: Emergency Activation - Hydraulic Outriggers

    Trailer Crane AHK 30/1400 Malfunctions 11.4.4 Emergency Activation - Hydraulic Outriggers Pos : 11.18 /Kothes! N etwor k/Boeker/Stör ung/N otbetätigung Stütz en AH K EU Böc ker ( 00985) @ 10\mod_1147698016366_1.doc @ 99357 WARNING! Danger to life! Overturning the device due to misoperation can cause life-threatening and fatal injuries! Always heed the following in the event of malfunction: –...
  • Page 179 Trailer Crane AHK 30/1400 Malfunctions Throw the lever on the mechanical hydraulic pump over to "Support mode". Fig. 209: Valve for crane mode Take the extension lever out of the tool box. Insert the extension lever (1) in the receptacle (2) of the manual hydraulic pump.

  • Page 180: Accessories

    Trailer Crane AHK 30/1400 Accessories Pos : 12.2 /Kothes! Networ k/Boeker/Z ubehör/1.Z ubehör Titel @ 8\mod_1141491711325_1.doc @ 73856 12 Accessories Pos : 12.3 /Kothes! Networ k/Boeker/Z ubehör/Z ubehör AH K EU Böc ker @ 10\mod_1147181088910_1.doc @ 97625 The following component is available for this device series: KM 500 aluminum dump body.
  • Page 181 Trailer Crane AHK 30/1400 Accessories Specifically designed for the transport of concrete and clay roofing tiles, be it loose, bundled or shrink-wrapped, the DZZ 1-200 is equipped with an automatic change-over system for the loading and unloading of roofing tiles. This caters for safe one-man operation of the machine.
  • Page 182 Trailer Crane AHK 30/1400 Accessories Suction traverse Abb. 215: Suction traverse Pos : 13.1 /FI/..Seitenumbruc h ..@ 0\mod272_1.doc @ 1522 02/2008...

  • Page 183: Appendix

    Trailer Crane AHK 30/1400 Appendix Pos : 13.2 /Kothes! Networ k/Boeker/Anhang/1 Anhang Titel @ 8\mod_1141318857572_1.doc @ 72722 13 Appendix Pos : 13.3 /Kothes! Networ k/Boeker/Anhang/1.1 F ehl ersuche AHK Böc ker (00980) @ 10\mod_1146154142286_1.doc @ 95217 13.1 Troubleshooting Pos : 13.4 /Kothes! Networ k/Boeker/Anhang/F ehl ersuche AHK EU Böc ker @ 28\mod_1169568590900_1.doc @ 330031 13.1.1 Motor does not Start...

  • Page 184: Motor Does Not Start (Only Mitsubishi Model )

    Trailer Crane AHK 30/1400 Appendix 13.1.2 Motor does not Start (only Mitsubishi model ) Error: motor does not start Abb. 217: Flow chart Mitsubishi - motor 02/2008...

  • Page 185: Check Remote Control System

    Trailer Crane AHK 30/1400 Appendix 13.1.3 Check Remote Control System Check the remote control system Error: Remote control system defective Switch on main switch System is switched on If repeated fuse change is Change the necessary, a different fault Switch on the charging unit must prevail.

  • Page 186: Check Support Mode

    Trailer Crane AHK 30/1400 Appendix 13.1.4 Check Support Mode Error: Support mode not possible Start the motor Motor is switched on Contact customer services 8) Place the mast into the resting block Angle indicator on mast defect Crane in basic...

  • Page 187: Check Rotary Function

    Trailer Crane AHK 30/1400 Appendix 13.1.5 Check Rotary Function Error: Crane rotation is not possible or is only possible with reduced speed. available Motor is switched on, crane operation selected Press "Sensor Fault" touch Check approach button on the remote control switch support FR system for approx.

  • Page 188: Check Telescoping Function

    Trailer Crane AHK 30/1400 Appendix 13.1.6 Check Telescoping Function Error: Telescoping arm does not telescope or only telescopes with reduced speed. Motor switched on, crane operation selected Check completed Press "Sensor Fault" touch button on the remote control system for approx. 15 seconds...

  • Page 189: Check Mast Lifting Function

    Trailer Crane AHK 30/1400 Appendix 13.1.7 Check Mast Lifting Function Error: Mast lift/lowering does not function or only functions with reduced speed. Motor switched on, crane operation selected Press "Sensor Fault" touch Check completed button on the remote control system for approx. 15...

  • Page 190: Check Cable Winch Function

    Trailer Crane AHK 30/1400 Appendix 13.1.8 Check Cable Winch Function Error: Cable winch raise/lower does not function or is only possible with reduced speed. Motor switched on, crane operation selected Check completed Press "Sensor Fault" touch button on the remote control system for approx.

  • Page 191: Check Telescoping Mast Lowering, And Telescope Out Function

    Trailer Crane AHK 30/1400 Appendix 13.1.9 Check Telescoping Mast Lowering, and Telescope Out Function Error: Functions "Lower" and Telescope out" for the telescoping mast do not work. Motor switched on, crane operation Movement lower mast selected. and/or extend telescope Overload indicator...

  • Page 192: Check Cable Winch And Telescope Out Function

    Trailer Crane AHK 30/1400 Appendix 13.1.10 Check Cable Winch and Telescope Out Function Error: "Telescope out" and "Raise cable winch" functions for the telescoping mast do not work. Motor switched on, crane operation Order a new standard selected. made load hook limit...

  • Page 193: Check Movement Functions With The Remote Control System

    Trailer Crane AHK 30/1400 Appendix 13.1.11 Check Movement Functions with the Remote Control System Error: Movements cannot be executed with the remote control system. Motor is running. Remote control system checked for proper functioning Crane supports properly unfolded and supported.

  • Page 194: Overload Light Is Flashing

    Trailer Crane AHK 30/1400 Appendix 13.1.12 Overload Light is Flashing Error: Overload light is flashing and there is no functional control. approach Overload indicator light flashes steadily Press the "Sensor Fault" touch button. The light stops flashing. Slowly actuate the last Check completed.

  • Page 195: Overload Light Illuminated

    Trailer Crane AHK 30/1400 Appendix 13.1.13 Overload Light Illuminated Error: Overload light is continuously illuminated although no load or a light load is hanging on the hook. Motor switched on Crane operation selected Press the "Sensor Fault" touch button on the remote control system for approx.

  • Page 196: Instruction Check List

    Trailer Crane AHK 30/1400 Appendix Pos : 13.6 /Kothes! Networ k/Boeker/Anhang/1.1 C hec klis te Ei nweis ung Titel @ 8\mod_1141318889131_1.doc @ 72731 13.2 Instruction Check List Pos : 13.7 /Kothes! Networ k/Boeker/Anhang/C hec kli ste Ei nweis ung AH K @ 10\mod_1146747123052_1.doc @ 96981...

  • Page 197: Referenced Documents

    Trailer Crane AHK 30/1400 Appendix Pos : 13.12 /Kothes! N etwor k/Boeker/Anhang/Anhang Spezial AHK Böc ker @ 12\mod_1151589234830_1.doc @ 128539 13.3 Referenced documents • Spare parts list • Operating instructions of the load take-up • Operating instructions of the internal-combustion engine •...
  • Page 198 Trailer Crane AHK 30/1400 Appendix ===== Ende der Stüc kliste ===== 02/2008...

  • Page 199: Index

    Trailer Crane AHK 30/1400 Index 14 Index Engine tests ........151 Explanation of Symbols ......10 Accessories .........180 Extend........... 94 Accident..........37 Adjusting the Fly Jib Boom....103 Aligning outriggers .........87 Fuels and lubricants ......159 Appendix..........183 Function ..........46 Applicable Documents ......8 General ...........
  • Page 200 Trailer Crane AHK 30/1400 Index Mitsubishi engine fault indicator ...166 Setup............. 94 Movement of load ........117 Site Inspection........72 Slewing Range ........42 Spare parts..........20 Operating Hour Meter ......147 Starting the petrol engine....... 76 Operating Manual ........8 Storage..........141 Operating Personnel ......

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