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Grove Crane GMK 2035E Driving Operating Instructions Manual – PDF DOWNLOAD
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Description
Grove Crane GMK 2035E Driving Operating Instructions Manual – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 2035E Driving Operating Instructions Manual – PDF DOWNLOAD
Language : English
Pages : 702
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 2035E Driving Operating Instructions Manual – PDF DOWNLOAD
Basic safety instructions
Intended use:
The GMK 2035E is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- Modifications may only be made to the truck crane following the approval of Deutsche GROVE GmbH.
- The GMK 2035E truck crane may only be used in a perfect technical condi- tion as intended and with
due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 2035E truck crane may only be operated without the correspond- ing special equipment within
the permitted temperature range; à Technical
information on the carrier, p. 8 – 1. - The GMK 2035E truck crane is designed solely for lifting loads which are within the permitted GMK
2035E lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also entails
– Observing the entire crane documentation, consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
TABLE OF CONTENTS:
Grove Crane GMK 2035E Driving Operating Instructions Manual – PDF DOWNLOAD
1 Overview........................................................................... 7 1.1 Identification............................................................... 7 1.2 EC Declaration of Conformity................................................. 11 1.3 Documentation supplied....................................................... 12 1.4 Information about the operating instructions................................. 13 1.4.1 What do the symbols used mean?......................................... 13 1.4.2 How are the operating instructions structured?......................... 15 Division................................................................. 15 Structure of the chapters................................................ 15 Structure of the pages................................................... 16 1.4.3 How do I find the information I need?.................................. 17 Cross-references example................................................. 18 1.4.4 What information is available for operations planning?................. 20 1.5 Conversion table for US measurements......................................... 21 2 Basic safety instructions.......................................................... 25 2.1 Intended use................................................................. 25 2.1.1 Improper use........................................................... 26 2.2 Organisational measures...................................................... 27 2.3 Qualifications of the personnel.............................................. 29 2.4 Safety instructions for driving the truck crane.............................. 30 2.5 Safety instructions for crane operation...................................... 31 2.6 Safety indications for welding work.......................................... 33 3 Operating elements when driving.................................................... 37 3.1 Overview of the operating elements........................................... 37 3.1.1 On the outside of the truck crane...................................... 38 3.1.2 In the driver's cab.................................................... 40 Top view of driver's cab................................................ 40 Below in the driver's cab............................................... 42 Above in the driver's cab............................................... 43 Behind the cover........................................................ 45 3.1.3 Front instrument panel................................................. 46 Left..................................................................... 46 Tachograph version 1.................................................... 48 Middle................................................................... 49 Right.................................................................... 50 3.1.4 Side instrument panel.................................................. 52 Standard heating......................................................... 54 Auxiliary water heater................................................. 55 Auxiliary air heater................................................... 56 3.1.5 Transmission........................................................... 57 3.1.6 Steering column........................................................ 58 3.1.7 Sockets for hand-held control.......................................... 59 3.1.8 Outrigger control units................................................ 60 3.2 Short description of the operating elements.................................. 61 3.2.1 Definition of positional references.................................... 61 Basic rule............................................................... 61 Switches and buttons.................................................... 62 3.2.2 General information on the operating elements.......................... 62 3.2.3 Engine................................................................. 63 Steering column.......................................................... 63 Multipurpose switch...................................................... 63 Instrument panels........................................................ 64 3.2.4 Electrical system/electronics.......................................... 65 Electrical system........................................................ 65 Electronics.............................................................. 65 3.2.5 Transmission........................................................... 67 3.2.6 Final drive............................................................ 71 Transverse differential locks............................................ 71 Longitudinal differential lock........................................... 71 3.2.7 Brakes................................................................. 72 Service brake............................................................ 72 Parking brake............................................................ 73 Additional brakes........................................................ 74 3.2.8 Steering/separate steering............................................. 75 Instrument panels........................................................ 75 In the driver's door..................................................... 75 3.2.9 Suspension............................................................. 76 3.2.10 Hydraulic system...................................................... 76 3.2.11 Lighting/windscreen wipers/horn....................................... 77 Steering column.......................................................... 77 Instrument panels........................................................ 77 Overhead in the driver's cab............................................. 79 3.2.12 Level adjustment system............................................... 80 3.2.13 Roof ventilator....................................................... 81 3.2.14 Tachograph/Speedometer................................................ 82 Tachograph............................................................... 82 Speedometer............................................................. 82 3.2.15 Diagnostics........................................................... 83 3.2.16 Windows, doors, keys.................................................. 84 Windows.................................................................. 84 Doors.................................................................... 85 Keys..................................................................... 86 3.2.17 Front flap............................................................ 86 4 Starting/turning off the engine for driving........................................ 89 4.1 Starting the engine from the driver's cab.................................... 89 4.1.1 CHECKLIST: Starting the engine......................................... 89 4.1.2 CHECKLIST: For low temperatures........................................ 92 4.1.3 Ladders and access ladders............................................. 93 Access ladders........................................................... 93 Ladders.................................................................. 93 4.1.4 Refuelling............................................................. 95 4.1.5 Checks before starting the engine...................................... 96 On the hydraulic tank.................................................... 96 Battery master switch.................................................... 96 Checking the hand-held control........................................... 97 4.1.6 Switch on the ignition................................................. 97 4.1.7 Lamp test/equalisation of the switching states......................... 98 Lamp test................................................................ 98 Equalisation of the switching states..................................... 99 4.1.8 Starting the engine.................................................... 99 Without flame start system...............................................100 With flame start system.................................................101 4.1.9 Checks after starting the engine.......................................102 4.1.10 Control elements......................................................103 4.1.11 Setting the idling speed..............................................104 4.2 Turning off the engine.......................................................105 4.2.1 On the ignition lock/with hand-held control............................105 After starting up from the driver's cab..................................105 After starting up with the hand- held control............................105 After parking...........................................................105 4.2.2 With emergency stop switches...........................................106 Resetting the emergency stop switch......................................106 4.3 Air intake inhibitor.........................................................107 Releasing the air intake inhibitor...........................................107 4.4 Operation if equipped with dual tank.........................................109 5 Driving............................................................................113 5.1 Before driving...............................................................113 5.1.1 CHECKLIST: Checks before on-road driving...............................113 5.1.2 Checking the condition of the truck crane..............................119 Windscreen washing system................................................119 Warning plates for vehicle width.........................................119 Change-over to driving mode..............................................120 Electrical system........................................................120 Mirror setting...........................................................120 Vehicle height...........................................................121 Supply pressure..........................................................122 Parking brake............................................................123 5.1.3 Adjusting the seats and steering column................................124 Adjusting the driver's seat.............................................124 Adjusting the passenger seat............................................125 Adjusting the steering column...........................................126 5.1.4 Switching the suspension on/off........................................127 Switching on thesuspension.............................................127 Switching off thesuspension............................................127 5.1.5 Setting the tachograph – version 1.....................................128 Prerequisites............................................................128 Display of error messages...............................................128 Adjusting the tachograph................................................129 5.2 Operating the transmission...................................................133 5.2.1 To switch on...........................................................133 5.2.2 Switching the transmission to neutral position.........................134 5.2.3 Selecting the direction of travel and starting gear....................134 Selecting the drivingdirection.........................................134 Selecting the starting gear............................................135 5.2.4 Changing the operating mode............................................136 Change-over to automatic mode............................................136 Change-over to manual mode...............................................136 5.2.5 Starting...............................................................137 5.2.6 Driving and changing gears.............................................139 In automatic operating mode..............................................139 In manual operatingmode.................................................140 5.2.7 Changing the driving direction.........................................141 5.2.8 Stopping...............................................................141 Stopping for a long period of time......................................141 5.2.9 Gear position L........................................................142 To switch on.............................................................142 To switch off............................................................143 5.2.10 On the roller type dynamometer........................................144 5.2.11 Preheat transmission..................................................144 5.3 Driving and turning off the truck crane......................................145 5.3.1 Checks while driving...................................................145 Directly after you start to move.........................................145 While driving............................................................146 5.3.2 Tempomat...............................................................148 Activating the Tempomat..................................................148 Driving with the Tempomat...............................................148 Switching off the Tempomat..............................................149 5.3.3 Temposet...............................................................150 Switching on theTemposet...............................................150 Driving with theTemposet...............................................150 Switching the Temposet off..............................................150 5.3.4 Driving downhill.......................................................151 Starting.................................................................151 Checks when driving downhill............................................152 Downshifting.............................................................153 Sustained action brake...................................................153 Retarder.................................................................154 5.3.5 Driving uphill.........................................................155 Starting.................................................................155 Driving..................................................................155 5.3.6 Warning messages in driving mode.......................................156 Meaning of the lamps.....................................................156 5.3.7 Parking the truck crane................................................159 Securing the truck crane against rolling away............................160 When standing still for more than 8 hours................................161 5.3.8 Fold-up berth..........................................................162 5.4 Off-road driving.............................................................163 Adjustments to the transmission..............................................163 Connections..................................................................163 Changing the vehicle level...................................................163 Rocking the vehicle free and towing..........................................163 5.4.1 Key-operated switch....................................................164 When switching on........................................................164 When switching off.......................................................164 5.4.2 Operating the longitudinal differential lock...........................165 5.4.3 Operation of the transverse differential locks.........................166 5.4.4 Operation of the level adjustment system...............................167 Setting the on-road level...............................................167 Preselecting lifting/lowering............................................168 Inclining the truck crane................................................168 Changing the overall level..............................................168 After changing the level.................................................168 5.4.5 Freeing the immobilised truck crane....................................169 Rocking the truck crane free............................................169 Towing free to the front................................................170 Towing free backwards...................................................170 5.5 Separate steering............................................................171 5.5.1 Switching to separate steering.........................................172 5.5.2 Steering with separate steering........................................173 5.5.3 Switching to normal steering mode......................................174 5.6 Heating and ventilating the driver's cab.....................................175 5.6.1 Standard heating system................................................175 To switch on.............................................................175 Temperature..............................................................175 Fan......................................................................175 Fresh air/recirculated air...............................................176 Air distribution.........................................................176 To switch off............................................................177 5.6.2 Auxiliary water heating system.........................................178 Preheating the engine....................................................178 Preheating the driver's cab.............................................178 To switch on.............................................................179 Setting the day and time................................................180 Storing the heating start...............................................181 Setting the heating period..............................................182 Switching the heating start on and off...................................182 To switch off............................................................183 Setting the remaining time..............................................183 5.6.3 Auxiliary air heater...................................................184 To switch on.............................................................184 Temperature..............................................................185 Additional functions.....................................................185 To switch off............................................................185 5.6.4 Air-conditioning system................................................186 To switch on.............................................................186 Operation................................................................186 Drying the air...........................................................187 To switch off............................................................187 5.7 Towing a trailer.............................................................189 Effects on the axle loads....................................................189 Coupling the trailer........................................................190 Connecting the supply lines.................................................191 Removing supply lines......................................................192 Uncoupling the trailer......................................................192 Checking the braking force...................................................194 6 Driving modes......................................................................197 6.1 Driving modes................................................................197 Information on the axle loads................................................197 6.1.1 Information on how to use the tables..................................198 6.1.2 Table for a maximum axle load of 12 t..................................199 7 Malfunctions in driving mode.......................................................203 7.1 Emergency stop switch........................................................203 7.2 What to do when a malfunction occurs in road traffic.........................205 7.3 Towing the truck crane.......................................................207 7.3.1 Towing in the event of engine or transmission damage...................208 Compressed-air supply....................................................208 Electric power supply....................................................208 On the transmission......................................................209 Axle drives..............................................................209 Parking brake............................................................209 Towing the truck crane out of the danger area............................210 7.3.2 Starting to tow........................................................210 7.4 Wheels and tyres.............................................................211 7.4.1 Wheel change...........................................................211 Removing a damaged wheel.................................................212 On the spare wheel holder................................................212 Wheel, installing........................................................213 7.4.2 Filling the tyres yourself.............................................215 Connecting the filling hose..............................................215 Filling the tyres........................................................216 Remove the filling hose.................................................216 7.5 Tilting/lowering the driver's cabin..........................................217 7.5.1 Prerequisites and information on tilting...............................217 7.5.2 Tilting and lowering the driver's cab..................................218 Operating the hand pump..................................................218 Tilting the driver's cab.................................................219 Lowering the driver's cab...............................................220 7.6 Fuses on the carrier.........................................................221 Information on replacing fuses.............................................221 7.6.1 Fuses in the driver's cab..............................................222 For the dual tank........................................................225 7.6.2 Fuses in the battery box...............................................226 7.6.3 Fuses on I/O boards....................................................227 7.7 Finding and eliminating malfunctions.........................................229 7.7.1 Malfunctions on the engine.............................................229 When operating with the dual tank........................................231 7.7.2 Malfunctions in the differential locks.................................231 7.7.3 Malfunctions on the transmission.......................................232 7.7.4 Steering malfunctions..................................................233 7.7.5 Service brake malfunctions.............................................234 7.7.6 Malfunctions to the suspension.........................................235 7.7.7 Level adjustment system malfunctions...................................235 7.7.8 Malfunctions on the ECOS carrier.......................................236 In the driver's cab......................................................236 On the control units.....................................................239 7.8 Procedure in the event of malfunctions.......................................241 7.8.1 Switching on emergency operation in coolant circuit....................241 7.8.2 Procedure in the event of transmission malfunctions....................242 Error messages...........................................................242 Displaying error codes..................................................243 8 Technical information on the carrier...............................................247 8.1 Technical data...............................................................247 8.1.1 Dimensions and weights of the truck crane, axle loads..................248 Dimensions...............................................................249 Weight and axle loads....................................................249 8.1.2 Dimensions and weights of removable parts..............................250 Spare wheel..............................................................250 Outriggers...............................................................250 8.1.3 Carrier................................................................251 Engine...................................................................251 Manual transmission......................................................251 Axle lines...............................................................251 Steering.................................................................251 Tyres....................................................................252 Electrical system........................................................252 Tools....................................................................252 Towing coupling.........................................................252 Outriggers...............................................................253 Driving speeds...........................................................253 Climbing ability.........................................................253 Turning circle radiuses..................................................254 9 Index..............................................................................257 A................................................................................259 B................................................................................259 C................................................................................259 D................................................................................261 E................................................................................263 F................................................................................264 H................................................................................265 I................................................................................266 K................................................................................266 L................................................................................266 M................................................................................267 O................................................................................267 P................................................................................268 R................................................................................268 S................................................................................269 T................................................................................270 V................................................................................272 W................................................................................272 10 Operating elements for crane operation............................................283 10.1 Overview of the operating elements..........................................283 10.1.1 On the outside of the truck crane.....................................284 10.1.2 Crane cab.............................................................286 10.1.3 Front panel...........................................................288 10.1.4 Side panel............................................................289 Bottom...................................................................289 Top......................................................................290 10.1.5 Control panels........................................................292 Left.....................................................................292 Right....................................................................293 10.1.6 Control lever assignment..............................................294 10.1.7 Heating system.......................................................295 10.1.8 ECOS control unit.....................................................296 10.1.9 ECOS display – main menu..............................................298 10.1.10 ECOS display – submenus..............................................300 Counterweight submenu...................................................300 Superstructure lock submenu............................................301 Outriggers submenu......................................................302 Telescoping submenu.....................................................304 Power unit speeds submenu.............................................306 Monitoring submenu......................................................307 Settings submenu.........................................................308 Operating hours submenu.................................................310 Warning submenu..........................................................310 Error submenu............................................................311 Working range limitation submenu........................................312 Driving submenu.........................................................314 10.1.11 SLI control unit.....................................................316 10.1.12 Hand-held control....................................................320 Outriggers control panel.................................................321 10.1.13 On the Outrigger control units.......................................322 Outriggers...............................................................323 Outrigger pressure display...............................................323 Inclination display......................................................323 10.1.14 For hydraulic emergency operation....................................324 10.2 Short description of the operating elements.................................325 10.2.1 Definition of positional references...................................325 Basic rule...............................................................325 Switch...................................................................326 10.2.2 General rules for buttons and symbols on the display..................326 10.2.3 Engine................................................................327 Side panel..............................................................327 ECOS display.............................................................327 10.2.4 Seat contact switch and dead man's switch.............................328 10.2.5 ECOS crane control....................................................329 Control unit.............................................................329 10.2.6 Outriggers............................................................332 Hand-held control........................................................332 In the Outriggers submenu...............................................333 In the Settings submenu..................................................334 On the Outrigger control units...........................................335 10.2.7 Inclination displays..................................................337 10.2.8 Anemometer displays...................................................338 10.2.9 Counterweight submenu.................................................339 Counterweight submenu...................................................339 10.2.10 Superstructure lock submenu..........................................341 Turntable locking.......................................................341 Houselock................................................................342 10.2.11 Main hoist...........................................................343 10.2.12 Slewing gear.........................................................344 10.2.13 Derricking gear......................................................346 10.2.14 Telescoping mechanism................................................347 Control panels...........................................................347 Telescoping submenu.....................................................348 In the Settings submenu..................................................350 10.2.15 Hydraulic system.....................................................351 10.2.16 Safe load indicator (SLI)............................................352 Input elements with displays.............................................352 Display elements.........................................................354 On the front panel.......................................................357 10.2.17 Electrical system....................................................359 10.2.18 Lighting, windscreen wiper/washing system............................359 Lighting.................................................................359 Windscreen wiper/ Washing system........................................361 10.2.19 Hand-held control....................................................362 Sockets on truck crane...................................................362 Engine control panel.....................................................363 Horn.....................................................................363 Outriggers control panel................................................364 10.2.20 Diagnostics..........................................................366 10.2.21 Windows, doors, keys.................................................367 Windows..................................................................367 Crane cab door...........................................................367 Keys.....................................................................368 10.3 Brief description of the operating elements – driving from the crane cab....369 10.3.1 Driving submenu.......................................................369 10.3.2 Transmission..........................................................370 10.3.3 Final drive...........................................................371 10.3.4 Brakes................................................................372 Side panel...............................................................372 ECOS display.............................................................372 10.3.5 Steering..............................................................373 Normal steering..........................................................373 Separate steering........................................................374 11 Starting/turning off the engine – for crane operation.............................377 11.1 When starting the engine the first time in the day..........................377 11.2 Starting the engine – from the crane cab....................................379 11.2.1 Checking the fuel level...............................................379 11.2.2 Checks before starting the engine.....................................380 Checks on the carrier...................................................380 Checking the hand-held control...........................................380 11.2.3 Switch on the ignition................................................380 11.2.4 Lamp test/equalisation of the switching states........................381 Lamp test................................................................381 Equalisation of the switching states.....................................382 11.2.5 Adjusting the brightness of the display...............................383 11.2.6 Starting the engine...................................................384 Without flame start system...............................................384 With flame start system..................................................385 11.2.7 Checks after starting the engine......................................386 11.2.8 Monitoring submenu....................................................387 11.2.9 Setting the idling speed..............................................388 11.3 Starting the engine – with the hand-held control............................389 In the driver's cab..........................................................389 Starting the engine..........................................................389 11.4 Turning off the engine......................................................391 11.4.1 On the ignition lock/with hand-held control...........................391 After starting from the crane cab........................................391 After starting up with the hand- held control............................391 After parking...........................................................391 11.4.2 With emergency stop switches..........................................392 Resetting the emergency stop switch......................................392 12 Crane operation...................................................................395 12.1 Before crane operation......................................................395 12.1.1 CHECKLIST: Checks prior to crane operation............................395 12.1.2 Checking the condition of the truck crane.............................399 Windscreen washing system................................................399 Crane cab heating system.................................................399 Visual inspection........................................................400 Checking the position of the hoist ropes.................................400 Checking the electrical system...........................................401 12.1.3 Adjusting the crane cab seat and front panel..........................401 Crane cab seat...........................................................401 Front panel..............................................................402 12.1.4 Checking the safety devices...........................................402 Safe load indicator......................................................402 Lifting limit switch....................................................403 Emergency stop switch....................................................403 Seat contact switch......................................................404 12.1.5 Earthing the load.....................................................405 12.1.6 Preheating the hydraulic oil..........................................406 12.1.7 Locking/Unlocking the turntable.......................................408 Locking points...........................................................408 Lock turntable..........................................................409 Unlock turntable........................................................409 12.1.8 Switching the houselock on/off........................................410 Switching on the houselock..............................................410 Switching off the houselock.............................................412 12.2 Operation of the safe load indicator........................................413 12.2.1 Switching on the SLI..................................................414 To switch on.............................................................414 Lamp test on theSLI.....................................................416 Brightness of the displays...............................................416 12.2.2 Entering the rigging mode.............................................417 Entering the SLI code...................................................418 Entering the reeving value..............................................421 Entering individual components...........................................422 12.2.3 Checks prior to crane operation.......................................425 12.2.4 Displays during crane operation.......................................426 Continuous displays......................................................426 Optional displays.......................................................428 12.2.5 SLI early warning.....................................................430 12.2.6 SLI shutdown..........................................................430 Shutdown due to overload.................................................431 12.2.7 Error message.........................................................432 12.2.8 SLI override..........................................................433 12.2.9 Displaying and entering the time and date.............................434 Display..................................................................434 Input....................................................................435 12.3 Crane operation with main boom..............................................437 12.3.1 Checks during crane operation.........................................437 Horizontal alignment.....................................................437 Safe distances..........................................................437 Checking the wind speed..................................................438 12.3.2 Permissible slewing ranges and working positions......................439 360 slewing range.......................................................439 0 to the rear working position..........................................439 180 to the front rigging position.......................................440 Free on wheels working position..........................................440 12.3.3 Main hoist............................................................441 Switching on the main hoist..............................................442 Lifting and lowering....................................................442 Switching off the main hoist............................................443 12.3.4 Lifting limit switch and lowering limit switch........................444 Lifting limit switch.....................................................444 Lowering limit switch....................................................446 12.3.5 Derricking gear.......................................................447 Switching on the derricking gear........................................447 Raising and lowering the boom............................................448 Switching off the derricking gear........................................449 Lowering the main boom to a horizontal position..........................449 12.3.6 Telescoping mechanism.................................................450 Fixed length, intermediate length, telescoping length...................450 Telescoping..............................................................451 Switching on thetelescoping mechanism...................................452 Manual telescoping......................................................452 Teleautomation...........................................................455 Telescoping in thehorizontal position...................................459 Switching off thetelescoping mechanism..................................459 12.3.7 High speed............................................................460 Switching on thefunction................................................460 Derricking gear/ Telescoping mechanism...................................460 Hoist....................................................................461 12.3.8 Slewing gear..........................................................462 Switching on theslewing gear...........................................462 Slewing..................................................................462 Braking the slewing movement.............................................464 Slewing gear freewheel...................................................465 Switching off the slewing gear..........................................465 12.3.9 Possible movement combinations........................................466 12.4 Settings and displays for crane operation...................................467 12.4.1 Inclining the crane cab...............................................467 12.4.2 Adjusting the stroke interval of the windscreen wiper.................468 12.4.3 Limiting the power unit speeds........................................468 12.4.4 Setting the characteristic curve for the control levers...............470 12.4.5 Operation of the directional spotlights...............................471 12.4.6 Displaying the operating hours........................................472 12.4.7 Warning submenu.......................................................473 Opening the submenu.....................................................473 Meaning of the symbols...................................................473 Exiting the submenu.....................................................476 12.4.8 Error submenu.........................................................476 12.5 Working range limiter.......................................................477 12.5.1 Opening the Working range limiter submenu.............................478 12.5.2 Viewing current settings..............................................478 12.5.3 Entering limit values.................................................480 Overall height/ Working radius..........................................480 Slewing angle............................................................481 Entering objects.........................................................483 12.5.4 Entering limit values/objects manually................................486 Limit values.............................................................486 Objects..................................................................487 12.5.5 Switching monitoring functions on/off.................................488 12.5.6 Shutdown by working range limiter.....................................489 12.6 Work break..................................................................491 12.6.1 Short work breaks.....................................................491 12.6.2 Work breaks of more than 8 hours......................................492 Securing the truck crane.................................................492 12.7 Heating and ventilating the crane cab.......................................493 12.7.1 Heating system........................................................493 To switch on............................................................494 Temperature..............................................................495 Fan......................................................................495 Fresh air/recirculated air...............................................495 Air distribution.........................................................496 Setting the day and time................................................497 Storing the heating start..............................................498 Setting the heating period..............................................499 Switching the heating start on and off...................................499 To switch off............................................................500 Setting the remaining time..............................................500 12.7.2 Air-conditioning system...............................................501 To switch on.............................................................501 Operation................................................................501 Drying the air...........................................................502 To switch off............................................................502 13 Rigging work......................................................................505 13.1 Rigging work checklists for crane operation with the main boom..............505 13.1.1 CHECKLIST: Rigging....................................................505 13.1.2 CHECKLIST: Unrigging..................................................510 13.2 Choosing a suitable site....................................................513 13.2.1 Determining the required ground bearing area..........................513 13.2.2 Safe distance from slopes and pits....................................516 13.2.3 Earthing the truck crane..............................................517 13.2.4 Safe distance from electrical lines...................................518 13.3 Connecting/Disconnecting the hand-held control..............................521 13.4 Outriggers..................................................................523 13.4.1 CHECKLIST: Extending the outriggers...................................523 13.4.2 CHECKLIST: Retract outriggers.........................................525 13.4.3 Permissible outrigger spans...........................................526 13.4.4 Preparing the truck crane.............................................527 In the driver's cab......................................................527 Outrigger control units.................................................527 13.4.5 Setting the spans.....................................................528 13.4.6 Extending/retracting outriggers.......................................530 From the control units...................................................531 With the hand- held control..............................................532 From the crane cab.......................................................534 13.4.7 Moving the outrigger pads into working/driving position...............536 13.4.8 Enlarging the ground bearing area.....................................537 13.4.9 Extending/retracting supporting cylinders.............................539 From the control units...................................................540 With the hand- held control..............................................541 From the crane cab.......................................................542 13.4.10 Levelling the truck crane on outriggers..............................544 Inclination displays....................................................544 Prerequisites............................................................545 Manual alignment........................................................546 Automatic alignment.....................................................547 13.4.11 Levelling the free-standing truck crane..............................549 When rigging.............................................................549 During crane operation..................................................550 13.5 Rigging/Unrigging the counterweight.........................................553 13.5.1 Counterweight parts...................................................553 13.5.2 Identification and slinging points....................................555 13.5.3 CHECKLIST: Rigging counterweight......................................556 13.5.4 CHECKLIST: Unrigging counterweight....................................557 13.5.5 Assemble counterweight versions.......................................558 Inspection...............................................................558 Assembling...............................................................559 13.5.6 Counterweight hoist unit..............................................561 Counterweight submenu...................................................561 Extending/ retracting the lifting cylinders.............................562 Locking/unlocking the counterweight......................................563 13.5.7 Removing/installing the counterweight on the turntable................564 Installing...............................................................564 Removing.................................................................565 13.5.8 Securing the counterweight sections for driving the truck crane.......565 13.5.9 Slewing with rigged counterweight.....................................566 13.6 Rigging work on the main boom...............................................567 13.6.1 Hook block on the bumper..............................................567 Picking up the hook block................................................567 Attaching the hook block.................................................568 13.6.2 Hook block on a separate vehicle......................................569 Picking up the hook block...............................................570 Setting down the hook block.............................................570 13.6.3 Reeving and unreeving the hoist rope..................................572 Fastening the rope end clamp.............................................572 Reeving the hoist rope...................................................574 Unreeving the hoist rope................................................576 13.6.4 Possible reeving methods on the main boom.............................577 13.6.5 Installing/Removing the lifting limit switch..........................580 Installing the lifting limit switch......................................580 Removing the lifting limit switch........................................583 13.6.6 Locking/Unlocking the lifting limit switch............................585 Locking..................................................................585 Unlocking...............................................................585 13.6.7 Installing/Removing the anemometer....................................586 13.6.8 Securing / releasing the main boom....................................587 13.6.9 Installing/removing the air traffic control light.....................588 13.7 Other rigging work..........................................................591 13.7.1 Folding mirrors in and out and adjusting them.........................591 13.7.2 Step on the crane cab.................................................592 14 Driving the rigged truck crane....................................................595 14.1 Route.......................................................................595 14.2 Permissible rigging modes and axle loads....................................596 14.2.1 To drive crane without a load.........................................596 14.2.2 To drive with a load..................................................596 14.2.3 Axle loads............................................................597 14.3 Before driving the rigged truck crane.......................................597 14.3.1 Checking the tyre pressure and the wind speed.........................597 14.3.2 Secure superstructure so it cannot slew...............................598 14.3.3 Putting the truck crane on the wheels.................................599 14.4 Driving from the driver's cab...............................................601 14.4.1 Preparing to drive....................................................601 Transmission.............................................................601 Switching on separate steering..........................................601 Connections..............................................................601 14.4.2 While driving.........................................................602 14.5 Driving from the crane cab..................................................603 14.5.1 Preparing to drive....................................................604 14.5.2 Opening/closing the driving mode submenu..............................605 Automatically............................................................605 Manually.................................................................606 Close....................................................................606 14.5.3 Steering..............................................................607 To switch on.............................................................607 Adapt steering direction.................................................607 Normal steering..........................................................608 Separate steering........................................................608 14.5.4 Operating the transmission............................................610 Driving direction........................................................610 Crane hydraulic system on/off............................................610 Selecting the gear position.............................................611 14.5.5 While driving.........................................................612 Gear position L, R.......................................................612 Gear position D..........................................................612 Warning messages........................................................612 14.5.6 Possible connections..................................................613 Longitudinal differential lock..........................................614 Transverse differential locks............................................615 14.5.7 After driving.........................................................616 15 Malfunctions during crane operation...............................................619 15.1 Emergency stop switch.......................................................619 15.2 What to do when a malfunction occurs during crane operation.................621 Load can be lowered.........................................................621 Load cannot be lowered.......................................................621 15.3 Fuses on the superstructure.................................................623 Information on replacing fuses.............................................623 15.3.1 Fuses on the turntable................................................624 Fuse group F1...........................................................624 On the circuit board.....................................................625 On the I/O-3 circuit board...............................................625 15.3.2 Fuses in the crane cab................................................626 15.3.3 SLI fuses.............................................................628 15.4 Finding and eliminating malfunctions........................................629 15.4.1 Malfunctions on the engine............................................629 15.4.2 Malfunctions when operating with the hand-held control................629 15.4.3 Malfunctions to the turntable lock....................................630 15.4.4 Malfunctions during the inclination of the crane cab..................630 15.4.5 Malfunctions on the main hoist........................................631 15.4.6 Malfunctions in the telescoping mechanism.............................632 Telescoping mechanism error messages.....................................633 15.4.7 Malfunctions on the derricking gear...................................634 15.4.8 Malfunctions on the slewing gear......................................635 15.4.9 Malfunctions on the counterweight hoist unit..........................636 15.4.10 Malfunctions in the hydraulic system / hydraulic oil cooler..........637 15.4.11 Malfunctions when driving from the crane cab.........................637 15.4.12 Malfunctions on the outriggers.......................................638 15.4.13 Troubleshooting on the SLI...........................................639 General malfunctions.....................................................639 Error messages...........................................................640 Table of error codes.....................................................642 Switching off thesensor/tachogenerator..................................644 15.4.14 Malfunctions ECOS – superstructure...................................645 ECOS program version.....................................................645 General malfunctions....................................................645 Error messages...........................................................646 Exiting the submenu.....................................................647 15.5 Emergency operations and programs...........................................649 15.5.1 Telescoping emergency program.........................................649 Starting the emergency program..........................................649 Operating in theemergency program.......................................650 Exiting the emergency program............................................651 15.5.2 Emergency operation with the hand-held control........................653 Preparations.............................................................653 Preselecting apower unit................................................654 Operating a power unit...................................................654 Stopping operations.....................................................655 Stopping movements in emergencies.......................................656 Turning off the engine...................................................656 15.6 Hydraulic emergency operation...............................................657 15.6.1 Connect/Disconnect....................................................657 15.6.2 Establishing the required hydraulic circuits..........................658 Switching over valves....................................................658 For lifting/ lowering...................................................660 15.6.3 Performing emergency operation........................................661 15.6.4 After the emergency activation........................................661 15.7 Hydraulic emergency operation BGR 159.......................................663 15.7.1 Operating principle...................................................663 15.7.2 Connecting/Disconnecting hoses........................................664 For the transformer......................................................664 For the hand pump........................................................665 15.7.3 Establishing the required hydraulic circuits..........................666 Switching positions of the valves........................................666 Switching over valves....................................................666 For lifting/lowering.....................................................668 For slewing..............................................................669 15.7.4 Carrying out emergency operation......................................669 Derricking...............................................................670 Lifting/lowering.........................................................671 Slewing..................................................................671 15.7.5 After emergency operation.............................................672 Switching offemergency operation........................................672 Switching overthe crane operation.......................................672 Disconnecting thehoses..................................................672 15.7.6 Emergency supply of another crane.....................................673 After emergency supply...................................................674 16 Technical information for the superstructure......................................677 16.1 Technical data..............................................................677 16.1.1 Maximum lifting capacity (DIN/ ISO/ EN)...............................677 16.1.2 Dimensions and weights of the truck crane, axle loads.................678 16.1.3 Dimensions and weights of removable parts.............................678 Hook blocks and hook tackle..............................................678 Counterweight parts.....................................................679 counterweight versions...................................................679 16.1.4 Superstructure........................................................679 Main hoist...............................................................679 Slewing gear.............................................................679 Derricking gear..........................................................680 Main boom................................................................680 Lattice extension........................................................680 Operating speeds.........................................................680 17 Index.............................................................................683 A................................................................................685 B................................................................................685 C................................................................................685 D................................................................................687 E................................................................................689 F................................................................................690 H................................................................................691 I................................................................................692 K................................................................................692 L................................................................................692 M................................................................................693 O................................................................................693 P................................................................................694 R................................................................................694 S................................................................................695 T................................................................................696 V................................................................................698 W................................................................................698
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