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Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112564 – PDF DOWNLOAD
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Description
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112564 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112564 – PDF DOWNLOAD
Language : English
Pages : 874
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
https://vimeo.com/853928306?share=copy
DESCRIPTION:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112564 – PDF DOWNLOAD
Intended use:
- The GMK 5110-1 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. - The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH.
The GMK 5110-1 truck crane may only be used in a perfect technical condition
as intended and with due attention paid to safe operation and possible
hazards. - Any malfunctions that could impair safety must be eliminated immediately.
Without the corresponding special equipment, the GMK 5110-1 truck crane
may only be operated within the permitted temperature range; àTechnical
data, p. 1 – 9. - The GMK 5110-1 truck crane is designed solely for lifting loads which are
within the permitted GMK 5110-1 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 includes
– 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.
The GMK 5110-1 may only be operated with parts of equipment which are
permitted by Manitowoc Crane Group Germany GmbH and which are labelled
with the serial number of the GMK 5110-1.
The manufacturer is not liable for any damage caused by improper or unauthorized
use of the GMK 5110-1 truck crane. The user alone bears the risk.
Improper use
Manitowoc Crane Group Germany GmbH is not liable for damage resulting
from the improper or unauthorized use of the GMK 5110-1 truck crane.
The user alone bears the risk.
Improper use includes:
– Transporting loads on the carrier
– Pushing, pulling or lifting loads with the level adjustment system, support
bearings or outrigger cylinders
– pushing or pulling loads or lifting them off the ground using the slewing
gear, derricking gear or telescoping mechanism
– Pulling off fixed objects with the crane.,
– Two-hook operation with the boom extension and two-hook operation on
the main boom head without additional equipment
– Setting SLI codes that do not correspond to the actual rigging mode
– Working with an overridden SLI or overridden lifting limit switch
– After SLI shutdown, increasing the working radius by pulling the raised
load at an angle (e.g. with a chain hoist)
– Misuse of the outrigger pressure indicator as a safety function to prevent
the crane from overturning (outrigger pressure higher than 0 t)
– On-road driving in an unauthorized driving mode (axle load, dimension)
– Moving the rigged crane in an impermissible driving mode
– Using equipment that is not permitted for the crane
– Transporting people in any way with the lifting tackle, on the load, or in
the crane cab while driving
– Transporting passengers outside the driver’s cab
– Loading and unloading work, i.e. continuous operation without a sufficiently
long break
– Usage for any kind of sport or recreation event, especially for “bungee”
jumping
TABLE OF CONTENTS:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112564 – PDF DOWNLOAD
Correction sheet.............................................................................. 3 Slewing gear freewheel.................................................................... 3 Switching on.......................................................................... 3 Switching off......................................................................... 5 1 Overview.................................................................................... 11 1.1 Accidents............................................................................. 11 1.2 Branches.............................................................................. 11 1.2.1 Crane Care...................................................................... 11 1.2.2 Dealer list..................................................................... 13 1.3 Warranty specifications............................................................... 14 1.4 Terms used............................................................................ 16 1.5 Technical data........................................................................ 19 1.5.1 Maximum lifting capacity (DIN/ ISO/ EN)......................................... 19 1.5.2 Maximum lifting capacity (ASME B 30.5).......................................... 19 1.5.3 Dimensions and weights of the truck crane, axle loads........................... 20 Dimensions........................................................................ 21 Weight and axle loads............................................................. 21 1.5.4 Dimensions and weights of removable parts....................................... 22 Spare wheel....................................................................... 22 Outriggers........................................................................ 22 Main boom......................................................................... 23 Hook blocks and hook tackle....................................................... 23 Counterweight parts.............................................................. 24 1.5.5 Carrier......................................................................... 25 Engine............................................................................ 25 Gearing........................................................................... 25 Transfer case..................................................................... 25 Axle lines........................................................................ 25 Steering.......................................................................... 25 Tyres............................................................................. 26 Outriggers........................................................................ 26 Electrical system................................................................. 27 Tools............................................................................. 27 Towing coupling.................................................................. 27 Driving speeds.................................................................... 27 Climbing ability.................................................................. 27 Turning circle radiuses........................................................... 28 1.5.6 Superstructure.................................................................. 28 Engine............................................................................ 28 Main hoist........................................................................ 29 Auxiliary hoist................................................................... 29 Slewing gears..................................................................... 29 Derricking gear................................................................... 30 Main boom......................................................................... 30 Lattice extension................................................................. 30 Operating speeds.................................................................. 30 1.6 Documentation supplied................................................................ 31 1.7 Information about the operating instructions.......................................... 33 1.7.1 What do the symbols used mean?.................................................. 33 1.7.2 How are the operating instructions structured?.................................. 35 Division.......................................................................... 35 Structure of the chapters......................................................... 35 Structure of the pages............................................................ 36 1.7.3 How do I find the information I need?........................................... 37 Cross-references example.......................................................... 38 1.7.4 What information is available for operations planning?.......................... 40 1.8 Conversion table for US measurements.................................................. 41 1.9 Training information.................................................................. 43 1.10 Identification....................................................................... 44 1.11 EC Declaration of Conformity......................................................... 46 2 Basic safety instructions................................................................... 49 2.1 Intended use.......................................................................... 49 2.1.1 Improper use.................................................................... 50 2.2 Organisational measures............................................................... 51 2.3 Qualifications of the personnel....................................................... 53 2.4 Safety instructions for driving the truck crane....................................... 54 2.5 Safety instructions for crane operation............................................... 54 3 Operating elements for driving.............................................................. 59 3.1 Overview of the operating elements.................................................... 59 3.1.1 On the outside of the truck crane............................................... 60 3.1.2 Driver's cab.................................................................... 62 Overview.......................................................................... 62 Behind the cover.................................................................. 64 3.1.3 Instrument panel................................................................ 65 Left/right........................................................................ 65 Middle............................................................................ 66 3.1.4 Display, driver's cab........................................................... 68 3.1.5 Steering column/steering wheel.................................................. 69 3.1.6 Transmission operating elements................................................. 70 3.1.7 Tachograph...................................................................... 71 3.1.8 ECOS control unit............................................................... 72 3.1.9 ECOS display – main menu........................................................ 74 3.1.10 ECOS display – submenus........................................................ 76 Level adjustment system submenu................................................... 76 Settings submenu.................................................................. 78 Operating hours submenu........................................................... 79 Warning submenu................................................................... 79 Transmission emergency program submenu............................................ 80 Error submenu..................................................................... 81 3.1.11 Heating/Air-conditioning system................................................ 82 Standard heating system........................................................... 82 Auxiliary heater.................................................................. 83 3.1.12 Sockets for hand-held control.................................................. 84 3.1.13 Outrigger control units........................................................ 85 3.2 Short description of the operating elements........................................... 87 3.2.1 Definition of information relating to directions of movement.................... 87 Basic rule........................................................................ 87 Switches and buttons.............................................................. 88 3.2.2 General information on the operating elements................................... 88 3.2.3 General rules for buttons and symbols on the display............................ 89 3.2.4 Engine.......................................................................... 90 Steering column................................................................... 90 Multipurpose switch............................................................... 90 Instrument panel.................................................................. 91 Main menu......................................................................... 92 3.2.5 Electrical system............................................................... 93 3.2.6 ECOS crane control.............................................................. 93 Control unit...................................................................... 93 3.2.7 Transmission.................................................................... 96 Transmission display.............................................................. 96 ECOS display...................................................................... 96 Operating elements................................................................ 97 Instrument panel.................................................................. 98 3.2.8 Transfer case................................................................... 99 3.2.9 Axle drive......................................................................100 3.2.10 Brakes.........................................................................101 Service brake.....................................................................101 Parking brake.....................................................................102 Additional brakes.................................................................103 3.2.11 Steering/separate steering.....................................................104 ECOS display......................................................................104 Driver's door.....................................................................104 3.2.12 Suspension.....................................................................105 3.2.13 Lighting/windscreen wipers/horn................................................106 Steering column...................................................................106 Instrument panel..................................................................106 Roof..............................................................................108 3.2.14 Level adjustment system........................................................108 3.2.15 Tachograph/speedometer.........................................................110 Tachograph........................................................................110 Speedometer.......................................................................110 3.2.16 Diagnostics....................................................................111 Displays/ submenu.................................................................111 3.2.17 On-board computer..............................................................112 3.2.18 Push-up roof...................................................................114 3.2.19 Windows, doors, keys...........................................................114 Window winder.....................................................................114 Doors.............................................................................115 Keys..............................................................................115 3.2.20 Front flap.....................................................................116 4 Starting/turning off the engine for driving.................................................119 4.1 Starting the engine from the driver's cab.............................................119 4.1.1 CHECKLIST: Starting the engine..................................................119 4.1.2 CHECKLIST: At low temperatures..................................................122 4.1.3 Ladders and access ladders......................................................123 Access ladders....................................................................123 Ladders...........................................................................123 4.1.4 Refueling.......................................................................125 4.1.5 Inspections before starting the engine..........................................126 On the hydraulic tank.............................................................126 Battery master switch.............................................................126 Checking the hand-held control....................................................127 4.1.6 Switch on the ignition..........................................................127 4.1.7 Lamp test/equalisation of the switching states..................................128 Lamp test.........................................................................128 Equalisation of the switching states..............................................129 4.1.8 Display – setting the brightness................................................130 4.1.9 Starting the engine.............................................................131 Without flame start system........................................................132 With flame start system...........................................................133 4.1.10 Inspections after starting the engine..........................................134 4.1.11 Monitoring elements............................................................135 Instrument panel..................................................................135 ECOS display......................................................................136 Driving display...................................................................136 4.1.12 Setting the idling speed.......................................................137 4.2 Turning off the engine................................................................139 4.2.1 On the ignition lock/with hand-held control.....................................139 After parking.....................................................................139 4.2.2 With emergency stop switches....................................................140 Resetting the emergency stop switch...............................................140 4.3 Air intake inhibitor..................................................................141 Releasing the air intake inhibitor....................................................141 5 Driving.....................................................................................145 5.1 Before driving........................................................................145 5.1.1 CHECKLIST: Checks before on-road driving........................................145 5.1.2 Checking the condition of the truck crane.......................................150 Windscreen washing system........................................................150 Electrical system.................................................................150 Adjusting the mirrors.............................................................151 Warning plates for vehicle width..................................................152 Displaying the vehicle height.....................................................152 Supply pressure...................................................................153 Parking brake.....................................................................154 5.1.3 Adjusting the seat and the steering column......................................155 Driver's seat.....................................................................155 Passenger's seat..................................................................156 Adjusting the steering column.....................................................157 5.1.4 Switching the suspension on/off.................................................158 Opening the submenu...............................................................158 Switching on the suspension.......................................................159 Switching off the suspension......................................................159 5.1.5 Adjusting the tachograph........................................................160 Prerequisites.....................................................................160 In the event of malfunctions......................................................160 Adjusting the tachograph..........................................................161 Additional displays...............................................................164 5.1.6 Displaying the operating hours..................................................165 5.1.7 Settings/displays with the on-board computer....................................167 Operation.........................................................................167 Overview..........................................................................168 Inspection information............................................................168 Error information.................................................................169 Alarm clock.......................................................................169 Language..........................................................................170 Settings..........................................................................170 Diagnostics.......................................................................171 5.2 Operating the transmission............................................................173 5.2.1 Switching on....................................................................173 5.2.2 Switching the transmission to neutral position..................................174 5.2.3 Changing the operating mode.....................................................174 Change-over to automatic mode.....................................................174 Change-over to manual mode........................................................174 5.2.4 Display of the selected gears...................................................175 5.2.5 Selecting the direction of travel and starting gear.............................175 Selecting the driving direction...................................................175 Selecting the starting gear.......................................................176 5.2.6 Starting........................................................................177 5.2.7 Driving and changing gears......................................................178 In automatic operating mode......................................................178 In manual operating mode.........................................................179 5.2.8 Changing the driving direction..................................................180 Quick change of gear..............................................................180 5.2.9 Stopping........................................................................181 Stopping for a long period of time................................................181 5.2.10 On the roller type dynamometer.................................................181 5.3 Driving and turning off the truck crane...............................................183 5.3.1 Checks while driving............................................................183 Immediately after you start to move...............................................183 While driving.....................................................................184 Switching on......................................................................185 Switching off.....................................................................186 5.3.3 Temposet........................................................................187 Switching on......................................................................187 Switching off.....................................................................187 5.3.4 Driving downhill................................................................188 Starting..........................................................................188 Checks when driving downhill.....................................................188 Downshifting......................................................................189 Additional brakes.................................................................190 5.3.5 Driving uphill..................................................................191 Starting..........................................................................191 Driving...........................................................................191 5.3.6 Warning submenu.................................................................192 Meaning of the symbols............................................................192 Exiting the submenu...............................................................193 5.3.7 Error submenu...................................................................194 5.3.8 Messages on the On-board computer display.......................................194 Warnings..........................................................................195 Warning messages..................................................................196 Error messages....................................................................197 Information.......................................................................199 5.3.9 Turning off the truck crane.....................................................202 Secure against rolling away.......................................................202 When stationary for more than 8hours.............................................203 5.4 Off-road driving......................................................................205 Adjustments to the transmission.......................................................205 Connections...........................................................................205 Changing the vehicle level............................................................205 Rocking the vehicle free and towing...................................................205 5.4.1 Transfer case – off-road gear on/off............................................206 Prerequisites.....................................................................206 Einschalten.......................................................................206 Switching off.....................................................................207 Neutral position..................................................................207 5.4.2 Longitudinal and transverse differential locks..................................208 5.4.3 Operating the level adjustment system...........................................210 Opening the submenu..............................................................210 Setting the on-road level.........................................................211 Pre-selecting suspension struts...................................................211 Changing the vehicle level........................................................212 Viewing the current inclination...................................................212 Exiting the submenu...............................................................213 5.4.4 Freeing the truck crane stuck in terrain........................................214 Rocking the truck crane free......................................................214 Towing free forward..............................................................215 Towing free to the rear...........................................................215 5.4.5 Separate steering...............................................................216 Switching to separate steering....................................................216 Steering..........................................................................217 Switching to normal steering mode.................................................218 5.5 Heating and air-conditioning system...................................................219 5.5.1 Standard heating system.........................................................219 Switching on......................................................................219 Heating...........................................................................219 Air distribution..................................................................220 Examples..........................................................................221 Switching off.....................................................................221 5.5.2 Air-conditioning system.........................................................222 Warnings..........................................................................222 Switching on/off..................................................................222 Cooling...........................................................................223 Drying............................................................................223 5.5.3 Auxiliary heater................................................................224 Switching on......................................................................224 Temperature.......................................................................225 Setting the day and time..........................................................225 Storing the heating start........................................................226 Setting the heating period.......................................................227 Switching the heating start on and off............................................227 Switching off.....................................................................228 Setting the remaining run time...................................................228 5.6 Towing a trailer......................................................................229 Effects on the axle loads.............................................................229 Coupling the trailer..................................................................230 Connecting the supply lines...........................................................231 Removing supply lines.................................................................232 Uncoupling the trailer................................................................232 Checking the braking force...........................................................234 6 Driving modes...............................................................................237 6.1 Driving modes.........................................................................237 Information about the axle loads......................................................237 6.1.1 Information on how to use the tables............................................238 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs).............................239 For 14.00 R25 tyres...............................................................239 For 16.00 R25 tyres...............................................................240 For 20.5 R25 tyres...............................................................241 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)............242 6.2 Rigging work for driving with a trailer...............................................243 6.2.1 Switching on the slewing gear freewheel.........................................244 Switching on boom floating position...............................................245 6.2.2 Switching on boom pre-tensioning................................................246 6.2.3 Switching the superstructure driving lights on/off..............................248 Switching off.....................................................................248 Switching on......................................................................248 6.3 Rigging the main boom.................................................................249 Additional equipment required.........................................................249 6.3.1 CHECKLIST: Removing the main boom...............................................250 Prerequisites.....................................................................250 Checklist.........................................................................250 6.3.2 CHECKLIST: Mounting the main boom...............................................253 Prerequisites.....................................................................253 Checklist.........................................................................253 6.3.3 Slinging the main boom..........................................................256 6.3.4 Removing/attaching the clamp....................................................257 6.3.5 Hydraulic connection for the lattice extension..................................258 6.3.6 Switching the pressure relief on/off............................................259 6.3.7 Retracting/fitting the derricking cylinder head pin.............................260 Retracting the derricking cylinder head axle.....................................261 Fitting the derricking cylinder head axle........................................262 6.3.8 Retracting/extending the boom pivot pin.........................................263 Before retracting.................................................................263 After extension...................................................................263 Retracting/ extending the pivot pin...............................................264 6.3.9 Disconnecting the hydraulic/electrical connections..............................265 Lifting in front of the turntable.................................................265 Disconnecting.....................................................................266 6.3.10 Establishing the hydraulic/electrical connection...............................267 Lifting onto the turntable........................................................267 Establishing......................................................................268 6.3.11 Aligning the connecting points.................................................269 6.3.12 Securing/releasing the derricking cylinder.....................................269 6.3.13 Transporting the main boom.....................................................270 6.3.14 Inspections after main boom mounting...........................................271 7 Malfunctions in driving mode................................................................275 7.1 Emergency stop switch.................................................................275 7.2 What to do when a malfunction occurs in road traffic..................................277 7.3 Towing the truck crane................................................................279 7.3.1 Towing in the event of engine or transmission damage............................280 Compressed-air supply.............................................................280 Electric power supply.............................................................280 On the transmission..............................................................281 Axle drives.......................................................................282 Transfer case.....................................................................282 Parking brake.....................................................................282 Towing the truck crane out of the danger area.....................................283 7.3.2 Tow starting....................................................................284 7.4 Wheels and tyres......................................................................285 7.4.1 Wheel change....................................................................285 Removing a damaged wheel.........................................................286 On the spare wheel holder.........................................................286 Mounting a wheel..................................................................287 7.4.2 Filling the tyres yourself......................................................289 Connecting the filling hose.......................................................289 Filling the tyres.................................................................290 Removing the filling hose........................................................290 7.5 Fuses.................................................................................291 Information on replacing fuses........................................................291 7.5.1 Fuses in the driver's cab.......................................................292 F1 to F 41........................................................................292 A1 to A3..........................................................................294 7.5.2 Fuses in the battery box........................................................296 7.6 Troubleshooting.......................................................................297 7.6.1 Malfunctions on the engine......................................................297 7.6.2 Malfunctions to the transmission................................................299 7.6.3 Malfunctions of the transfer case...............................................300 7.6.4 Malfunctions of the service brake...............................................300 7.6.5 Malfunctions of the steering....................................................301 7.6.6 Differential lock malfunctions..................................................302 7.6.7 Malfunctions in the hydraulic system/hydraulic oil cooler.......................302 7.6.8 Malfunctions on the suspension..................................................303 7.6.9 Malfunctions of the level adjustment system.....................................303 7.6.10 Malfunctions on the ECOS carrier...............................................304 ECOS program version..............................................................304 General malfunctions.............................................................304 Error messages....................................................................305 Exiting the submenu..............................................................306 On the control units..............................................................307 7.7 Procedure in the event of malfunctions................................................309 7.7.1 Switching on emergency operation in coolant circuit.............................309 7.7.2 Procedure in the event of malfunctions to the transmission andengine...........310 Engine............................................................................310 Transmission......................................................................311 Transmission emergency program submenu..........................................312 Emergency compressed air supply...................................................315 ID number of the transmission.....................................................317 8 Index.......................................................................................321 A.........................................................................................323 B.........................................................................................323 C.........................................................................................323 D.........................................................................................325 E.........................................................................................327 F.........................................................................................329 H.........................................................................................329 I.........................................................................................330 K.........................................................................................330 L.........................................................................................330 M.........................................................................................331 O.........................................................................................332 P.........................................................................................333 R.........................................................................................333 S.........................................................................................334 T.........................................................................................335 V.........................................................................................337 W.........................................................................................337 Correction sheet..............................................................................343 Slewing gear freewheel....................................................................343 Switching on..........................................................................343 Switching off.........................................................................345 9 Operating elements for crane operation......................................................351 9.1 Overview of the operating elements....................................................351 9.1.1 On the outside of the truck crane...............................................352 9.1.2 Crane cab.......................................................................354 9.1.3 Front panel.....................................................................356 9.1.4 Side panel......................................................................357 Bottom............................................................................357 Top...............................................................................358 Rear panel........................................................................360 Standard heating system...........................................................361 Auxiliary water heating system....................................................362 Auxiliary air heater..............................................................363 9.1.5 Control panels..................................................................364 Left..............................................................................364 Right.............................................................................365 9.1.6 Control lever assignment........................................................366 Version 1.........................................................................366 Version 2.........................................................................367 9.1.7 ECOS control unit...............................................................368 9.1.8 ECOS display – main menu........................................................370 9.1.9 ECOS display – submenus.........................................................372 Counterweight submenu.............................................................372 Slewing gear/ Houselock submenu..................................................373 Outriggers submenu...............................................................374 Telescoping submenu..............................................................376 Submenu Power unit speed..........................................................378 Monitoring submenu...............................................................379 Settings submenu..................................................................380 Submenu Operating hours..........................................................382 Submenu Warning..................................................................383 Error submenu.....................................................................385 Working range limiter submenu.....................................................386 Driving submenu...................................................................388 9.1.10 SLI control unit...............................................................390 9.1.11 Hand-held control..............................................................394 Outriggers control panel.........................................................395 9.1.12 Outriggers control units.......................................................396 Outriggers........................................................................397 Outrigger pressure display.......................................................397 Inclination indicator............................................................397 9.2 Short description of the operating elements...........................................399 9.2.1 Definition of information relating to directions of movement....................399 Basic rule........................................................................399 Switch............................................................................399 9.2.2 General rules for buttons and symbols on the display............................400 9.2.3 Engine for crane operation......................................................401 Side panel........................................................................401 Rear panel........................................................................402 ECOS display......................................................................402 9.2.4 Engine for driving..............................................................402 Side panel........................................................................402 Main menu.........................................................................402 Outriggers submenu...............................................................403 9.2.5 Seat contact switch and dead man's switch.......................................404 9.2.6 ECOS crane control..............................................................405 Control unit......................................................................405 9.2.7 Outriggers......................................................................408 Hand-held control.................................................................408 In the Outriggers submenu.........................................................409 In the settings submenu...........................................................410 On the Outriggers control units...................................................411 9.2.8 Inclination indicators..........................................................413 9.2.9 Outrigger pressure displays.....................................................414 Outriggers submenu...............................................................414 Outriggers control units.........................................................414 9.2.10 Anemometer display.............................................................414 9.2.11 Counterweight submenu..........................................................415 Counterweight submenu.............................................................415 9.2.12 Main hoist.....................................................................417 9.2.13 Auxiliary hoist................................................................419 9.2.14 Slewing gear...................................................................420 Submenu...........................................................................421 9.2.15 Derricking gear................................................................423 9.2.16 Telescoping mechanism..........................................................424 Control panels....................................................................424 Submenu...........................................................................425 In the settings submenu...........................................................429 9.2.17 Hydraulic system...............................................................431 9.2.18 Houselock......................................................................432 9.2.19 Safe load indicator (SLI)......................................................433 Input elements with displays......................................................433 Display elements..................................................................435 On the front panel................................................................438 9.2.20 Electrical system..............................................................439 9.2.21 Lighting, windscreen wiper/washing system......................................439 Lighting..........................................................................439 Windscreen wiper/ washing system..................................................441 9.2.22 Hand-held control..............................................................442 Sockets for hand- held control....................................................442 Engine control panel..............................................................443 Horn..............................................................................443 Outriggers control panel.........................................................444 9.2.23 Windows, doors, keys...........................................................446 Windows...........................................................................446 Crane cab door....................................................................446 Keys..............................................................................447 9.2.24 Diagnostics....................................................................448 9.3 Short description of the operating elements – driving from the crane cab..............449 9.3.1 Driving submenu.................................................................449 9.3.2 Engine for driving..............................................................450 9.3.3 Transmission....................................................................451 9.3.4 Axle drive......................................................................452 9.3.5 Brakes..........................................................................453 Side panel........................................................................453 ECOS display......................................................................453 9.3.6 Steering........................................................................454 Normal steering...................................................................455 Separate steering.................................................................455 10 Starting/Stopping the engine – for crane operation........................................459 10.1 Starting the engine – from the crane cab.............................................459 10.1.1 CHECKLIST: Starting the engine.................................................459 10.1.2 CHECKLIST: At low temperatures.................................................462 10.1.3 Refueling......................................................................462 10.1.4 Inspections before starting the engine.........................................464 On the hydraulic tank.............................................................464 Battery master switch.............................................................464 Checking the hand-held control....................................................465 10.1.5 Switching on the ignition......................................................465 10.1.6 Lamp test/equalisation of the switching states.................................466 Lamp test.........................................................................466 Equalisation of the switching states..............................................467 10.1.7 Setting the display brightness.................................................468 10.1.8 Starting the engine............................................................469 Without flame start system........................................................469 With flame start system...........................................................470 10.1.9 Inspections after starting the engine..........................................471 10.1.10 Monitoring submenu............................................................472 10.1.11 Setting the idling speed......................................................473 10.2 Starting the engine – with the hand-held control.....................................475 Prerequisites.........................................................................475 Starting the engine...................................................................475 10.3 Turning off the engine...............................................................477 10.3.1 During normal operation, with the ignition lock/with the hand- held control....477 After parking.....................................................................477 10.3.2 In emergencies, with the emergency stop switches...............................478 Resetting the emergency stop switch...............................................478 10.4 Air intake inhibitor.................................................................479 Releasing the air intake inhibitor....................................................479 11 Crane operation............................................................................483 11.1 Before crane operation...............................................................483 11.1.1 CHECKLIST: Inspections prior to crane operation................................483 11.1.2 Checking the condition of the truck crane......................................487 Tank for windscreen washing system................................................487 Visual inspection.................................................................487 Checking the position of the hoist ropes.........................................488 Checking the electrical system...................................................488 11.1.3 Adjusting the crane cab seat and front panel...................................489 Crane cab seat....................................................................489 Front panel.......................................................................490 11.1.4 Checking the safety devices....................................................491 Safe load indicator...............................................................491 Lifting limit switch..............................................................491 Emergency stop switch.............................................................492 Seat contact switch...............................................................493 11.1.5 Load, earthing.................................................................494 11.1.6 Preheating the hydraulic oil...................................................495 11.1.7 Locking/unlocking the turntable................................................496 Locking points....................................................................496 Locking the turntable............................................................497 Unlocking the turntable...........................................................497 11.1.8 Switching the houselock on/off.................................................498 Switching on the houselock........................................................498 Switching off the houselock.......................................................500 11.2 Operation of the safe load indicator.................................................501 11.2.1 Switching on the SLI...........................................................502 Switching on......................................................................502 Lamp test on the SLI..............................................................504 Brightness of the displays........................................................504 11.2.2 Entering the rigging mode......................................................505 Entering the SLIcode.............................................................506 Entering the reeving.............................................................509 Entering individual components....................................................510 11.2.3 Inspections prior to crane operation...........................................513 11.2.4 Displays during crane operation................................................515 Continuous displays..............................................................515 Optional displays.................................................................517 11.2.5 SLI early warning..............................................................519 11.2.6 SLI shutdown...................................................................520 Shutdown due to overload..........................................................520 11.2.7 Error message..................................................................521 11.2.8 SLI override...................................................................522 11.2.9 Displaying and entering the time and date......................................523 Display...........................................................................523 Input.............................................................................524 11.3 Crane operation with main boom.......................................................525 11.3.1 Checks during crane operation..................................................525 Horizontal alignment.............................................................525 Safe distances....................................................................525 Checking the wind speed...........................................................526 11.3.2 Permissible slewing ranges and working positions...............................527 360 slewing range................................................................527 Working position 0 to the rear...................................................527 180 to the front rigging position................................................528 Free-on-wheels working position...................................................528 11.3.3 Main hoist.....................................................................529 Switching on the main hoist.......................................................530 Lifting and lowering.............................................................530 Switching off the main hoist......................................................531 11.3.4 Auxiliary hoist................................................................532 Switching on the auxiliary hoist..................................................532 Lifting and lowering.............................................................533 Switching off the auxiliary hoist.................................................534 11.3.5 Lifting limit switch and lowering limit switch.................................535 Lifting limit switch..............................................................535 Lowering limit switch.............................................................537 11.3.6 Derricking gear................................................................538 Switching on the derricking gear..................................................538 Raising and lowering.............................................................539 Switching off the derricking gear.................................................540 Lowering the main boom to ahorizontal position..................................540 11.3.7 Telescoping mechanism..........................................................541 Overview..........................................................................542 Telescoping process..............................................................542 Assignment for display............................................................544 Fixed length, intermediate length, telescoping length............................546 Telescoping.......................................................................547 Telescoping sequence..............................................................547 Inspections prior to starting operations.........................................548 Switching on the telescoping mechanism...........................................549 Function of the control lever.....................................................549 Switching off the telescoping mechanism...........................................551 Manual telescoping...............................................................552 Checking the initial position....................................................552 Unlocking the telescoping cylinder..............................................555 Extending/ retracting the telescoping cylinder.................................557 Lock telescoping cylinder.........................................................558 Unlocking the telescopic section.................................................559 Telescoping the telescopic section................................................561 Locking the telescopic section...................................................562 Locking the telescopic section for on-road driving...............................563 Telescoping with teleautomation...................................................564 Telescoping the main boom in horizontal position................................568 11.3.8 High-speed mode................................................................569 Switch on function...............................................................569 Derricking gear/ Telescoping mechanism............................................569 Hoists............................................................................570 11.3.9 Slewing gear...................................................................571 Slewing gear brake................................................................571 Switching on the slewing gear.....................................................572 Releasing the slewing gear brake..................................................572 Engaging the slewing gear brake...................................................572 Slewing...........................................................................573 Slewing to 0 or 180 .............................................................575 Braking the slewing movement......................................................576 Slewing gear freewheel...........................................................576 Switching off the slewing gear....................................................577 11.3.10 Possible movement combinations................................................577 11.3.11 Hydraulic oil cooling.........................................................578 11.4 Settings and displays for crane operation............................................579 11.4.1 Inclining the crane cab........................................................579 11.4.2 Setting the idling speed.......................................................579 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................580 11.4.4 Limiting the power unit speeds.................................................580 11.4.5 Setting the characteristic curves for the control levers.......................582 11.4.6 Critical load control..........................................................583 Function..........................................................................583 Switching on andoff..............................................................583 11.4.7 Operation of the directional spotlights........................................584 11.4.8 Displaying the operating hours.................................................585 11.4.9 Warning submenu................................................................586 Meaning of the symbols............................................................586 Exiting the submenu..............................................................589 11.4.10 Error submenu.................................................................589 11.5 Working range limiter................................................................591 11.5.1 Opening the Working range limiter submenu......................................592 11.5.2 Viewing current settings.......................................................592 11.5.3 Entering limit values..........................................................594 Overall height/ Working radius....................................................594 Slewing angle.....................................................................595 Entering objects..................................................................597 11.5.4 Entering limit values/objects manually.........................................600 Limit values......................................................................600 Objects...........................................................................601 11.5.5 Switching monitoring functions on/off..........................................602 11.5.6 Shutdown by working range limiter..............................................603 11.6 Work break...........................................................................605 11.6.1 In case of short work breaks...................................................605 11.6.2 In case of work breaks of more than 8 hours....................................606 To secure the truck crane.........................................................606 11.7 Heating and air-conditioning system..................................................607 11.7.1 Standard heating system........................................................607 Switching on......................................................................607 Heating...........................................................................607 Air distribution..................................................................608 Switching off.....................................................................609 11.7.2 Air-conditioning system........................................................609 Warnings..........................................................................609 Switching on/off..................................................................610 Cooling...........................................................................610 Drying the air....................................................................611 11.7.3 Auxiliary water heating system.................................................611 Preheating the engine.............................................................612 Preheating the crane cab..........................................................612 Switching on......................................................................613 Setting the day and time..........................................................614 Storing the heating start........................................................615 Setting the heating period.......................................................616 Switching heating start on/off....................................................616 Switching off.....................................................................617 Setting the remaining run time....................................................617 11.7.4 Auxiliary air heater...........................................................618 Switching on......................................................................618 Temperature.......................................................................619 Switching off.....................................................................619 Other functions...................................................................619 12 Rigging work...............................................................................623 12.1 Rigging work checklists for crane operation with the main boom.......................623 12.1.1 CHECKLIST: Rigging.............................................................623 12.1.2 CHECKLIST: Unrigging...........................................................627 12.2 Choosing a suitable site.............................................................631 12.2.1 Determining the required ground bearing area...................................631 12.2.2 Safe distance from slopes and pits.............................................634 12.2.3 Earthing the truck crane.......................................................635 12.2.4 Safe distance from electrical cables...........................................636 12.3 Rigging work after driving with a trailer............................................639 12.3.1 Switching off the boom floating position.......................................639 12.3.2 Switching off the slewing gear freewheel.......................................640 Before slewing....................................................................640 12.3.3 Switching off boom pre-tensioning..............................................641 12.4 Connecting/disconnecting the hand-held control.......................................643 12.5 Starting the engine for driving for rigging work.....................................645 12.5.1 Starting/turning off the engine with the hand-held control.....................645 Prerequisites.....................................................................645 Starting the engine...............................................................646 Turning off the engine............................................................646 12.5.2 Starting/turning off the engine from the crane cab.............................647 Prerequisites.....................................................................647 Starting the engine...............................................................647 After starting the engine.........................................................648 Turning off the engine............................................................648 12.6 Outriggers...........................................................................649 12.6.1 CHECKLIST: Extending the outriggers............................................649 12.6.2 CHECKLIST: Retracting the outriggers...........................................651 12.6.3 Permissible outrigger spans....................................................652 12.6.4 Preparing the truck crane......................................................653 In the driver's cab...............................................................653 Outriggers controlunits..........................................................653 12.6.5 Setting the spans..............................................................654 For on-road driving..............................................................656 12.6.6 Extending/retracting outriggers................................................657 From the control units............................................................658 With the hand- held control.......................................................659 From the crane cab................................................................661 12.6.7 Moving the outrigger pads into working/driving position........................663 12.6.8 Enlarging the ground bearing area..............................................664 12.6.9 Extending/retracting supporting cylinders......................................665 From the control units............................................................666 With the hand- held control.......................................................667 From the crane cab................................................................668 12.6.10 Leveling the truck crane on outriggers horizontally...........................670 Inclination indicators...........................................................670 Prerequisites.....................................................................671 Manual alignment..................................................................672 Automatic alignment..............................................................673 12.6.11 Leveling the free-standing truck crane........................................675 12.6.12 Outrigger pressure display....................................................677 12.7 Rigging/unrigging the counterweight..................................................679 12.7.1 Counterweight sections.........................................................679 Basic version.....................................................................679 Additional version1..............................................................680 Additional version2..............................................................680 Additional version3..............................................................681 Additional version4..............................................................681 12.7.2 Identification.................................................................682 12.7.3 Slinging points on the counterweight sections..................................683 12.7.4 CHECKLIST: Rigging the counterweight...........................................685 12.7.5 CHECKLIST: Unrigging the counterweight.........................................687 12.7.6 Assembling counterweight combination...........................................689 Combinations on the turntable.....................................................690 Setting down the 2.5 t base plate.................................................691 Combinations for the basic version................................................693 Combinations with additional equipment............................................698 12.7.7 Counterweight hoist unit.......................................................709 Counterweight submenu.............................................................709 Extending/ retracting the lifting cylinders.....................................710 Locking/Unlocking counterweight...................................................712 12.7.8 Mounting/Dismounting the counterweight on the turntable........................713 Mounting..........................................................................713 Dismounting.......................................................................715 12.7.9 Assembling counterweight sections for driving the truck crane..................717 12.7.10 Slewing with rigged counterweight.............................................719 12.8 Rigging work on the main boom........................................................721 12.8.1 Hook block on the bumper.......................................................721 Picking up the hook block.........................................................721 Attaching the hook block..........................................................722 12.8.2 Hook block on a separate vehicle...............................................723 Picking up the hook block.........................................................724 Setting down the hook block.......................................................724 12.8.3 Reeving and unreeving the hoist rope...........................................726 Fastening the rope end clamp......................................................726 Reeving the hoist rope............................................................728 Unreeving hoist rope..............................................................731 12.8.4 Possible reeving methods on the main boom......................................732 With 8 head sheaves...............................................................732 12.8.5 Installing/removing the lifting limit switch...................................736 Installing the lifting limit switch..............................................736 Removing the lifting limit switch................................................739 12.8.6 Locking/Unlocking the lifting limit switch.....................................740 Locking...........................................................................740 Removing the lock.................................................................741 12.8.7 Anemometer and air traffic control light.......................................742 Mounting..........................................................................742 Dismounting.......................................................................743 12.9 Other rigging work...................................................................745 12.9.1 Rigging in free on wheels working position.....................................745 12.9.2 Mirror for crane operation.....................................................747 13 Driving with a rigged truck crane..........................................................751 13.1 Driving route........................................................................753 13.2 Before driving the rigged truck crane................................................753 13.2.1 check the tyre pressure and the wind speed.....................................753 13.3 Permissible rigging modes and axle loads.............................................755 13.3.1 Axle loads.....................................................................755 13.3.2 To drive without a load........................................................755 13.3.3 To drive with a load...........................................................756 13.4 Driving from the driver's cab........................................................757 13.4.1 Preparing to drive.............................................................757 Transmission......................................................................757 Switching on separate steering....................................................757 Connections.......................................................................757 13.4.2 While driving..................................................................758 13.5 Driving from the crane cab...........................................................759 13.5.1 Preparing to drive.............................................................759 13.5.2 Opening/closing the Driving mode submenu.......................................760 Automatic.........................................................................760 Manual............................................................................762 Closing...........................................................................762 13.5.3 Starting/turning off the engine for driving....................................763 Starting the engine...............................................................763 Turning off the engine............................................................764 13.5.4 Steering.......................................................................764 Switching on......................................................................764 Adjusting the steering direction..................................................764 Displays when steering............................................................765 Normal steering...................................................................765 Separate steering.................................................................766 13.5.5 Operating the transmission.....................................................767 Driving direction.................................................................768 Selecting the gear position.......................................................768 13.5.6 Starting.......................................................................769 13.5.7 While driving..................................................................769 13.5.8 Warning messages...............................................................770 13.5.9 Possible connections...........................................................771 Longitudinal/ transverse differential locks......................................772 13.5.10 After driving.................................................................773 13.6 Driving in combined operation........................................................775 13.6.1 Switching combined operation on/off............................................775 Prerequisites.....................................................................775 Switching on......................................................................776 Switching off.....................................................................776 13.6.2 Starting/turning off the engine................................................777 13.6.3 Preparing to drive.............................................................778 Transmission......................................................................778 Switching on separate steering...................................................778 Connections.......................................................................778 13.6.4 While driving..................................................................779 Without load......................................................................779 With load.........................................................................780 14 Malfunctions during crane operation........................................................783 14.1 Emergency stop switch................................................................783 14.2 What to do when malfunctions occur during craneoperation............................785 Load can be lowered..................................................................785 Load cannot be lowered................................................................785 14.3 Fuses................................................................................787 Information on replacing fuses........................................................787 14.3.1 Fuses on the turntable.........................................................788 Fuse groups F1/F2/F3..............................................................788 Fuses on the circuit board.......................................................789 14.3.2 Fuses in the crane cab.........................................................790 14.3.3 Fuses in the battery box.......................................................792 14.3.4 SLI fuses......................................................................793 14.4 Finding and eliminating malfunctions.................................................795 14.4.1 Malfunctions on the engine.....................................................795 14.4.2 Malfunctions on the main hoist/auxiliary hoist.................................797 14.4.3 Malfunctions on the derricking gear............................................798 14.4.4 Malfunctions in the telescoping mechanism......................................799 Telescoping mechanism error messages..............................................801 14.4.5 Malfunctions on the slewing gear...............................................802 14.4.6 Malfunctions on the counterweight hoist unit...................................803 14.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................804 14.4.8 Malfunctions when inclining the crane cab......................................804 14.4.9 Malfunctions when operating with the hand-held control.........................804 14.4.10 Malfunctions when driving from the crane cab..................................805 14.4.11 Malfunctions of the outriggers................................................806 14.4.12 Troubleshooting the SLI.......................................................807 General malfunctions.............................................................807 Error messages....................................................................808 Table of error codes..............................................................810 Switching off the sensor/tachogenerator..........................................813 14.4.13 Malfunctions ECOS – superstructure............................................814 ECOS program version..............................................................814 General malfunctions.............................................................814 Error messages....................................................................815 Exiting the submenu...............................................................816 14.5 Emergency operations and programs....................................................817 14.5.1 Mechanical emergency operation for retracting..................................818 Prior to the emergency operation, check...........................................818 Procedure.........................................................................818 Mechanical emergency operation....................................................819 14.5.2 Telescoping emergency program..................................................821 Starting the emergency program....................................................821 Determining the type of error.....................................................822 If there is an error on the length indicator......................................823 If there is an error at a proximity switch........................................827 Terminating the emergency program.................................................828 Tables for approaching the locking points.........................................829 14.5.3 Entering the current telescoping...............................................831 14.5.4 Emergency operation with the hand-held control.................................833 Preparations......................................................................833 Operating a power unit............................................................834 Stopping movements...............................................................836 Stopping movements in emergencies................................................836 Turning off the engine............................................................836 14.5.5 Switching on emergency operation in coolant circuit............................837 14.6 Hydraulic emergency operation........................................................839 14.6.1 Operating principle............................................................839 14.6.2 Connecting/Disconnecting hoses.................................................840 Establishing connections.........................................................840 Disconnecting connections.........................................................841 14.6.3 Switching emergency operation on/off...........................................842 14.6.4 Establishing the hydraulic circuits required...................................843 Switching over valves.............................................................843 For lifting/ lowering............................................................845 For slewing.......................................................................846 14.6.5 Carrying out emergency operation...............................................847 Lifting/Lowering in emergency mode................................................847 Slewing in emergency mode.........................................................848 Raising/Lowering in emergency mode................................................849 14.6.6 After emergency operation......................................................850 Switch off emergency operation....................................................850 Switch over to crane operation....................................................850 Disconnecting the hoses.........................................................850 14.6.7 Emergency supply of another crane..............................................851 For emergency supply..............................................................851 After emergency supply............................................................851 15 Index......................................................................................855 A.........................................................................................857 B.........................................................................................857 C.........................................................................................857 D.........................................................................................859 E.........................................................................................861 F.........................................................................................863 H.........................................................................................863 I.........................................................................................864 K.........................................................................................864 L.........................................................................................864 M.........................................................................................865 O.........................................................................................866 P.........................................................................................867 R.........................................................................................867 S.........................................................................................868 T.........................................................................................869 V.........................................................................................871 W.........................................................................................871
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