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Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112574 – PDF DOWNLOAD
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Description
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112574 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112574 – PDF DOWNLOAD
Language : English
Pages : 882
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
Contact us: [email protected]
DESCRIPTION:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112574 – 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.
TABLE OF CONTENTS:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3112574 – PDF DOWNLOAD
Additional pages.............................................................................. 3 Auxiliary air heater...................................................................... 3 Switching on.......................................................................... 4 Setting the heating level............................................................. 5 Setting the day and time.............................................................. 6 Setting the preselection time......................................................... 6 Deleting preselection times........................................................... 8 Switching off......................................................................... 9 1 Overview.................................................................................... 15 1.1 Accidents............................................................................. 15 1.2 Branches.............................................................................. 15 1.2.1 Crane Care...................................................................... 15 1.2.2 Dealer list..................................................................... 17 1.3 Warranty specifications............................................................... 18 1.4 Terms used............................................................................ 20 1.5 Technical data........................................................................ 23 1.5.1 Maximum lifting capacity (DIN/ ISO/ EN)......................................... 23 1.5.2 Maximum lifting capacity (ASME B 30.5).......................................... 23 1.5.3 Dimensions and weights of the truck crane, axle loads........................... 24 Dimensions........................................................................ 25 Weight and axle loads............................................................. 25 1.5.4 Dimensions and weights of removable parts....................................... 26 Spare wheel....................................................................... 26 Outriggers........................................................................ 26 Main boom......................................................................... 27 Hook blocks and hook tackle....................................................... 27 Counterweight parts.............................................................. 28 1.5.5 Carrier......................................................................... 29 Engine............................................................................ 29 Gearing........................................................................... 29 Transfer case..................................................................... 29 Axle lines........................................................................ 29 Steering.......................................................................... 29 Tyres............................................................................. 30 Outriggers........................................................................ 30 Electrical system................................................................. 31 Tools............................................................................. 31 Towing coupling.................................................................. 31 Driving speeds.................................................................... 31 Climbing ability.................................................................. 31 Turning circle radiuses........................................................... 32 1.5.6 Superstructure.................................................................. 32 Engine............................................................................ 32 Main hoist........................................................................ 33 Auxiliary hoist................................................................... 33 Slewing gears..................................................................... 33 Derricking gear................................................................... 34 Main boom......................................................................... 34 Lattice extension................................................................. 34 Operating speeds.................................................................. 34 1.6 Documentation supplied................................................................ 35 1.7 Information about the operating instructions.......................................... 37 1.7.1 What do the symbols used mean?.................................................. 37 1.7.2 How are the operating instructions structured?.................................. 39 Division.......................................................................... 39 Structure of the chapters......................................................... 39 Structure of the pages............................................................ 40 1.7.3 How do I find the information I need?........................................... 41 Cross-references example.......................................................... 42 1.7.4 What information is available for operations planning?.......................... 44 1.8 Conversion table for US measurements.................................................. 45 1.9 Training information.................................................................. 47 1.10 Identification....................................................................... 48 1.11 EC Declaration of Conformity......................................................... 50 2 Basic safety instructions................................................................... 53 2.1 Intended use.......................................................................... 53 2.1.1 Improper use.................................................................... 54 2.2 Organisational measures............................................................... 55 2.3 Qualifications of the personnel....................................................... 57 2.4 Safety instructions for driving the truck crane....................................... 58 2.5 Safety instructions for crane operation............................................... 58 3 Operating elements for driving.............................................................. 63 3.1 Overview of the operating elements.................................................... 63 3.1.1 On the outside of the truck crane............................................... 64 3.1.2 Driver's cab.................................................................... 66 Overview.......................................................................... 66 Behind the cover.................................................................. 68 3.1.3 Instrument panel................................................................ 69 Left/right........................................................................ 69 Middle............................................................................ 70 3.1.4 Display, driver's cab........................................................... 72 3.1.5 Steering column/steering wheel.................................................. 73 3.1.6 Transmission operating elements................................................. 74 3.1.7 Tachograph...................................................................... 75 3.1.8 ECOS control unit............................................................... 76 3.1.9 ECOS display – main menu........................................................ 78 3.1.10 ECOS display – submenus........................................................ 80 Level adjustment system submenu................................................... 80 Settings submenu.................................................................. 82 Operating hours submenu........................................................... 83 Warning submenu................................................................... 83 Transmission emergency program submenu............................................ 84 Error submenu..................................................................... 85 3.1.11 Heating/Air-conditioning system................................................ 86 Standard heating system........................................................... 86 Auxiliary heater.................................................................. 87 3.1.12 Sockets for hand-held control.................................................. 88 3.1.13 Outrigger control units........................................................ 89 3.2 Short description of the operating elements........................................... 91 3.2.1 Definition of information relating to directions of movement.................... 91 Basic rule........................................................................ 91 Switches and buttons.............................................................. 92 3.2.2 General information on the operating elements................................... 92 3.2.3 General rules for buttons and symbols on the display............................ 93 3.2.4 Engine.......................................................................... 94 Steering column................................................................... 94 Multipurpose switch............................................................... 94 Instrument panel.................................................................. 95 Main menu......................................................................... 96 3.2.5 Electrical system............................................................... 97 3.2.6 ECOS crane control.............................................................. 97 Control unit...................................................................... 97 3.2.7 Transmission....................................................................100 Transmission display..............................................................100 ECOS display......................................................................100 Operating elements................................................................101 Instrument panel..................................................................102 3.2.8 Transfer case...................................................................103 3.2.9 Axle drive......................................................................104 3.2.10 Brakes.........................................................................105 Service brake.....................................................................105 Parking brake.....................................................................106 Additional brakes.................................................................107 3.2.11 Steering/separate steering.....................................................108 ECOS display......................................................................108 Driver's door.....................................................................108 3.2.12 Suspension.....................................................................109 3.2.13 Lighting/windscreen wipers/horn................................................110 Steering column...................................................................110 Instrument panel..................................................................110 Roof..............................................................................112 3.2.14 Level adjustment system........................................................112 3.2.15 Tachograph/speedometer.........................................................114 Tachograph........................................................................114 Speedometer.......................................................................114 3.2.16 Diagnostics....................................................................115 Displays/ submenu.................................................................115 3.2.17 On-board computer..............................................................116 3.2.18 Push-up roof...................................................................118 3.2.19 Windows, doors, keys...........................................................118 Window winder.....................................................................118 Doors.............................................................................119 Keys..............................................................................119 3.2.20 Front flap.....................................................................120 4 Starting/turning off the engine for driving.................................................123 4.1 Starting the engine from the driver's cab.............................................123 4.1.1 CHECKLIST: Starting the engine..................................................123 4.1.2 CHECKLIST: At low temperatures..................................................126 4.1.3 Ladders and access ladders......................................................127 Access ladders....................................................................127 Ladders...........................................................................127 4.1.4 Refueling.......................................................................129 4.1.5 Inspections before starting the engine..........................................130 On the hydraulic tank.............................................................130 Battery master switch.............................................................130 Checking the hand-held control....................................................131 4.1.6 Switch on the ignition..........................................................131 4.1.7 Lamp test/equalisation of the switching states..................................132 Lamp test.........................................................................132 Equalisation of the switching states..............................................133 4.1.8 Display – setting the brightness................................................134 4.1.9 Starting the engine.............................................................135 Without flame start system........................................................136 With flame start system...........................................................137 4.1.10 Inspections after starting the engine..........................................138 4.1.11 Monitoring elements............................................................139 Instrument panel..................................................................139 ECOS display......................................................................140 Driving display...................................................................140 4.1.12 Setting the idling speed.......................................................141 4.2 Turning off the engine................................................................143 4.2.1 On the ignition lock/with hand-held control.....................................143 After parking.....................................................................143 4.2.2 With emergency stop switches....................................................144 Resetting the emergency stop switch...............................................144 4.3 Air intake inhibitor..................................................................145 Releasing the air intake inhibitor....................................................145 5 Driving.....................................................................................149 5.1 Before driving........................................................................149 5.1.1 CHECKLIST: Checks before on-road driving........................................149 5.1.2 Checking the condition of the truck crane.......................................154 Windscreen washing system........................................................154 Electrical system.................................................................154 Adjusting the mirrors.............................................................155 Warning plates for vehicle width..................................................156 Displaying the vehicle height.....................................................156 Supply pressure...................................................................157 Parking brake.....................................................................158 5.1.3 Adjusting the seat and the steering column......................................159 Driver's seat.....................................................................159 Passenger's seat..................................................................160 Adjusting the steering column.....................................................161 5.1.4 Switching the suspension on/off.................................................162 Opening the submenu...............................................................162 Switching on the suspension.......................................................163 Switching off the suspension......................................................163 5.1.5 Adjusting the tachograph........................................................164 Prerequisites.....................................................................164 In the event of malfunctions......................................................164 Adjusting the tachograph..........................................................165 Additional displays...............................................................168 5.1.6 Displaying the operating hours..................................................169 5.1.7 Settings/displays with the on-board computer....................................171 Operation.........................................................................171 Overview..........................................................................172 Inspection information............................................................172 Error information.................................................................173 Alarm clock.......................................................................173 Language..........................................................................174 Settings..........................................................................174 Diagnostics.......................................................................175 5.2 Operating the transmission............................................................177 5.2.1 Switching on....................................................................177 5.2.2 Switching the transmission to neutral position..................................178 5.2.3 Changing the operating mode.....................................................178 Change-over to automatic mode.....................................................178 Change-over to manual mode........................................................178 5.2.4 Display of the selected gears...................................................179 5.2.5 Selecting the direction of travel and starting gear.............................179 Selecting the driving direction...................................................179 Selecting the starting gear.......................................................180 5.2.6 Starting........................................................................181 5.2.7 Driving and changing gears......................................................182 In automatic operating mode......................................................182 In manual operating mode.........................................................183 5.2.8 Changing the driving direction..................................................184 Quick change of gear..............................................................184 5.2.9 Stopping........................................................................185 Stopping for a long period of time................................................185 5.2.10 On the roller type dynamometer.................................................185 5.3 Driving and turning off the truck crane...............................................187 5.3.1 Checks while driving............................................................187 Immediately after you start to move...............................................187 While driving.....................................................................188 Switching on......................................................................189 Switching off.....................................................................190 5.3.3 Temposet........................................................................191 Switching on......................................................................191 Switching off.....................................................................191 5.3.4 Driving downhill................................................................192 Starting..........................................................................192 Checks when driving downhill.....................................................192 Downshifting......................................................................193 Additional brakes.................................................................194 5.3.5 Driving uphill..................................................................195 Starting..........................................................................195 Driving...........................................................................195 5.3.6 Warning submenu.................................................................196 Meaning of the symbols............................................................196 Exiting the submenu...............................................................197 5.3.7 Error submenu...................................................................198 5.3.8 Messages on the On-board computer display.......................................198 Warnings..........................................................................199 Warning messages..................................................................200 Error messages....................................................................201 Information.......................................................................203 5.3.9 Turning off the truck crane.....................................................206 Secure against rolling away.......................................................206 When stationary for more than 8hours.............................................207 5.4 Off-road driving......................................................................209 Adjustments to the transmission.......................................................209 Connections...........................................................................209 Changing the vehicle level............................................................209 Rocking the vehicle free and towing...................................................209 5.4.1 Transfer case – off-road gear on/off............................................210 Prerequisites.....................................................................210 Einschalten.......................................................................210 Switching off.....................................................................211 Neutral position..................................................................211 5.4.2 Longitudinal and transverse differential locks..................................212 5.4.3 Operating the level adjustment system...........................................214 Opening the submenu..............................................................214 Setting the on-road level.........................................................215 Pre-selecting suspension struts...................................................215 Changing the vehicle level........................................................216 Viewing the current inclination...................................................216 Exiting the submenu...............................................................217 5.4.4 Freeing the truck crane stuck in terrain........................................218 Rocking the truck crane free......................................................218 Towing free forward..............................................................219 Towing free to the rear...........................................................219 5.4.5 Separate steering...............................................................220 Switching to separate steering....................................................220 Steering..........................................................................221 Switching to normal steering mode.................................................222 5.5 Heating and air-conditioning system...................................................223 5.5.1 Standard heating system.........................................................223 Switching on......................................................................223 Heating...........................................................................223 Air distribution..................................................................224 Examples..........................................................................225 Switching off.....................................................................225 5.5.2 Air-conditioning system.........................................................226 Warnings..........................................................................226 Switching on/off..................................................................226 Cooling...........................................................................227 Drying............................................................................227 5.5.3 Auxiliary heater................................................................228 Switching on......................................................................228 Temperature.......................................................................229 Setting the day and time..........................................................229 Storing the heating start........................................................230 Setting the heating period.......................................................231 Switching the heating start on and off............................................231 Switching off.....................................................................232 Setting the remaining run time...................................................232 5.6 Towing a trailer......................................................................233 Effects on the axle loads.............................................................233 Coupling the trailer..................................................................234 Connecting the supply lines...........................................................235 Removing supply lines.................................................................236 Uncoupling the trailer................................................................236 Checking the braking force...........................................................238 6 Driving modes...............................................................................241 6.1 Driving modes.........................................................................241 Information about the axle loads......................................................241 6.1.1 Information on how to use the tables............................................242 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs).............................243 For 14.00 R25 tyres...............................................................243 For 16.00 R25 tyres...............................................................244 For 20.5 R25 tyres...............................................................245 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)............246 6.2 Rigging work for driving with a trailer...............................................247 6.2.1 Switching on the slewing gear freewheel.........................................248 Switching on boom floating position...............................................249 6.2.2 Switching on boom pre-tensioning................................................250 6.2.3 Switching the superstructure driving lights on/off..............................252 Switching off.....................................................................252 Switching on......................................................................252 6.3 Rigging the main boom.................................................................253 Additional equipment required.........................................................253 6.3.1 CHECKLIST: Removing the main boom...............................................254 Prerequisites.....................................................................254 Checklist.........................................................................254 6.3.2 CHECKLIST: Mounting the main boom...............................................257 Prerequisites.....................................................................257 Checklist.........................................................................257 6.3.3 Slinging the main boom..........................................................260 6.3.4 Removing/attaching the clamp....................................................261 6.3.5 Hydraulic connection for the lattice extension..................................262 6.3.6 Switching the pressure relief on/off............................................263 6.3.7 Retracting/fitting the derricking cylinder head pin.............................264 Retracting the derricking cylinder head axle.....................................265 Fitting the derricking cylinder head axle........................................266 6.3.8 Retracting/extending the boom pivot pin.........................................267 Before retracting.................................................................267 After extension...................................................................267 Retracting/ extending the pivot pin...............................................268 6.3.9 Disconnecting the hydraulic/electrical connections..............................269 Lifting in front of the turntable.................................................269 Disconnecting.....................................................................270 6.3.10 Establishing the hydraulic/electrical connection...............................271 Lifting onto the turntable........................................................271 Establishing......................................................................272 6.3.11 Aligning the connecting points.................................................273 6.3.12 Securing/releasing the derricking cylinder.....................................273 6.3.13 Transporting the main boom.....................................................274 6.3.14 Inspections after main boom mounting...........................................275 7 Malfunctions in driving mode................................................................279 7.1 Emergency stop switch.................................................................279 7.2 What to do when a malfunction occurs in road traffic..................................281 7.3 Towing the truck crane................................................................283 7.3.1 Towing in the event of engine or transmission damage............................284 Compressed-air supply.............................................................284 Electric power supply.............................................................284 On the transmission..............................................................285 Axle drives.......................................................................286 Transfer case.....................................................................286 Parking brake.....................................................................286 Towing the truck crane out of the danger area.....................................287 7.3.2 Tow starting....................................................................288 7.4 Wheels and tyres......................................................................289 7.4.1 Wheel change....................................................................289 Removing a damaged wheel.........................................................290 On the spare wheel holder.........................................................290 Mounting a wheel..................................................................291 7.4.2 Filling the tyres yourself......................................................293 Connecting the filling hose.......................................................293 Filling the tyres.................................................................294 Removing the filling hose........................................................294 7.5 Fuses.................................................................................295 Information on replacing fuses........................................................295 7.5.1 Fuses in the driver's cab.......................................................296 F1 to F 41........................................................................296 A1 to A3..........................................................................298 7.5.2 Fuses in the battery box........................................................300 7.6 Troubleshooting.......................................................................301 7.6.1 Malfunctions on the engine......................................................301 7.6.2 Malfunctions to the transmission................................................303 7.6.3 Malfunctions of the transfer case...............................................304 7.6.4 Malfunctions of the service brake...............................................304 7.6.5 Malfunctions of the steering....................................................305 7.6.6 Differential lock malfunctions..................................................306 7.6.7 Malfunctions in the hydraulic system/hydraulic oil cooler.......................306 7.6.8 Malfunctions on the suspension..................................................307 7.6.9 Malfunctions of the level adjustment system.....................................307 7.6.10 Malfunctions on the ECOS carrier...............................................308 ECOS program version..............................................................308 General malfunctions.............................................................308 Error messages....................................................................309 Exiting the submenu..............................................................310 On the control units..............................................................311 7.7 Procedure in the event of malfunctions................................................313 7.7.1 Switching on emergency operation in coolant circuit.............................313 7.7.2 Procedure in the event of malfunctions to the transmission andengine...........314 Engine............................................................................314 Transmission......................................................................315 Transmission emergency program submenu..........................................316 Emergency compressed air supply...................................................319 ID number of the transmission.....................................................321 8 Index.......................................................................................325 A.........................................................................................327 B.........................................................................................327 C.........................................................................................327 D.........................................................................................329 E.........................................................................................331 F.........................................................................................333 H.........................................................................................333 I.........................................................................................334 K.........................................................................................334 L.........................................................................................334 M.........................................................................................335 O.........................................................................................336 P.........................................................................................337 R.........................................................................................337 S.........................................................................................338 T.........................................................................................339 V.........................................................................................341 W.........................................................................................341 Additional pages..............................................................................347 Auxiliary air heater......................................................................347 Switching on..........................................................................348 Setting the heating level.............................................................349 Setting the day and time..............................................................350 Setting the preselection time.........................................................350 Deleting preselection times...........................................................352 Switching off.........................................................................353 9 Operating elements for crane operation......................................................359 9.1 Overview of the operating elements....................................................359 9.1.1 On the outside of the truck crane...............................................360 9.1.2 Crane cab.......................................................................362 9.1.3 Front panel.....................................................................364 9.1.4 Side panel......................................................................365 Bottom............................................................................365 Top...............................................................................366 Rear panel........................................................................368 Standard heating system...........................................................369 Auxiliary water heating system....................................................370 Auxiliary air heater..............................................................371 9.1.5 Control panels..................................................................372 Left..............................................................................372 Right.............................................................................373 9.1.6 Control lever assignment........................................................374 Version 1.........................................................................374 Version 2.........................................................................375 9.1.7 ECOS control unit...............................................................376 9.1.8 ECOS display – main menu........................................................378 9.1.9 ECOS display – submenus.........................................................380 Counterweight submenu.............................................................380 Slewing gear/ Houselock submenu..................................................381 Outriggers submenu...............................................................382 Telescoping submenu..............................................................384 Submenu Power unit speed..........................................................386 Monitoring submenu...............................................................387 Settings submenu..................................................................388 Submenu Operating hours..........................................................390 Submenu Warning..................................................................391 Error submenu.....................................................................393 Working range limiter submenu.....................................................394 Driving submenu...................................................................396 9.1.10 SLI control unit...............................................................398 9.1.11 Hand-held control..............................................................402 Outriggers control panel.........................................................403 9.1.12 Outriggers control units.......................................................404 Outriggers........................................................................405 Outrigger pressure display.......................................................405 Inclination indicator............................................................405 9.2 Short description of the operating elements...........................................407 9.2.1 Definition of information relating to directions of movement....................407 Basic rule........................................................................407 Switch............................................................................407 9.2.2 General rules for buttons and symbols on the display............................408 9.2.3 Engine for crane operation......................................................409 Side panel........................................................................409 Rear panel........................................................................410 ECOS display......................................................................410 9.2.4 Engine for driving..............................................................410 Side panel........................................................................410 Main menu.........................................................................410 Outriggers submenu...............................................................411 9.2.5 Seat contact switch and dead man's switch.......................................412 9.2.6 ECOS crane control..............................................................413 Control unit......................................................................413 9.2.7 Outriggers......................................................................416 Hand-held control.................................................................416 In the Outriggers submenu.........................................................417 In the settings submenu...........................................................418 On the Outriggers control units...................................................419 9.2.8 Inclination indicators..........................................................421 9.2.9 Outrigger pressure displays.....................................................422 Outriggers submenu...............................................................422 Outriggers control units.........................................................422 9.2.10 Anemometer display.............................................................422 9.2.11 Counterweight submenu..........................................................423 Counterweight submenu.............................................................423 9.2.12 Main hoist.....................................................................425 9.2.13 Auxiliary hoist................................................................427 9.2.14 Slewing gear...................................................................428 Submenu...........................................................................429 9.2.15 Derricking gear................................................................431 9.2.16 Telescoping mechanism..........................................................432 Control panels....................................................................432 Submenu...........................................................................433 In the settings submenu...........................................................437 9.2.17 Hydraulic system...............................................................439 9.2.18 Houselock......................................................................440 9.2.19 Safe load indicator (SLI)......................................................441 Input elements with displays......................................................441 Display elements..................................................................443 On the front panel................................................................446 9.2.20 Electrical system..............................................................447 9.2.21 Lighting, windscreen wiper/washing system......................................447 Lighting..........................................................................447 Windscreen wiper/ washing system..................................................449 9.2.22 Hand-held control..............................................................450 Sockets for hand- held control....................................................450 Engine control panel..............................................................451 Horn..............................................................................451 Outriggers control panel.........................................................452 9.2.23 Windows, doors, keys...........................................................454 Windows...........................................................................454 Crane cab door....................................................................454 Keys..............................................................................455 9.2.24 Diagnostics....................................................................456 9.3 Short description of the operating elements – driving from the crane cab..............457 9.3.1 Driving submenu.................................................................457 9.3.2 Engine for driving..............................................................458 9.3.3 Transmission....................................................................459 9.3.4 Axle drive......................................................................460 9.3.5 Brakes..........................................................................461 Side panel........................................................................461 ECOS display......................................................................461 9.3.6 Steering........................................................................462 Normal steering...................................................................463 Separate steering.................................................................463 10 Starting/Stopping the engine – for crane operation........................................467 10.1 Starting the engine – from the crane cab.............................................467 10.1.1 CHECKLIST: Starting the engine.................................................467 10.1.2 CHECKLIST: At low temperatures.................................................470 10.1.3 Refueling......................................................................470 10.1.4 Inspections before starting the engine.........................................472 On the hydraulic tank.............................................................472 Battery master switch.............................................................472 Checking the hand-held control....................................................473 10.1.5 Switching on the ignition......................................................473 10.1.6 Lamp test/equalisation of the switching states.................................474 Lamp test.........................................................................474 Equalisation of the switching states..............................................475 10.1.7 Setting the display brightness.................................................476 10.1.8 Starting the engine............................................................477 Without flame start system........................................................477 With flame start system...........................................................478 10.1.9 Inspections after starting the engine..........................................479 10.1.10 Monitoring submenu............................................................480 10.1.11 Setting the idling speed......................................................481 10.2 Starting the engine – with the hand-held control.....................................483 Prerequisites.........................................................................483 Starting the engine...................................................................483 10.3 Turning off the engine...............................................................485 10.3.1 During normal operation, with the ignition lock/with the hand- held control....485 After parking.....................................................................485 10.3.2 In emergencies, with the emergency stop switches...............................486 Resetting the emergency stop switch...............................................486 10.4 Air intake inhibitor.................................................................487 Releasing the air intake inhibitor....................................................487 11 Crane operation............................................................................491 11.1 Before crane operation...............................................................491 11.1.1 CHECKLIST: Inspections prior to crane operation................................491 11.1.2 Checking the condition of the truck crane......................................495 Tank for windscreen washing system................................................495 Visual inspection.................................................................495 Checking the position of the hoist ropes.........................................496 Checking the electrical system...................................................496 11.1.3 Adjusting the crane cab seat and front panel...................................497 Crane cab seat....................................................................497 Front panel.......................................................................498 11.1.4 Checking the safety devices....................................................499 Safe load indicator...............................................................499 Lifting limit switch..............................................................499 Emergency stop switch.............................................................500 Seat contact switch...............................................................501 11.1.5 Load, earthing.................................................................502 11.1.6 Preheating the hydraulic oil...................................................503 11.1.7 Locking/unlocking the turntable................................................504 Locking points....................................................................504 Locking the turntable............................................................505 Unlocking the turntable...........................................................505 11.1.8 Switching the houselock on/off.................................................506 Switching on the houselock........................................................506 Switching off the houselock.......................................................508 11.2 Operation of the safe load indicator.................................................509 11.2.1 Switching on the SLI...........................................................510 Switching on......................................................................510 Lamp test on the SLI..............................................................512 Brightness of the displays........................................................512 11.2.2 Entering the rigging mode......................................................513 Entering the SLIcode.............................................................514 Entering the reeving.............................................................517 Entering individual components....................................................518 11.2.3 Inspections prior to crane operation...........................................521 11.2.4 Displays during crane operation................................................523 Continuous displays..............................................................523 Optional displays.................................................................525 11.2.5 SLI early warning..............................................................527 11.2.6 SLI shutdown...................................................................528 Shutdown due to overload..........................................................528 11.2.7 Error message..................................................................529 11.2.8 SLI override...................................................................530 11.2.9 Displaying and entering the time and date......................................531 Display...........................................................................531 Input.............................................................................532 11.3 Crane operation with main boom.......................................................533 11.3.1 Checks during crane operation..................................................533 Horizontal alignment.............................................................533 Safe distances....................................................................533 Checking the wind speed...........................................................534 11.3.2 Permissible slewing ranges and working positions...............................535 360 slewing range................................................................535 Working position 0 to the rear...................................................535 180 to the front rigging position................................................536 Free-on-wheels working position...................................................536 11.3.3 Main hoist.....................................................................537 Switching on the main hoist.......................................................538 Lifting and lowering.............................................................538 Switching off the main hoist......................................................539 11.3.4 Auxiliary hoist................................................................540 Switching on the auxiliary hoist..................................................540 Lifting and lowering.............................................................541 Switching off the auxiliary hoist.................................................542 11.3.5 Lifting limit switch and lowering limit switch.................................543 Lifting limit switch..............................................................543 Lowering limit switch.............................................................545 11.3.6 Derricking gear................................................................546 Switching on the derricking gear..................................................546 Raising and lowering.............................................................547 Switching off the derricking gear.................................................548 Lowering the main boom to ahorizontal position..................................548 11.3.7 Telescoping mechanism..........................................................549 Overview..........................................................................550 Telescoping process..............................................................550 Assignment for display............................................................552 Fixed length, intermediate length, telescoping length............................554 Telescoping.......................................................................555 Telescoping sequence..............................................................555 Inspections prior to starting operations.........................................556 Switching on the telescoping mechanism...........................................557 Function of the control lever.....................................................557 Switching off the telescoping mechanism...........................................559 Manual telescoping...............................................................560 Checking the initial position....................................................560 Unlocking the telescoping cylinder..............................................563 Extending/ retracting the telescoping cylinder.................................565 Lock telescoping cylinder.........................................................566 Unlocking the telescopic section.................................................567 Telescoping the telescopic section................................................569 Locking the telescopic section...................................................570 Locking the telescopic section for on-road driving...............................571 Telescoping with teleautomation...................................................572 Telescoping the main boom in horizontal position................................576 11.3.8 High-speed mode................................................................577 Switch on function...............................................................577 Derricking gear/ Telescoping mechanism............................................577 Hoists............................................................................578 11.3.9 Slewing gear...................................................................579 Slewing gear brake................................................................579 Switching on the slewing gear.....................................................580 Releasing the slewing gear brake..................................................580 Engaging the slewing gear brake...................................................580 Slewing...........................................................................581 Slewing to 0 or 180 .............................................................583 Braking the slewing movement......................................................584 Slewing gear freewheel...........................................................584 Switching off the slewing gear....................................................585 11.3.10 Possible movement combinations................................................585 11.3.11 Hydraulic oil cooling.........................................................586 11.4 Settings and displays for crane operation............................................587 11.4.1 Inclining the crane cab........................................................587 11.4.2 Setting the idling speed.......................................................587 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................588 11.4.4 Limiting the power unit speeds.................................................588 11.4.5 Setting the characteristic curves for the control levers.......................590 11.4.6 Critical load control..........................................................591 Function..........................................................................591 Switching on andoff..............................................................591 11.4.7 Operation of the directional spotlights........................................592 11.4.8 Displaying the operating hours.................................................593 11.4.9 Warning submenu................................................................594 Meaning of the symbols............................................................594 Exiting the submenu..............................................................597 11.4.10 Error submenu.................................................................597 11.5 Working range limiter................................................................599 11.5.1 Opening the Working range limiter submenu......................................600 11.5.2 Viewing current settings.......................................................600 11.5.3 Entering limit values..........................................................602 Overall height/ Working radius....................................................602 Slewing angle.....................................................................603 Entering objects..................................................................605 11.5.4 Entering limit values/objects manually.........................................608 Limit values......................................................................608 Objects...........................................................................609 11.5.5 Switching monitoring functions on/off..........................................610 11.5.6 Shutdown by working range limiter..............................................611 11.6 Work break...........................................................................613 11.6.1 In case of short work breaks...................................................613 11.6.2 In case of work breaks of more than 8 hours....................................614 To secure the truck crane.........................................................614 11.7 Heating and air-conditioning system..................................................615 11.7.1 Standard heating system........................................................615 Switching on......................................................................615 Heating...........................................................................615 Air distribution..................................................................616 Switching off.....................................................................617 11.7.2 Air-conditioning system........................................................617 Warnings..........................................................................617 Switching on/off..................................................................618 Cooling...........................................................................618 Drying the air....................................................................619 11.7.3 Auxiliary water heating system.................................................619 Preheating the engine.............................................................620 Preheating the crane cab..........................................................620 Switching on......................................................................621 Setting the day and time..........................................................622 Storing the heating start........................................................623 Setting the heating period.......................................................624 Switching heating start on/off....................................................624 Switching off.....................................................................625 Setting the remaining run time....................................................625 11.7.4 Auxiliary air heater...........................................................626 Switching on......................................................................626 Temperature.......................................................................627 Switching off.....................................................................627 Other functions...................................................................627 12 Rigging work...............................................................................631 12.1 Rigging work checklists for crane operation with the main boom.......................631 12.1.1 CHECKLIST: Rigging.............................................................631 12.1.2 CHECKLIST: Unrigging...........................................................635 12.2 Choosing a suitable site.............................................................639 12.2.1 Determining the required ground bearing area...................................639 12.2.2 Safe distance from slopes and pits.............................................642 12.2.3 Earthing the truck crane.......................................................643 12.2.4 Safe distance from electrical cables...........................................644 12.3 Rigging work after driving with a trailer............................................647 12.3.1 Switching off the boom floating position.......................................647 12.3.2 Switching off the slewing gear freewheel.......................................648 Before slewing....................................................................648 12.3.3 Switching off boom pre-tensioning..............................................649 12.4 Connecting/disconnecting the hand-held control.......................................651 12.5 Starting the engine for driving for rigging work.....................................653 12.5.1 Starting/turning off the engine with the hand-held control.....................653 Prerequisites.....................................................................653 Starting the engine...............................................................654 Turning off the engine............................................................654 12.5.2 Starting/turning off the engine from the crane cab.............................655 Prerequisites.....................................................................655 Starting the engine...............................................................655 After starting the engine.........................................................656 Turning off the engine............................................................656 12.6 Outriggers...........................................................................657 12.6.1 CHECKLIST: Extending the outriggers............................................657 12.6.2 CHECKLIST: Retracting the outriggers...........................................659 12.6.3 Permissible outrigger spans....................................................660 12.6.4 Preparing the truck crane......................................................661 In the driver's cab...............................................................661 Outriggers controlunits..........................................................661 12.6.5 Setting the spans..............................................................662 For on-road driving..............................................................664 12.6.6 Extending/retracting outriggers................................................665 From the control units............................................................666 With the hand- held control.......................................................667 From the crane cab................................................................669 12.6.7 Moving the outrigger pads into working/driving position........................671 12.6.8 Enlarging the ground bearing area..............................................672 12.6.9 Extending/retracting supporting cylinders......................................673 From the control units............................................................674 With the hand- held control.......................................................675 From the crane cab................................................................676 12.6.10 Leveling the truck crane on outriggers horizontally...........................678 Inclination indicators...........................................................678 Prerequisites.....................................................................679 Manual alignment..................................................................680 Automatic alignment..............................................................681 12.6.11 Leveling the free-standing truck crane........................................683 12.6.12 Outrigger pressure display....................................................685 12.7 Rigging/unrigging the counterweight..................................................687 12.7.1 Counterweight sections.........................................................687 Basic version.....................................................................687 Additional version1..............................................................688 Additional version2..............................................................688 Additional version3..............................................................689 Additional version4..............................................................689 12.7.2 Identification.................................................................690 12.7.3 Slinging points on the counterweight sections..................................691 12.7.4 CHECKLIST: Rigging the counterweight...........................................693 12.7.5 CHECKLIST: Unrigging the counterweight.........................................695 12.7.6 Assembling counterweight combination...........................................697 Combinations on the turntable.....................................................698 Setting down the 2.5 t base plate.................................................699 Combinations for the basic version................................................701 Combinations with additional equipment............................................706 12.7.7 Counterweight hoist unit.......................................................717 Counterweight submenu.............................................................717 Extending/ retracting the lifting cylinders.....................................718 Locking/Unlocking counterweight...................................................720 12.7.8 Mounting/Dismounting the counterweight on the turntable........................721 Mounting..........................................................................721 Dismounting.......................................................................723 12.7.9 Assembling counterweight sections for driving the truck crane..................725 12.7.10 Slewing with rigged counterweight.............................................727 12.8 Rigging work on the main boom........................................................729 12.8.1 Hook block on the bumper.......................................................729 Picking up the hook block.........................................................729 Attaching the hook block..........................................................730 12.8.2 Hook block on a separate vehicle...............................................731 Picking up the hook block.........................................................732 Setting down the hook block.......................................................732 12.8.3 Reeving and unreeving the hoist rope...........................................734 Fastening the rope end clamp......................................................734 Reeving the hoist rope............................................................736 Unreeving hoist rope..............................................................739 12.8.4 Possible reeving methods on the main boom......................................740 With 8 head sheaves...............................................................740 12.8.5 Installing/removing the lifting limit switch...................................744 Installing the lifting limit switch..............................................744 Removing the lifting limit switch................................................747 12.8.6 Locking/Unlocking the lifting limit switch.....................................748 Locking...........................................................................748 Removing the lock.................................................................749 12.8.7 Anemometer and air traffic control light.......................................750 Mounting..........................................................................750 Dismounting.......................................................................751 12.9 Other rigging work...................................................................753 12.9.1 Rigging in free on wheels working position.....................................753 12.9.2 Mirror for crane operation.....................................................755 13 Driving with a rigged truck crane..........................................................759 13.1 Driving route........................................................................761 13.2 Before driving the rigged truck crane................................................761 13.2.1 check the tyre pressure and the wind speed.....................................761 13.3 Permissible rigging modes and axle loads.............................................763 13.3.1 Axle loads.....................................................................763 13.3.2 To drive without a load........................................................763 13.3.3 To drive with a load...........................................................764 13.4 Driving from the driver's cab........................................................765 13.4.1 Preparing to drive.............................................................765 Transmission......................................................................765 Switching on separate steering....................................................765 Connections.......................................................................765 13.4.2 While driving..................................................................766 13.5 Driving from the crane cab...........................................................767 13.5.1 Preparing to drive.............................................................767 13.5.2 Opening/closing the Driving mode submenu.......................................768 Automatic.........................................................................768 Manual............................................................................770 Closing...........................................................................770 13.5.3 Starting/turning off the engine for driving....................................771 Starting the engine...............................................................771 Turning off the engine............................................................772 13.5.4 Steering.......................................................................772 Switching on......................................................................772 Adjusting the steering direction..................................................772 Displays when steering............................................................773 Normal steering...................................................................773 Separate steering.................................................................774 13.5.5 Operating the transmission.....................................................775 Driving direction.................................................................776 Selecting the gear position.......................................................776 13.5.6 Starting.......................................................................777 13.5.7 While driving..................................................................777 13.5.8 Warning messages...............................................................778 13.5.9 Possible connections...........................................................779 Longitudinal/ transverse differential locks......................................780 13.5.10 After driving.................................................................781 13.6 Driving in combined operation........................................................783 13.6.1 Switching combined operation on/off............................................783 Prerequisites.....................................................................783 Switching on......................................................................784 Switching off.....................................................................784 13.6.2 Starting/turning off the engine................................................785 13.6.3 Preparing to drive.............................................................786 Transmission......................................................................786 Switching on separate steering...................................................786 Connections.......................................................................786 13.6.4 While driving..................................................................787 Without load......................................................................787 With load.........................................................................788 14 Malfunctions during crane operation........................................................791 14.1 Emergency stop switch................................................................791 14.2 What to do when malfunctions occur during craneoperation............................793 Load can be lowered..................................................................793 Load cannot be lowered................................................................793 14.3 Fuses................................................................................795 Information on replacing fuses........................................................795 14.3.1 Fuses on the turntable.........................................................796 Fuse groups F1/F2/F3..............................................................796 Fuses on the circuit board.......................................................797 14.3.2 Fuses in the crane cab.........................................................798 14.3.3 Fuses in the battery box.......................................................800 14.3.4 SLI fuses......................................................................801 14.4 Finding and eliminating malfunctions.................................................803 14.4.1 Malfunctions on the engine.....................................................803 14.4.2 Malfunctions on the main hoist/auxiliary hoist.................................805 14.4.3 Malfunctions on the derricking gear............................................806 14.4.4 Malfunctions in the telescoping mechanism......................................807 Telescoping mechanism error messages..............................................809 14.4.5 Malfunctions on the slewing gear...............................................810 14.4.6 Malfunctions on the counterweight hoist unit...................................811 14.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................812 14.4.8 Malfunctions when inclining the crane cab......................................812 14.4.9 Malfunctions when operating with the hand-held control.........................812 14.4.10 Malfunctions when driving from the crane cab..................................813 14.4.11 Malfunctions of the outriggers................................................814 14.4.12 Troubleshooting the SLI.......................................................815 General malfunctions.............................................................815 Error messages....................................................................816 Table of error codes..............................................................818 Switching off the sensor/tachogenerator..........................................821 14.4.13 Malfunctions ECOS – superstructure............................................822 ECOS program version..............................................................822 General malfunctions.............................................................822 Error messages....................................................................823 Exiting the submenu...............................................................824 14.5 Emergency operations and programs....................................................825 14.5.1 Mechanical emergency operation for retracting..................................826 Prior to the emergency operation, check...........................................826 Procedure.........................................................................826 Mechanical emergency operation....................................................827 14.5.2 Telescoping emergency program..................................................829 Starting the emergency program....................................................829 Determining the type of error.....................................................830 If there is an error on the length indicator......................................831 If there is an error at a proximity switch........................................835 Terminating the emergency program.................................................836 Tables for approaching the locking points.........................................837 14.5.3 Entering the current telescoping...............................................839 14.5.4 Emergency operation with the hand-held control.................................841 Preparations......................................................................841 Operating a power unit............................................................842 Stopping movements...............................................................844 Stopping movements in emergencies................................................844 Turning off the engine............................................................844 14.5.5 Switching on emergency operation in coolant circuit............................845 14.6 Hydraulic emergency operation........................................................847 14.6.1 Operating principle............................................................847 14.6.2 Connecting/Disconnecting hoses.................................................848 Establishing connections.........................................................848 Disconnecting connections.........................................................849 14.6.3 Switching emergency operation on/off...........................................850 14.6.4 Establishing the hydraulic circuits required...................................851 Switching over valves.............................................................851 For lifting/ lowering............................................................853 For slewing.......................................................................854 14.6.5 Carrying out emergency operation...............................................855 Lifting/Lowering in emergency mode................................................855 Slewing in emergency mode.........................................................856 Raising/Lowering in emergency mode................................................857 14.6.6 After emergency operation......................................................858 Switch off emergency operation....................................................858 Switch over to crane operation....................................................858 Disconnecting the hoses.........................................................858 14.6.7 Emergency supply of another crane..............................................859 For emergency supply..............................................................859 After emergency supply............................................................859 15 Index......................................................................................863 A.........................................................................................865 B.........................................................................................865 C.........................................................................................865 D.........................................................................................867 E.........................................................................................869 F.........................................................................................871 H.........................................................................................871 I.........................................................................................872 K.........................................................................................872 L.........................................................................................872 M.........................................................................................873 O.........................................................................................874 P.........................................................................................875 R.........................................................................................875 S.........................................................................................876 T.........................................................................................877 V.........................................................................................879 W.........................................................................................879
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