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Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3113120 – PDF DOWNLOAD
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Description
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3113120 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3113120 – PDF DOWNLOAD
Language : English
Pages : 940
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
Customer Support: [email protected]
DESCRIPTION:
Grove Crane GMK 5110-1 Driving Operating Instruction Manual 3113120 – PDF DOWNLOAD
Basic safety instructions:
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 when it is in perfect technical condition and for its
intended purpose 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; à Technical
data, p. 1 – 7. - 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 unau- thorized 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 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, outrigger
beams 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 RCL codes that do not correspond to the actual rigging mode.
– Working with an overridden RCL or overridden lifting limit switch.
– After RCL shutdown, increasing the working radius by pulling the raised
load at an angle (e.g. with a chain hoist).
– Misuse of the outrigger pressure display as a safety function to prevent
the crane from overturning (outrigger pressure higher than 0 t).
– On-road driving in an impermissible 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 using 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 3113120 – PDF DOWNLOAD
1 Overview................................................................................... 7 1.1 Accidents............................................................................ 7 1.2 Branch offices....................................................................... 9 1.2.1 Manitowoc Crane Care........................................................... 9 1.2.2 Dealer list.................................................................... 9 1.3 Warranty specifications.............................................................. 9 1.4 Terms used........................................................................... 10 1.5 Technical data....................................................................... 13 1.5.1 Maximum lifting capacity (DIN/ISO/EN).......................................... 13 1.5.2 Dimensions and weights of the truck crane, axle loads.......................... 14 Dimensions....................................................................... 15 Weight and axle loads............................................................ 15 1.5.3 Dimensions and weights of removable parts...................................... 16 Spare wheel...................................................................... 16 Outriggers....................................................................... 16 Main boom........................................................................ 16 Counterweight parts.............................................................. 17 Counterweight combinations....................................................... 17 Hook blocks and hook tackle...................................................... 18 1.5.4 Carrier........................................................................ 19 Engine........................................................................... 19 Transmission..................................................................... 19 Transfer case.................................................................... 19 Axle lines....................................................................... 19 Steering......................................................................... 20 Tyres............................................................................ 20 Outriggers....................................................................... 20 Electrical system................................................................ 21 Tool............................................................................. 21 Towing couplings................................................................. 21 Driving speeds................................................................... 21 Climbing ability................................................................. 21 Turning radii.................................................................... 22 1.5.5 Superstructure................................................................. 23 Engine........................................................................... 23 Main hoist....................................................................... 23 Auxiliary hoist.................................................................. 24 Slewing gear..................................................................... 24 Derricking gear.................................................................. 24 Main boom........................................................................ 25 Lattice extension................................................................ 25 Operating speeds................................................................. 25 1.6 Documentation supplied............................................................... 27 1.6.1 Questions on documentation..................................................... 28 1.7 Notes on the operating instructions.................................................. 29 1.7.1 What do the symbols used mean?................................................. 29 1.7.2 How are the operating instructions structured?................................. 31 Division......................................................................... 31 Structure of the chapters........................................................ 31 Structure of the pages........................................................... 32 1.7.3 How do I find the information I need?.......................................... 33 Cross-references example......................................................... 34 1.7.4 What information is available for operations planning?......................... 36 1.8 Conversion table for US measuring units.............................................. 37 1.9 Training – Information............................................................... 39 1.10 Identification,..................................................................... 40 1.11 EC Declaration of Conformity........................................................ 42 2 Basic safety instructions.................................................................. 45 2.1 Intended use......................................................................... 45 2.1.1 Improper use................................................................... 46 2.2 Organisational measures.............................................................. 47 2.3 Personnel qualifications............................................................. 49 2.4 Safety instructions for driving the truck crane...................................... 50 2.5 Safety instructions for crane operation.............................................. 51 2.6 Notes on transporting persons........................................................ 53 Equipment for lifting persons........................................................ 53 Personnel............................................................................ 53 Operation............................................................................ 54 Truck crane.......................................................................... 55 3 Operating elements for driving............................................................. 59 3.1 Overview of the operating elements................................................... 61 3.1.1 On the outside of the truck crane.............................................. 62 3.1.2 Driver's cab................................................................... 64 Overview......................................................................... 64 Behind the cover................................................................. 66 3.1.3 Instrument panel............................................................... 67 Left/right....................................................................... 67 Middle........................................................................... 68 3.1.4 On-board computer.............................................................. 70 Display, driving mode............................................................ 70 On-board computer time correction................................................ 71 3.1.5 Steering column/steering wheel................................................. 72 3.1.6 Transmission operating elements................................................ 73 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................................................................ 81 Operating hours submenu.......................................................... 82 Warning submenu.................................................................. 83 Transmission emergency program submenu........................................... 84 Error submenu.................................................................... 85 3.1.11 Heating/Air-conditioning system............................................... 86 Standard heating system.......................................................... 86 Auxiliary air heater............................................................. 87 Auxiliary water heater........................................................... 89 3.1.12 Sockets for hand-held control................................................. 90 3.1.13 Outrigger control units....................................................... 91 3.2 Short description of the operating elements.......................................... 93 3.2.1 Definition of direction information............................................ 93 Basic rule....................................................................... 93 Switches and buttons............................................................. 94 3.2.2 General rules for buttons and symbols on the display........................... 94 3.2.3 Engine......................................................................... 95 Steering column.................................................................. 95 Multipurpose switch.............................................................. 95 Instrument panel................................................................. 97 Main menu........................................................................ 97 3.2.4 DEF system..................................................................... 98 Instrument panel................................................................. 98 3.2.5 Electrical system.............................................................. 99 3.2.6 ECOS crane control.............................................................100 Control unit.....................................................................100 3.2.7 Transmission...................................................................103 Transmission display.............................................................103 ECOS display.....................................................................103 operating elements...............................................................104 Instrument panel.................................................................105 3.2.8 Transfer case..................................................................106 Main menu........................................................................106 3.2.9 Final drive....................................................................107 3.2.10 Reverse camera................................................................108 3.2.11 Brakes........................................................................109 Service brake....................................................................109 Parking brake....................................................................110 Additional brakes................................................................111 3.2.12 Steering/separate steering....................................................112 ECOS display.....................................................................112 Driver's door....................................................................113 3.2.13 Suspension....................................................................113 3.2.14 Lighting/windscreen wipers/horn...............................................114 Steering column..................................................................114 Instrument panel.................................................................114 Roof.............................................................................116 3.2.15 Level adjustment system.......................................................116 3.2.16 Tachograph/speedometer........................................................118 Tachograph.......................................................................118 Speedometer......................................................................118 3.2.17 Diagnostics...................................................................119 Displays/ submenu................................................................119 3.2.18 On-board computer.............................................................120 3.2.19 Push-up roof..................................................................122 3.2.20 Windows, doors, keys..........................................................122 Window winder....................................................................122 Doors............................................................................123 Keys.............................................................................123 3.2.21 Front flap....................................................................124 3.2.22 Hand-held control storage compartment.........................................124 4 Starting/turning off the engine for driving................................................127 4.1 Starting the engine from the driver's cab............................................127 4.1.1 CHECKLIST: Starting the engine.................................................127 4.1.2 CHECKLIST: At low temperatures.................................................130 4.1.3 Ladders and access ladders.....................................................131 Ladders..........................................................................131 Access ladders...................................................................132 4.1.4 Refuel.........................................................................133 Fuel tank........................................................................133 DEF tank.........................................................................134 4.1.5 Checks before starting the engine..............................................135 On hydraulic tank................................................................135 Battery master switch............................................................135 Checking handheld control.......................................................136 4.1.6 Switching on the ignition......................................................136 4.1.7 Lamp test/equalisation of the switching states.................................137 Lamp test........................................................................137 Equalisation of the switching states.............................................138 4.1.8 Display – setting the brightness...............................................139 4.1.9 Starting the engine............................................................140 Without flame start system.......................................................141 With flame start system..........................................................142 4.1.10 Checks after starting the engine..............................................143 4.1.11 Monitoring elements...........................................................144 Instrument panel.................................................................144 ECOS display.....................................................................145 Display driving mode............................................................145 4.1.12 Setting idling speed..........................................................146 4.2 Turning off the engine...............................................................147 4.2.1 On the ignition lock/with hand-held control....................................147 After turning off................................................................147 4.2.2 Using the emergency stop switches..............................................148 Resetting the emergency stop switch..............................................148 4.3 Air intake inhibitor.................................................................149 Releasing the air intake inhibitor...................................................149 5 Driving....................................................................................153 5.1 Before driving.......................................................................153 5.1.1 CHECKLIST: Checks before on-road driving.......................................153 5.1.2 Checking the condition of the truck crane......................................159 Electrical system................................................................159 Adjusting themirrors............................................................159 Adjusting the reverse camera.....................................................160 Warning plates for vehicle width.................................................161 Displaying vehicle height........................................................161 Supply pressure..................................................................162 Parking brake....................................................................163 5.1.3 Adjusting the seat and the steering column.....................................164 Driver's seat....................................................................164 Passenger's seat.................................................................165 Adjusting the steering column....................................................165 5.1.4 Switching the suspension on/off................................................166 Opening thesubmenu..............................................................166 Switching on the suspension......................................................167 Switching off the suspension.....................................................167 5.1.5 Setting the tachograph.........................................................168 Prerequisites....................................................................168 In the event of malfunctions.....................................................168 Setting the tachograph...........................................................169 Additional displays..............................................................172 5.1.6 Displaying the operating hours.................................................173 5.1.7 Settings/displays with the on-board computer...................................174 Operation........................................................................174 Overview.........................................................................176 Monitoring information...........................................................176 Error information................................................................177 Alarm clock......................................................................178 Language.........................................................................178 Settings.........................................................................179 Diagnostics......................................................................179 5.2 Operating the transmission...........................................................181 5.2.1 Switching on...................................................................181 5.2.2 Switching the transmission to neutral position.................................182 5.2.3 Changing the operating mode....................................................182 Change to automatic mode.........................................................182 Change to manual mode............................................................183 5.2.4 Display of the selected gears..................................................183 5.2.5 Selecting the direction of travel and starting gear............................185 Selecting the driving direction..................................................185 Selecting the starting gear......................................................186 5.2.6 Starting.......................................................................187 5.2.7 Driving and changing gears.....................................................188 In automatic operating mode......................................................188 In manual operating mode.........................................................189 5.2.8 Changing the driving direction.................................................190 Quick change ofgear.............................................................190 5.2.9 Stopping.......................................................................191 Stopping for along period oftime...............................................191 5.2.10 On the roller type dynamometer................................................191 5.3 Driving and turning off the truck crane..............................................193 5.3.1 Checks while driving...........................................................193 Immediately after you start to move..............................................193 While driving....................................................................194 5.3.2 Tempomat.......................................................................196 Switching on.....................................................................196 Switching off....................................................................197 5.3.3 Cruise control.................................................................197 Switching on.....................................................................197 Switching off....................................................................198 5.3.4 Driving downhill...............................................................199 Starting.........................................................................199 Inspections when driving downhill................................................199 Downshifting.....................................................................200 Additional brakes................................................................201 5.3.5 Driving uphill.................................................................202 Starting.........................................................................202 Driving..........................................................................202 5.3.6 Warning submenu................................................................202 Meaning of the symbols...........................................................203 Exiting the submenu..............................................................204 5.3.7 Notes on torque reduction......................................................205 5.3.8 Error submenu..................................................................206 5.3.9 Messages on the on-board computer display......................................206 Warnings.........................................................................207 Warning messages.................................................................208 Error messages...................................................................209 Information......................................................................211 5.3.10 Turning off the truck crane...................................................215 Securing against rolling away....................................................215 When stationary for more than 8hours............................................216 5.4 Off-road driving.....................................................................217 Adjustments to the transmission......................................................217 Connections..........................................................................217 Changing the vehicle level...........................................................217 Rocking the vehicle free and towing..................................................217 5.4.1 Transfer case – switching the off-road gear on/off.............................218 Neutral position.................................................................218 5.4.2 Longitudinal and transverse differential locks.................................219 5.4.3 Operating the level adjustment system..........................................221 Opening the submenu..............................................................221 Setting the onroad level........................................................221 Pre-selecting suspension struts..................................................222 Changing the vehicle level.......................................................223 Viewing the current inclination..................................................223 Exiting the submenu..............................................................224 5.4.4 Freeing truck crane stuck in terrain...........................................225 Rocking the truck crane free.....................................................225 Towing free forwards.............................................................226 Towing free in reverse gear......................................................226 5.4.5 Separate steering..............................................................227 Switching to separate steering...................................................227 Steering.........................................................................228 Switching to normal steering mode................................................229 5.5 Heating and air-conditioning system..................................................231 5.5.1 Standard heating system........................................................231 Switching on.....................................................................231 Heating..........................................................................231 Air distribution.................................................................232 Examples.........................................................................233 Switching off....................................................................233 5.5.2 Air-conditioning system........................................................234 Warnings.........................................................................234 Switching on/off.................................................................234 Cooling..........................................................................235 Drying...........................................................................235 5.5.3 Auxiliary air heater – Version A...............................................236 Switching on.....................................................................236 Temperature......................................................................237 Setting the day and time.........................................................237 Storing the heating start........................................................238 Setting the heating period.......................................................239 Switching the heating start on and off...........................................240 Switching off....................................................................240 Setting the remaining time.......................................................241 5.5.4 Auxiliary air heater – Version B...............................................242 Switching on.....................................................................242 Setting the heating level........................................................243 Setting the day and time.........................................................244 Setting the preselection time....................................................244 Preselection times Delete........................................................246 Switching off....................................................................246 5.5.5 Auxiliary water heater.........................................................247 Preheating the engine............................................................247 Preheating the driver's cab......................................................248 Switching on.....................................................................248 Setting the day and time.........................................................249 Storing the heating start........................................................250 Switching heating start on/off...................................................251 Switching off....................................................................252 Additional functions.............................................................252 5.6 Towing a trailer.....................................................................253 Effects on the axle loads............................................................253 Coupling the trailer.................................................................254 Connecting the supply lines..........................................................255 Removing the supply lines............................................................256 Uncoupling the trailer...............................................................256 Checking the braking force...........................................................258 6 Driving modes..............................................................................261 6.1 Driving modes........................................................................261 Information about the axle loads.....................................................261 6.1.1 Information on how to use the tables...........................................262 6.1.2 Table for a maximum axle load of 12 t..........................................263 For 14.00 R25 tyres..............................................................263 For 16.00 R25 tyres..............................................................264 For 20.5 R25 tyres...............................................................265 6.1.3 Maximum permitted speeds with an axle load of over 12t........................267 6.2 Rigging work for driving with a trailer..............................................269 6.2.1 Switching on the slewing gear freewheel........................................270 6.2.2 Switching on boom floating position............................................271 6.2.3 Switching on boom pre-tensioning...............................................272 6.2.4 Switching the superstructure driving lights on/off.............................274 Switching off....................................................................274 Switching on.....................................................................274 6.3 Rigging the main boom................................................................275 Additional equipment required........................................................275 6.3.1 CHECKLIST: Removing the main boom..............................................276 Prerequisites....................................................................276 Checklist........................................................................276 6.3.2 CHECKLIST: Mounting the main boom..............................................279 Prerequisites....................................................................279 Checklist........................................................................279 6.3.3 Slinging the main boom.........................................................282 6.3.4 Removing/attaching the clamps..................................................283 6.3.5 Hydraulic connection for the lattice extension.................................284 6.3.6 Switching the pressure relief on/off...........................................285 6.3.7 Retracting/fitting the derricking cylinder head pin............................286 Retracting the derricking cylinder head axle.....................................287 Fitting the derricking cylinder head axle........................................288 6.3.8 Retracting/extending the boom pivot pin........................................289 Before retracting................................................................289 After extending..................................................................289 Retracting/ extending the pivot pin..............................................290 6.3.9 Disconnecting the hydraulic/electrical connections.............................291 Lifting in front ofthe turntable................................................291 Detachment.......................................................................292 6.3.10 Establishing the hydraulic/electrical connection..............................293 Lifting onto the turntable.......................................................293 Connecting.......................................................................294 6.3.11 Aligning the connecting points................................................295 6.3.12 Securing/releasing the derricking cylinder....................................295 6.3.13 Transporting the main boom....................................................296 6.3.14 Inspections after main boom mounting..........................................297 6.3.15 Rigging the hose drum.........................................................298 Installing the hose drum.........................................................298 Removing the hose drum...........................................................299 7 Malfunctions in driving mode...............................................................303 7.1 Emergency stop switch................................................................303 7.2 What to do when a malfunction occurs in road traffic.................................305 7.3 Towing the truck crane...............................................................307 7.3.1 Towing after engine/transmission damage........................................308 Compressed-air supply............................................................308 Electric power supply............................................................308 On the transmission..............................................................309 Axle drives......................................................................310 Transfer case....................................................................310 Parking brake....................................................................310 Towing the truck crane out of the danger area....................................311 7.3.2 Tow starting...................................................................312 7.4 Wheels and tyres.....................................................................313 7.4.1 Wheel change...................................................................313 Removing adamaged wheel.........................................................313 On the spare wheel holder........................................................314 Mounting a wheel.................................................................315 7.4.2 Inflating the tyres yourself...................................................317 Connecting the filling hose......................................................317 Inflating the tyres..............................................................318 Removing the filling hose........................................................318 7.5 Fuses on the carrier.................................................................319 Notes on changing fuses..............................................................319 7.5.1 Fuses in the driver's cab......................................................320 F1 to F 41.......................................................................320 A1 to A3.........................................................................322 7.5.2 Fuses in the battery box.......................................................324 7.6 Troubleshooting......................................................................325 7.6.1 Malfunctions on the engine.....................................................325 7.6.2 Faults on the DEF system.......................................................327 7.6.3 Malfunctions in the transmission...............................................328 7.6.4 Malfunctions of the service brake..............................................329 7.6.5 Malfunctions of the steering...................................................330 7.6.6 Transfer case malfunctions.....................................................330 7.6.7 Malfunctions in the differential locks.........................................331 7.6.8 Malfunctions in the hydraulic system/hydraulic oil cooler......................331 7.6.9 Malfunctions on the suspension.................................................332 7.6.10 Malfunctions of the level adjustment system...................................332 7.6.11 Malfunctions of the reverse camera............................................332 7.6.12 Malfunctions on the ECOS carrier..............................................333 ECOS programme version...........................................................333 General malfunctions.............................................................333 Error messages...................................................................334 Exiting the submenu..............................................................335 On the control units.............................................................336 7.7 Procedure in the event of malfunctions...............................................337 7.7.1 Switching on emergency operation in coolant circuit............................337 7.7.2 Procedure in the event of malfunctions to the transmission and engine..........338 Engine...........................................................................338 Transmission.....................................................................339 Transmission emergency program submenu...........................................340 Compressed air emergency switching...............................................343 ID number of the transmission....................................................345 7.8 Emergency operation..................................................................347 7.8.1 External starting socket.......................................................347 Performing a jump start..........................................................348 7.8.2 Battery charger................................................................348 8 Index......................................................................................351 A........................................................................................353 B........................................................................................353 C........................................................................................353 D........................................................................................355 E........................................................................................357 F........................................................................................359 H........................................................................................359 I........................................................................................360 K........................................................................................361 L........................................................................................361 M........................................................................................362 O........................................................................................363 P........................................................................................364 R........................................................................................364 S........................................................................................365 T........................................................................................366 V........................................................................................368 W........................................................................................368 9 Operating elements for crane operation.....................................................379 9.1 Overview of the operating elements...................................................381 9.1.1 Exterior of the truck crane....................................................382 9.1.2 Crane cab......................................................................386 9.1.3 Front panel....................................................................388 9.1.4 Side panel.....................................................................389 Below............................................................................389 Top..............................................................................390 Console, rear....................................................................392 Standard heating system..........................................................393 Auxiliary water heater...........................................................394 Auxiliary air heater.............................................................395 9.1.5 Control panels.................................................................396 Left.............................................................................396 Right............................................................................397 9.1.6 Control lever configuration....................................................398 Version 1........................................................................398 Version 2........................................................................399 9.1.7 ECOS control unit..............................................................400 9.1.8 ECOS display – main menu.......................................................402 9.1.9 ECOS display – submenus........................................................404 Counterweight submenu............................................................404 Slewing gear/ houselock submenu..................................................405 Outriggers submenu...............................................................406 Telescoping submenu..............................................................408 Power unit speeds submenu........................................................409 Monitoring submenu...............................................................410 Settings submenu.................................................................411 Operating hours submenu..........................................................412 Error submenu....................................................................413 Warning submenu..................................................................414 Working range limiter submenu...................................................416 Enter slewing angle submenu......................................................417 Enter objects submenu............................................................418 Driving submenu..................................................................419 9.1.10 RCL control unit..............................................................420 9.1.11 Hand-held control.............................................................424 Outriggers control panel........................................................425 9.1.12 Outrigger control units.......................................................426 Outrigger........................................................................427 Outrigger pressure display.......................................................427 Inclination indicator............................................................427 9.2 Short description of the operating elements..........................................429 9.2.1 Definition of direction information............................................429 Basic rule.......................................................................429 Switches.........................................................................430 9.2.2 General rules for buttons and symbols on the display...........................430 9.2.3 Engine for crane operation.....................................................431 Side panel.......................................................................431 Console, rear....................................................................432 ECOS display.....................................................................432 9.2.4 DEF system.....................................................................432 Side panel from above............................................................432 ECOS display.....................................................................433 9.2.5 Engine for driving.............................................................433 Side panel.......................................................................433 Main menu........................................................................434 Outriggers submenu...............................................................434 9.2.6 Seat contact switch and dead man's switch......................................435 9.2.7 ECOS crane control.............................................................437 Control unit.....................................................................437 9.2.8 Outrigger......................................................................440 Hand-held control................................................................440 In the Outrigger submenu.........................................................441 In the Settings submenu..........................................................442 On the outrigger control units...................................................443 9.2.9 Inclination indicators.........................................................445 9.2.10 Outrigger pressure displays...................................................446 Outrigger submenu................................................................446 Outrigger control units..........................................................446 9.2.11 Anemometer display............................................................446 9.2.12 Counterweight submenu.........................................................447 Counterweight submenu............................................................447 9.2.13 Main hoist....................................................................449 9.2.14 Auxiliary hoist...............................................................451 9.2.15 Slewing gear..................................................................453 Submenu..........................................................................454 9.2.16 Derricking gear...............................................................457 9.2.17 Telescoping mechanism.........................................................458 Control panels...................................................................458 Submenu..........................................................................459 In the Settings submenu..........................................................463 9.2.18 Hydraulic system..............................................................465 9.2.19 Houselock.....................................................................466 9.2.20 Rated capacity limiter (RCL)..................................................467 Input elements with displays.....................................................467 Display elements.................................................................470 RCL override.....................................................................473 External displays................................................................474 9.2.21 Electrical system.............................................................475 9.2.22 Lighting, windscreen wiper/washing system.....................................475 Lighting.........................................................................475 Windscreen wiper/washing system..................................................477 9.2.23 Hand-held control.............................................................478 Sockets for handheld control....................................................478 Engine control panel.............................................................479 Horn.............................................................................479 Outrigger control panel..........................................................480 9.2.24 Diagnostics...................................................................482 9.2.25 Windows, doors, keys..........................................................482 Windscreen.......................................................................482 Rear window......................................................................483 Crane cab door...................................................................483 Keys.............................................................................484 9.3 Short description of the operating elements – driving from the crane cab.............485 9.3.1 Driving submenu................................................................485 9.3.2 Engine for driving.............................................................486 9.3.3 Transmission...................................................................487 9.3.4 Final drive....................................................................488 9.3.5 Brakes.........................................................................489 Side panel.......................................................................489 ECOS display.....................................................................489 9.3.6 Steering.......................................................................490 Normal steering..................................................................491 Separate steering................................................................491 10 Starting/turning off the engine – for crane operation.....................................495 10.1 Starting the engine – from the crane cab............................................495 10.1.1 CHECKLIST: Starting the engine................................................495 10.1.2 CHECKLIST: At low temperatures................................................498 10.1.3 Refuel........................................................................499 Fuel tank........................................................................499 DEF tank.........................................................................500 10.1.4 Checks before starting the engine.............................................501 On hydraulic tank................................................................501 Battery master switch............................................................501 Checking the hand-held control...................................................502 10.1.5 Switching on the ignition.....................................................502 10.1.6 Lamp test/switching state equalisation........................................503 Lamp test........................................................................503 Equalisation of the switching states.............................................504 10.1.7 Adjusting display brightness..................................................505 10.1.8 Starting the engine...........................................................506 Without flame start system.......................................................506 With flame start system..........................................................507 10.1.9 Checks after starting the engine..............................................508 10.1.10 Monitoring submenu...........................................................509 10.1.11 Setting idling speed.........................................................510 10.2 Starting the engine – with the hand-held control....................................511 Prerequisites........................................................................511 Starting the engine..................................................................511 10.3 Turning off the engine..............................................................513 10.3.1 During normal operation, with the ignition lock/with the handheld control....513 After turning off................................................................513 10.3.2 In emergencies, with the emergency stop switches..............................514 Resetting the emergency stop switch..............................................514 10.4 Air intake inhibitor................................................................515 Releasing the air intake inhibitor...................................................515 11 Crane operation...........................................................................519 11.1 Before operating the crane..........................................................519 11.1.1 CHECKLIST: Checks before operating the crane..................................519 11.1.2 Checking the condition of the truck crane.....................................523 Visual inspection................................................................523 Checking the position of the hoist ropes.........................................523 Checking the electrical system...................................................524 11.1.3 Adjusting the crane cab seat and front control panel..........................525 Crane cab seat...................................................................525 Front panel......................................................................526 11.1.4 Checking the safety equipment.................................................527 Rated capacity limiter...........................................................527 Lifting limit switch.............................................................527 Emergency stop switch............................................................528 Seat contact switch..............................................................529 11.1.5 Earthing the load.............................................................530 11.1.6 Preheating the hydraulic oil..................................................531 11.1.7 Locking/unlocking the turntable...............................................532 Locking points...................................................................532 Lock turntable...................................................................533 Unlock turntable.................................................................533 11.1.8 Switching the houselock on/off................................................534 Switching on the houselock.......................................................534 Switching off the houselock......................................................536 11.2 Operation of the rated capacity limiter.............................................537 11.2.1 Switching on the RCL..........................................................538 Switching on.....................................................................538 Lamp test on the RCL.............................................................540 Brightness of the displays.......................................................540 11.2.2 Enter rigging mode............................................................541 Entering the RCL code............................................................542 Entering the reeving.............................................................545 Entering individual components...................................................546 11.2.3 Checks before operating the crane.............................................550 11.2.4 Displays during crane operation...............................................552 Continuous displays..............................................................552 Optional displays................................................................554 11.2.5 RCL early warning.............................................................556 11.2.6 RCL shutdown..................................................................556 Shutdown due to overload.........................................................556 11.2.7 Error message.................................................................558 11.2.8 RCL override – version A......................................................559 11.2.9 RCL override – version B......................................................560 Overview status display..........................................................560 When rigging.....................................................................561 To raise the boom................................................................562 In emergencies...................................................................563 11.2.10 Displaying and entering the time and date....................................564 Display..........................................................................564 Input............................................................................565 11.3 Crane operation with main boom......................................................567 11.3.1 Checks during crane operation.................................................567 Horizontal alignment.............................................................567 Safe distances...................................................................567 Checking the wind speed..........................................................568 11.3.2 Permissible slewing ranges and working positions..............................569 360 slewing range...............................................................569 0 to the rear working position..................................................569 180 to the front rigging position...............................................570 Free-on-wheels working position..................................................570 11.3.3 Main hoist....................................................................571 Switching on the main hoist......................................................572 Lifting and lowering.............................................................572 Switching off the main hoist.....................................................573 11.3.4 Auxiliary hoist...............................................................575 Switching on the auxiliary hoist.................................................576 Lifting and lowering.............................................................577 Switching off the auxiliary hoist................................................578 11.3.5 Lifting limit switch, lowering limit switch, height contact switch............579 Lifting limit switch.............................................................579 Lowering limit switch............................................................581 11.3.6 Derricking gear...............................................................581 Switching on the derricking gear.................................................582 Raising and lowering.............................................................582 Re-enable raising function.......................................................583 Switching off the derricking gear................................................584 Lowering the main boom to ahorizontal position..................................584 11.3.7 Telescoping mechanism.........................................................585 Overview.........................................................................586 Telescoping process..............................................................586 Assignment for display...........................................................588 Fixed length, intermediate length, telescoping length............................590 Telescoping......................................................................591 Telescoping sequence.............................................................591 Checks before starting work......................................................592 Switching on the telescoping mechanism...........................................592 Function of the control lever....................................................593 Switching off the telescoping mechanism..........................................595 Manual telescoping...............................................................595 Checking the initial position....................................................596 Unlocking the telescoping cylinder...............................................598 Extending/ retracting the telescoping cylinder...................................600 Lock telescoping cylinder........................................................601 Unlocking the telescopic section.................................................602 Telescoping the telescopic section...............................................605 Locking the telescopic section...................................................606 Locking the telescopic section for on-road driving...............................607 Telescoping with teleautomation..................................................608 Telescoping the main boom when horizontal........................................612 11.3.8 High-speed mode...............................................................613 Switch on function...............................................................613 Derricking gear/ telescoping mechanism...........................................613 Hoist............................................................................614 11.3.9 Slewing gear..................................................................615 Slewing gear brake...............................................................615 Switching on the slewing gear....................................................616 Releasing the slewing gear brake.................................................616 Engaging the slewing gear brake..................................................616 Slew.............................................................................617 Braking the slewing movement.....................................................619 Slewing gear freewheel...........................................................619 Switching off the slewing gear...................................................620 11.3.10 Possible movement combinations...............................................621 11.3.11 Hydraulic oil cooling........................................................621 11.4 Settings and displays for crane operation...........................................623 11.4.1 Inclining the crane cab.......................................................623 11.4.2 Setting idling speed..........................................................624 11.4.3 Adjusting the wiper stroke interval of the windscreen wiper...................624 11.4.4 Limiting the power unit speeds................................................625 11.4.5 Setting the characteristic curves for the control levers......................626 11.4.6 Critical load control.........................................................627 Function.........................................................................627 Switching on and off.............................................................627 11.4.7 Using the slewable spotlights.................................................628 11.4.8 Displaying the operating hours................................................629 11.4.9 Warning submenu...............................................................630 Meaning of the symbols...........................................................630 Exiting the submenu..............................................................633 11.4.10 Notes on torque reduction....................................................634 11.4.11 Error submenu................................................................635 11.5 Working range limiter...............................................................637 11.5.1 Opening the working range limiter submenu.....................................638 11.5.2 Viewing current settings......................................................638 11.5.3 Entering limit values.........................................................640 Overall height/ Working radius...................................................640 Slewing angle....................................................................641 Entering objects.................................................................643 11.5.4 Entering limit values/objects manually........................................646 Limit values.....................................................................646 Objects..........................................................................647 11.5.5 Switching monitoring functions on/off.........................................648 11.5.6 Shutdown by working range limiter.............................................649 11.6 Work break..........................................................................651 11.6.1 In case of short work breaks..................................................651 11.6.2 In case of work breaks of more than 8 hours...................................652 To secure the truck crane........................................................652 11.7 Heating and air-conditioning system.................................................653 11.7.1 Standard heating system,......................................................653 Switching on.....................................................................653 Heating..........................................................................653 Air distribution.................................................................654 Switching off....................................................................655 11.7.2 Air-conditioning system.......................................................655 Information......................................................................655 Switching on/off.................................................................656 Cooling..........................................................................656 Drying the air...................................................................657 11.7.3 Auxiliary water heater........................................................657 Preheating the engine............................................................658 Preheating the crane cab.........................................................658 Switching on.....................................................................659 Setting the day and time.........................................................660 Storing the heating start........................................................661 Setting the heating period.......................................................662 Switching heating start on/off...................................................663 Switching off....................................................................663 Setting the remaining time.......................................................664 11.7.4 Auxiliary air heater..........................................................665 Switching on.....................................................................665 Temperature......................................................................666 Switching off....................................................................666 Other functions.................................................................666 11.8 CraneSTAR system....................................................................667 11.8.1 Overview......................................................................667 11.8.2 Position of the components....................................................667 12 Rigging work..............................................................................671 12.1 Rigging work checklists for crane operation with the main boom......................671 12.1.1 CHECKLIST: Rigging............................................................671 12.1.2 CHECKLIST: Unrigging..........................................................677 12.2 Choosing a suitable site............................................................681 12.2.1 Determining the required ground bearing area..................................681 12.2.2 Safe distance from slopes and pits............................................684 12.2.3 Earthing the truck crane......................................................685 12.2.4 Safe distance from electrical cables..........................................686 12.3 Rigging work after driving with a trailer...........................................689 12.3.1 Switching off the boom floating position......................................689 12.3.2 Switching off boom pre-tensioning.............................................690 12.3.3 Switching off the slewing gear freewheel......................................691 Before slewing...................................................................691 12.4 Connecting/disconnecting the hand-held control......................................693 12.5 Starting the engine for driving for rigging work....................................695 12.5.1 Starting/turning off the engine with the hand-held control....................695 Prerequisites....................................................................695 Starting the engine..............................................................696 Turning off the engine...........................................................696 12.5.2 Starting/turning off the engine from the crane cab............................697 Prerequisites....................................................................697 Starting the engine..............................................................697 After starting the engine........................................................698 Turning off the engine...........................................................698 12.6 Outrigger...........................................................................699 12.6.1 CHECKLIST: Extending the outriggers...........................................699 12.6.2 CHECKLIST: Retracting the outriggers..........................................701 12.6.3 Permissible outrigger spans...................................................702 12.6.4 Preparing the truck crane.....................................................703 In the driver's cab..............................................................703 Outrigger control units..........................................................703 12.6.5 Setting the outrigger spans...................................................705 For on-road driving..............................................................707 12.6.6 Extending/retracting outrigger beams..........................................708 From the control units...........................................................708 With the hand- held control......................................................709 From the crane cab...............................................................711 12.6.7 Moving the outrigger pads into working/driving position.......................713 12.6.8 Enlarging the ground bearing area.............................................714 12.6.9 Extending/retracting supporting cylinders.....................................715 From the control units...........................................................716 With the hand- held control......................................................717 From the crane cab...............................................................718 12.6.10 Levelling the truck crane on outriggers......................................720 Inclination indicators...........................................................720 Prerequisites....................................................................721 Manual alignment.................................................................722 Automatic alignment..............................................................723 12.6.11 Levelling the free-on-wheels truck crane.....................................725 12.6.12 Outrigger pressure display...................................................727 12.7 Rigging/unrigging the counterweight.................................................729 12.7.1 Counterweight sections........................................................729 Basic version....................................................................729 Additional version1.............................................................730 Additional version2.............................................................730 Additional version3.............................................................731 Additional version4.............................................................731 12.7.2 Identification................................................................732 12.7.3 Slinging points on the counterweight sections.................................733 12.7.4 CHECKLIST: Rigging the counterweight..........................................735 12.7.5 CHECKLIST: Unrigging the counterweight........................................737 12.7.6 Assembling counterweight combinations.........................................739 Combinations on the turntable....................................................740 Setting down the 2.5 t base plate................................................741 Combinations for the basic version...............................................743 Combinations with additional equipment...........................................748 12.7.7 Counterweight hoist unit......................................................759 Counterweight submenu............................................................759 Extending/ retracting the lifting cylinders......................................760 Locking/unlocking counterweight..................................................762 12.7.8 Mounting/dismounting the counterweight on the turntable.......................763 Installing.......................................................................763 Removing.........................................................................765 12.7.9 Assembling counterweight sections for driving the truck crane.................767 12.7.10 Slewing with rigged counterweight............................................769 12.8 Rigging work on the main boom.......................................................771 12.8.1 Hook block on the bumper......................................................771 Picking up the hook block........................................................771 Attaching the hook block.........................................................772 12.8.2 Hook block on a separate vehicle..............................................773 Picking up the hook block........................................................774 Setting down the hook block......................................................774 12.8.3 Reeving and unreeving the hoist rope..........................................777 Pocket lock......................................................................777 Fork.............................................................................778 Rope end clamp...................................................................779 Reeving the hoist rope...........................................................780 Unreeving the hoist rope.........................................................784 12.8.4 Possible reeving methods on the main boom.....................................785 With 8 head sheaves..............................................................785 12.8.5 Installing/removing the lifting limit switch..................................789 Installing the lifting limit switch..............................................789 Removing the lifting limit switch................................................792 12.8.6 Locking/unlocking the lifting limit switch....................................793 Locking..........................................................................793 Releasing locking................................................................794 12.8.7 Anemometer and air traffic control light......................................795 Installing.......................................................................795 Removing.........................................................................796 12.9 Other rigging work..................................................................797 12.9.1 Rigging in Free-on-wheels working position....................................797 12.9.2 Mirror for crane operation....................................................801 12.9.3 Cameras for crane operation...................................................802 Cameras on the hoists............................................................802 Camera on main boom..............................................................802 Turning the monitor on/off and switching.........................................804 13 Driving with rigged truck crane...........................................................807 13.1 Safety instructions.................................................................807 13.2 Driving distance....................................................................809 13.3 Before driving the rigged truck crane...............................................809 13.3.1 Check the tyre pressure and the wind speed....................................809 13.4 Permissible rigging modes and axle loads............................................811 13.4.1 Axle loads....................................................................811 13.4.2 To drive without a load.......................................................811 13.4.3 To drive with a load..........................................................812 13.5 Driving from the driver's cab.......................................................813 13.5.1 Preparing to drive............................................................813 Transmission.....................................................................813 Switching on separate steering...................................................813 Connections......................................................................813 13.5.2 While driving.................................................................814 13.6 Driving from the crane cab..........................................................815 13.6.1 Preparing to drive............................................................815 13.6.2 Opening/closing the Driving mode submenu......................................816 Automatic........................................................................816 Manual...........................................................................818 Closing..........................................................................818 13.6.3 Starting/turning off the engine for driving...................................819 Start the engine.................................................................819 Turning off the engine...........................................................820 13.6.4 Steering system...............................................................820 Switching on.....................................................................820 Adjusting the steering direction.................................................820 Displays when steering...........................................................821 Normal steering..................................................................821 Separate steering................................................................822 13.6.5 Operating the transmission....................................................823 Driving direction................................................................824 Selecting the transmission mode..................................................824 13.6.6 Camera system for driving from the crane cab..................................825 13.6.7 Starting......................................................................826 13.6.8 While driving.................................................................826 13.6.9 Warning messages..............................................................827 13.6.10 Possible connections.........................................................828 Longitudinal/ transverse differential locks......................................829 13.6.11 After driving................................................................830 13.7 Driving in combined operation.......................................................831 13.7.1 Switching combined operation on/off...........................................831 Prerequisites....................................................................831 Switching on.....................................................................832 Switching off....................................................................832 13.7.2 Starting/turning off the engine...............................................833 13.7.3 Preparing to drive............................................................834 Transmission.....................................................................834 Switching on separate steering...................................................834 Connections......................................................................834 13.7.4 While driving.................................................................835 Without load.....................................................................835 With load........................................................................836 14 Malfunctions during crane operation.......................................................839 14.1 Emergency stop switch...............................................................839 14.2 What to do when malfunctions occur during crane operation...........................841 Load can be lowered..................................................................841 Load cannot be lowered...............................................................841 14.3 Fuses on the superstructure.........................................................843 Notes on changing fuses..............................................................843 14.3.1 Fuses on the turntable........................................................844 Fuse groups F1/F2................................................................844 Fuses on the circuit board.......................................................845 14.3.2 Fuses in the crane cab........................................................846 14.3.3 Fuses in the battery box......................................................848 14.3.4 RCL fuses.....................................................................849 14.4 Finding and eliminating malfunctions................................................851 14.4.1 Malfunctions on the engine for crane operation................................851 14.4.2 Faults on the DEF system......................................................853 14.4.3 Malfunctions on the main hoist/auxiliary hoist................................854 14.4.4 Malfunctions in the hoist cameras.............................................855 14.4.5 Malfunctions in the main boom camera..........................................855 14.4.6 Malfunctions on the derricking gear...........................................856 14.4.7 Malfunctions in the telescoping mechanism.....................................857 Telescoping mechanism error messages.............................................859 14.4.8 Malfunctions on the slewing gear..............................................860 14.4.9 Malfunctions on the counterweight hoist unit..................................861 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler....................862 14.4.11 Malfunctions when inclining the crane cab....................................862 14.4.12 Malfunctions when operating with the hand-held control.......................862 14.4.13 Malfunctions when driving from the crane cab.................................863 14.4.14 Malfunctions of the outriggers...............................................864 14.4.15 Troubleshooting the RCL......................................................865 General malfunctions.............................................................865 Error messages...................................................................866 Table of error codes.............................................................868 Switching off thesensor/ tachogenerator.........................................871 14.4.16 Malfunctions ECOS – superstructure...........................................872 ECOS programme version...........................................................872 General malfunctions.............................................................872 Error messages...................................................................873 Exiting the submenu..............................................................874 14.4.17 Malfunctions on CraneSTAR system.............................................875 14.5 Emergency operations and programmes.................................................879 14.5.1 Mechanical emergency activation for retracting................................880 Prior to the emergency activation, check.........................................880 Procedure........................................................................880 Mechanical emergency activation..................................................881 14.5.2 Telescoping emergency programme...............................................883 Start the emergency program......................................................883 Determining the error type.......................................................884 Error on length indicator........................................................885 If there is an error at a proximity switch.......................................888 Terminating the emergency program................................................890 Tables for approaching the locking points........................................891 14.5.3 Entering the current telescoping..............................................893 14.5.4 Emergency operation with the hand-held control................................895 Preparations.....................................................................895 Operating a power unit...........................................................896 Stopping movements...............................................................898 Stopping movements in emergencies................................................898 Turning off the engine...........................................................898 14.5.5 Switching on emergency operation in coolant circuit...........................899 14.6 Hydraulic emergency operation.......................................................901 14.6.1 Operating principle...........................................................901 14.6.2 Connecting/disconnecting hoses................................................903 Establishing connections.........................................................903 Disconnecting....................................................................904 14.6.3 Switching emergency operation on/off..........................................905 14.6.4 Establishing the hydraulic circuits required..................................906 Switching over valves............................................................906 For lifting/ lowering............................................................908 For slewing......................................................................909 14.6.5 Performing emergency operation................................................909 Slewing in emergency operation...................................................910 Raising/lowering the boom in emergency operation.................................911 Lifting/lowering in emergency operation..........................................911 14.6.6 After emergency operation.....................................................912 Switching off emergency operation................................................912 Switching over to crane operation................................................912 Disconnecting the hoses..........................................................912 14.6.7 Emergency supply of another crane.............................................913 For emergency supply.............................................................913 After emergency supply...........................................................913 14.7 Other emergency operations..........................................................915 14.7.1 External starting socket......................................................915 Performing a jump start..........................................................916 14.7.2 Battery charger...............................................................916 15 Index.....................................................................................919 A........................................................................................921 B........................................................................................921 C........................................................................................921 D........................................................................................923 E........................................................................................925 F........................................................................................927 H........................................................................................927 I........................................................................................928 K........................................................................................929 L........................................................................................929 M........................................................................................930 O........................................................................................931 P........................................................................................932 R........................................................................................932 S........................................................................................933 T........................................................................................934 V........................................................................................936 W........................................................................................936
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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