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Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112498 – PDF DOWNLOAD
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Description
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112498 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112498 – PDF DOWNLOAD
Language : English
Pages : 936
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112498 – PDF DOWNLOAD
Intended use:
The GMK 5130-2 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 5130-2 truck crane may only be used in a perfect technical condi- tion as intended and with
due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - Without the corresponding special equipment, the GMK 5130-2 truck crane may only be operated within
the permitted temperature range; à Technical
Information on the carrier, p. 8 – 1. - The GMK 5130-2 truck crane is designed solely for lifting loads which are within the permitted GMK
5130-2 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 5130-2 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 5130-2.
TABLE OF CONTENTS:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112498 – PDF DOWNLOAD
Additional pages.............................................................................. 3 Auxiliary air heater...................................................................... 3 Switching on.......................................................................... 4 Setting the heating level............................................................. 5 Setting the day and time.............................................................. 6 Setting the preselection time......................................................... 6 Deleting preselection times........................................................... 8 Switching off......................................................................... 9 Additional page............................................................................... 11 Transfer case............................................................................. 11 Short description of the operating elements........................................... 11 Transfer case – off-road gear on / off................................................ 12 Towing the truck crane................................................................ 13 Transfer case malfunctions............................................................ 13 Longitudinal differential locks....................................................... 13 Technical data........................................................................ 14 Correction sheet.............................................................................. 15 Possible reeving methods on the main boom................................................. 15 Correction sheet.............................................................................. 19 Slewing gear freewheel.................................................................... 19 Switching on.......................................................................... 19 Switching off......................................................................... 21 Additional page............................................................................... 23 Driving modes 12 t (26,500 lbs) axle load................................................. 23 Information on how to use the tables.................................................. 23 Tables for a maximum axle load of 12 t (26,500 lbs)................................... 24 For 14.00 R25 tyres............................................................... 24 For 16.00 R25 tyres............................................................... 25 For 20.5 R25 tyres................................................................ 26 Correction sheet – Accepting the telescope status............................................. 27 1 Overview.................................................................................... 33 1.1 Identification........................................................................ 33 1.2 EC Declaration of Conformity.......................................................... 37 1.3 Documentation supplied................................................................ 38 1.4 Information about the operating instructions.......................................... 39 1.4.1 What do the symbols used mean?.................................................. 39 1.4.2 How are the operating instructions structured?.................................. 41 Division.......................................................................... 41 Structure of the chapters......................................................... 41 Structure of the pages............................................................ 42 1.4.3 How do I find the information I need?........................................... 43 Cross-references example.......................................................... 44 1.4.4 What information is available for operations planning?.......................... 46 1.5 Conversion table for US measurements.................................................. 47 2 Basic safety instructions................................................................... 51 2.1 Intended use.......................................................................... 51 2.1.1 Improper use.................................................................... 52 2.2 Organisational measures............................................................... 53 2.3 Qualifications of the personnel....................................................... 55 2.4 Safety instructions for driving the truck crane....................................... 56 2.5 Safety instructions for crane operation............................................... 57 3 Operating elements for driving.............................................................. 61 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 Display, driver's cab........................................................... 70 3.1.5 Steering column/steering wheel.................................................. 71 3.1.6 Transmission operating elements................................................. 72 3.1.7 Tachograph...................................................................... 73 3.1.8 ECOS control unit............................................................... 74 3.1.9 ECOS display – main menu........................................................ 76 3.1.10 ECOS display – submenus........................................................ 78 Level adjustment system submenu................................................... 78 Settings submenu.................................................................. 80 Operating hours submenu........................................................... 81 Warning submenu................................................................... 81 Transmission emergency program submenu............................................ 82 Error submenu..................................................................... 83 3.1.11 Heating/Air-conditioning system................................................ 84 Standard heating system........................................................... 84 Auxiliary heater.................................................................. 85 3.1.12 Sockets for hand-held control.................................................. 86 3.1.13 Outrigger control units........................................................ 87 3.2 Short description of the operating elements........................................... 89 3.2.1 Definition of information relating to directions of movement.................... 89 Basic rule........................................................................ 89 Switches and buttons.............................................................. 90 3.2.2 General information on the operating elements................................... 90 3.2.3 General rules for buttons and symbols on the display............................ 91 3.2.4 Engine.......................................................................... 92 Steering column................................................................... 92 Multipurpose switch............................................................... 92 Instrument panel.................................................................. 93 Main menu......................................................................... 94 3.2.5 Electrical system............................................................... 95 3.2.6 ECOS crane control.............................................................. 95 Control unit...................................................................... 95 3.2.7 Transmission.................................................................... 98 Transmission display.............................................................. 98 ECOS display...................................................................... 98 Operating elements................................................................ 99 Instrument panel..................................................................100 3.2.8 Axle drive......................................................................101 3.2.9 Brakes..........................................................................102 Service brake.....................................................................102 Parking brake.....................................................................103 Additional brakes.................................................................104 3.2.10 Steering/separate steering.....................................................105 ECOS display......................................................................105 Driver's door.....................................................................105 3.2.11 Suspension.....................................................................106 3.2.12 Lighting/windscreen wipers/horn................................................107 Steering column...................................................................107 Instrument panel..................................................................107 Roof..............................................................................109 3.2.13 Level adjustment system........................................................109 3.2.14 Tachograph/speedometer.........................................................111 Tachograph........................................................................111 Speedometer.......................................................................111 3.2.15 Diagnostics....................................................................112 Displays/ submenu.................................................................112 3.2.16 On-board computer..............................................................113 3.2.17 Push-up roof...................................................................115 3.2.18 Windows, doors, keys...........................................................115 Window winder.....................................................................115 Doors.............................................................................116 Keys..............................................................................116 3.2.19 Front flap.....................................................................117 4 Starting/turning off the engine for driving.................................................121 4.1 Starting the engine from the driver's cab.............................................121 4.1.1 CHECKLIST: Starting the engine..................................................121 4.1.2 CHECKLIST: At low temperatures..................................................124 4.1.3 Ladders and access ladders......................................................125 Access ladders....................................................................125 Ladders...........................................................................125 4.1.4 Refueling.......................................................................127 4.1.5 Inspections before starting the engine..........................................128 On the hydraulic tank.............................................................128 Battery master switch.............................................................128 Checking the hand-held control....................................................129 4.1.6 Switch on the ignition..........................................................129 4.1.7 Lamp test/equalisation of the switching states..................................130 Lamp test.........................................................................130 Equalisation of the switching states..............................................131 4.1.8 Display – setting the brightness................................................132 4.1.9 Starting the engine.............................................................133 Without flame start system........................................................134 With flame start system...........................................................135 4.1.10 Inspections after starting the engine..........................................136 4.1.11 Monitoring elements............................................................137 Instrument panel..................................................................137 ECOS display......................................................................138 Driving display...................................................................138 4.1.12 Setting the idling speed.......................................................139 4.2 Turning off the engine................................................................141 4.2.1 On the ignition lock/with hand-held control.....................................141 After parking.....................................................................141 4.2.2 With emergency stop switches....................................................142 Resetting the emergency stop switch...............................................142 4.3 Air intake inhibitor..................................................................143 Releasing the air intake inhibitor....................................................143 5 Driving.....................................................................................147 5.1 Before driving........................................................................147 5.1.1 CHECKLIST: Checks before on-road driving........................................147 5.1.2 Checking the condition of the truck crane.......................................152 Windscreen washing system........................................................152 Electrical system.................................................................152 Adjusting the mirrors.............................................................153 Warning plates for vehicle width..................................................154 Displaying the vehicle height.....................................................154 Supply pressure...................................................................155 Parking brake.....................................................................156 5.1.3 Adjusting the seat and the steering column......................................157 Driver's seat.....................................................................157 Passenger's seat..................................................................158 Adjusting the steering column.....................................................159 5.1.4 Switching the suspension on/off.................................................160 Opening the submenu...............................................................160 Switching on the suspension.......................................................161 Switching off the suspension......................................................161 5.1.5 Adjusting the tachograph........................................................162 Prerequisites.....................................................................162 In the event of malfunctions......................................................162 Adjusting the tachograph..........................................................163 Additional displays...............................................................166 5.1.6 Displaying the operating hours..................................................167 5.1.7 Settings/displays with the on-board computer....................................169 Operation.........................................................................169 Overview..........................................................................170 Inspection information............................................................170 Error information.................................................................171 Alarm clock.......................................................................171 Language..........................................................................172 Settings..........................................................................172 Diagnostics.......................................................................173 5.2 Operating the transmission............................................................175 5.2.1 Switching on....................................................................175 5.2.2 Switching the transmission to neutral position..................................176 5.2.3 Changing the operating mode.....................................................176 Change-over to automatic mode.....................................................176 Change-over to manual mode........................................................176 5.2.4 Display of the selected gears...................................................177 5.2.5 Selecting the direction of travel and starting gear.............................177 Selecting the driving direction...................................................177 Selecting the starting gear.......................................................178 5.2.6 Starting........................................................................179 5.2.7 Driving and changing gears......................................................180 In automatic operating mode......................................................180 In manual operating mode.........................................................181 5.2.8 Changing the driving direction..................................................182 Quick change of gear..............................................................182 5.2.9 Stopping........................................................................183 Stopping for a long period of time................................................183 5.2.10 On the roller type dynamometer.................................................183 5.3 Driving and turning off the truck crane...............................................185 5.3.1 Checks while driving............................................................185 Immediately after you start to move...............................................185 While driving.....................................................................186 Switching on......................................................................187 Switching off.....................................................................188 5.3.3 Temposet........................................................................189 Switching on......................................................................189 Switching off.....................................................................189 5.3.4 Driving downhill................................................................190 Starting..........................................................................190 Checks when driving downhill.....................................................190 Downshifting......................................................................191 Additional brakes.................................................................192 5.3.5 Driving uphill..................................................................193 Starting..........................................................................193 Driving...........................................................................193 5.3.6 Warning submenu.................................................................194 Meaning of the symbols............................................................194 Exiting the submenu...............................................................195 5.3.7 Error submenu...................................................................196 5.3.8 Messages on the On-board computer display.......................................196 Warnings..........................................................................197 Warning messages..................................................................198 Error messages....................................................................199 Information.......................................................................201 5.3.9 Turning off the truck crane.....................................................204 Secure against rolling away.......................................................204 When stationary for more than 8hours.............................................205 5.4 Off-road driving......................................................................207 Adjustments to the transmission.......................................................207 Connections...........................................................................207 Changing the vehicle level............................................................207 Rocking the vehicle free and towing...................................................207 5.4.1 Longitudinal and transverse differential locks..................................208 5.4.2 Operating the level adjustment system...........................................210 Opening the submenu..............................................................210 Setting the on-road level.........................................................211 Pre-selecting suspension struts...................................................211 Changing the vehicle level........................................................212 Viewing the current inclination...................................................212 Exiting the submenu...............................................................213 5.4.3 Freeing the truck crane stuck in terrain........................................214 Rocking the truck crane free......................................................214 Towing free forward..............................................................215 Towing free to the rear...........................................................215 5.4.4 Separate steering...............................................................216 Switching to separate steering....................................................216 Steering..........................................................................217 Switching to normal steering mode.................................................218 5.5 Heating and air-conditioning system...................................................219 5.5.1 Standard heating system.........................................................219 Switching on......................................................................219 Heating...........................................................................219 Air distribution..................................................................220 Examples..........................................................................221 Switching off.....................................................................221 5.5.2 Air-conditioning system.........................................................222 Warnings..........................................................................222 Switching on/off..................................................................222 Cooling...........................................................................223 Drying............................................................................223 5.5.3 Auxiliary heater................................................................224 Switching on......................................................................224 Temperature.......................................................................225 Setting the day and time..........................................................225 Storing the heating start........................................................226 Setting the heating period.......................................................227 Switching the heating start on and off............................................227 Switching off.....................................................................228 Setting the remaining run time...................................................228 5.6 Towing a trailer......................................................................229 Effects on the axle loads.............................................................229 Coupling the trailer..................................................................230 Connecting the supply lines...........................................................231 Removing supply lines.................................................................232 Uncoupling the trailer................................................................232 Checking the braking force...........................................................234 6 Driving modes...............................................................................237 6.1 Driving modes.........................................................................237 Information about the axle loads......................................................237 6.1.1 Information on how to use the tables............................................238 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs).............................239 For 14.00 R25 tyres...............................................................239 For 16.00 R25 tyres...............................................................240 For 20.5 R25 tyres...............................................................241 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)............242 6.2 Rigging work for driving with a trailer...............................................243 6.2.1 Switching on the slewing gear freewheel.........................................244 Switching on boom floating position...............................................245 6.2.2 Switching on boom pre-tensioning................................................246 6.2.3 Switching the superstructure driving lights on/off..............................248 Switching off.....................................................................248 Switching on......................................................................248 6.3 Rigging the main boom.................................................................249 Additional equipment required.........................................................249 6.3.1 CHECKLIST: Removing the main boom...............................................250 Prerequisites.....................................................................250 Checklist.........................................................................250 6.3.2 CHECKLIST: Mounting the main boom...............................................253 Prerequisites.....................................................................253 Checklist.........................................................................253 6.3.3 Slinging the main boom..........................................................256 6.3.4 Removing/attaching the clamp....................................................257 6.3.5 Hydraulic connection for the lattice extension..................................258 6.3.6 Switching the pressure relief on/off............................................259 6.3.7 Retracting/fitting the derricking cylinder head pin.............................260 Retracting the derricking cylinder head axle.....................................261 Fitting the derricking cylinder head axle........................................262 6.3.8 Retracting/extending the boom pivot pin.........................................263 Before retracting.................................................................263 After extension...................................................................263 Retracting/ extending the pivot pin...............................................264 6.3.9 Disconnecting the hydraulic/electrical connections..............................265 Lifting in front of the turntable.................................................265 Disconnecting.....................................................................266 6.3.10 Establishing the hydraulic/electrical connection...............................267 Lifting onto the turntable........................................................267 Establishing......................................................................268 6.3.11 Aligning the connecting points.................................................269 6.3.12 Securing/releasing the derricking cylinder.....................................269 6.3.13 Transporting the main boom.....................................................270 6.3.14 Inspections after main boom mounting...........................................271 7 Malfunctions in driving mode................................................................275 7.1 Emergency stop switch.................................................................275 7.2 What to do when a malfunction occurs in road traffic..................................277 7.3 Towing the truck crane................................................................279 7.3.1 Towing in the event of engine or transmission damage............................280 Compressed-air supply.............................................................280 Electric power supply.............................................................280 On the transmission..............................................................281 Axle drives.......................................................................282 Parking brake.....................................................................282 Towing the truck crane out of the danger area.....................................283 7.3.2 Tow starting....................................................................284 7.4 Wheels and tyres......................................................................285 7.4.1 Wheel change....................................................................285 Removing a damaged wheel.........................................................286 On the spare wheel holder.........................................................286 Mounting a wheel..................................................................287 7.4.2 Filling the tyres yourself......................................................289 Connecting the filling hose.......................................................289 Filling the tyres.................................................................290 Removing the filling hose........................................................290 7.5 Fuses.................................................................................291 Information on replacing fuses........................................................291 7.5.1 Fuses in the driver's cab.......................................................292 F1 to F 41........................................................................292 A1 to A3..........................................................................294 7.5.2 Fuses in the battery box........................................................296 7.6 Troubleshooting.......................................................................297 7.6.1 Malfunctions on the engine......................................................297 7.6.2 Malfunctions to the transmission................................................299 7.6.3 Malfunctions of the service brake...............................................300 7.6.4 Malfunctions of the steering....................................................301 7.6.5 Differential lock malfunctions..................................................302 7.6.6 Malfunctions in the hydraulic system/hydraulic oil cooler.......................302 7.6.7 Malfunctions on the suspension..................................................303 7.6.8 Malfunctions of the level adjustment system.....................................303 7.6.9 Malfunctions on the ECOS carrier................................................304 ECOS program version..............................................................304 General malfunctions.............................................................304 Error messages....................................................................305 Exiting the submenu..............................................................306 On the control units..............................................................307 7.7 Procedure in the event of malfunctions................................................309 7.7.1 Switching on emergency operation in coolant circuit.............................309 7.7.2 Procedure in the event of malfunctions to the transmission andengine...........310 Engine............................................................................310 Transmission......................................................................311 Transmission emergency program submenu..........................................312 Emergency compressed air supply...................................................315 ID number of the transmission.....................................................317 8 Technical Information on the carrier........................................................321 8.1 Technical data........................................................................321 8.1.1 Dimensions and weights of the truck crane, axle loads...........................322 Dimensions........................................................................323 Weight and axle loads.............................................................323 8.1.2 Dimensions and weights of removable parts.......................................324 Spare wheel.......................................................................324 Outriggers........................................................................324 Main boom.........................................................................324 8.1.3 Carrier.........................................................................325 Engine............................................................................325 Transmission......................................................................325 Transfer case.....................................................................325 Axle lines........................................................................325 Steering..........................................................................325 Tyres.............................................................................326 Outriggers........................................................................326 Electrical system.................................................................326 Tools.............................................................................327 Towing coupling...................................................................327 Driving speeds....................................................................327 Climbing ability..................................................................327 Turning circle radiuses..........................................................327 9 Index.......................................................................................331 A.........................................................................................333 B.........................................................................................333 C.........................................................................................333 D.........................................................................................335 E.........................................................................................337 F.........................................................................................339 H.........................................................................................339 I.........................................................................................340 K.........................................................................................340 L.........................................................................................340 M.........................................................................................341 O.........................................................................................342 P.........................................................................................343 R.........................................................................................343 S.........................................................................................344 T.........................................................................................346 V.........................................................................................347 W.........................................................................................347 Additional pages..............................................................................353 Auxiliary air heater......................................................................353 Switching on..........................................................................354 Setting the heating level.............................................................355 Setting the day and time..............................................................356 Setting the preselection time.........................................................356 Deleting preselection times...........................................................358 Switching off.........................................................................359 Additional page...............................................................................361 Transfer case.............................................................................361 Short description of the operating elements...........................................361 Transfer case – off-road gear on / off................................................362 Towing the truck crane................................................................363 Transfer case malfunctions............................................................363 Longitudinal differential locks.......................................................363 Technical data........................................................................364 Correction sheet..............................................................................365 Possible reeving methods on the main boom.................................................365 Correction sheet..............................................................................369 Slewing gear freewheel....................................................................369 Switching on..........................................................................369 Switching off.........................................................................371 Additional page...............................................................................373 Driving modes 12 t (26,500 lbs) axle load.................................................373 Information on how to use the tables..................................................373 Tables for a maximum axle load of 12 t (26,500 lbs)...................................374 For 14.00 R25 tyres...............................................................374 For 16.00 R25 tyres...............................................................375 For 20.5 R25 tyres................................................................376 Correction sheet – Accepting the telescope status ............................................377 10 Operating elements for crane operation.....................................................383 10.1 Overview of the operating elements...................................................383 10.1.1 On the outside of the truck crane..............................................384 10.1.2 Crane cab......................................................................386 10.1.3 Front panel....................................................................388 10.1.4 Side panel.....................................................................389 Bottom............................................................................389 Top...............................................................................390 Standard heating system...........................................................393 Auxiliary water heating system....................................................394 Auxiliary air heater..............................................................395 10.1.5 Control panels.................................................................396 Left..............................................................................396 Right.............................................................................397 10.1.6 Control lever assignment.......................................................398 Version 1.........................................................................398 Version 2.........................................................................399 10.1.7 ECOS control unit..............................................................400 10.1.8 ECOS display – main menu.......................................................402 10.1.9 ECOS display – submenus........................................................404 Counterweight submenu.............................................................404 Slewing gear/ Houselock submenu..................................................405 Outriggers submenu...............................................................406 Telescoping submenu..............................................................408 Submenu Power unit speed..........................................................410 Monitoring submenu...............................................................411 Settings submenu..................................................................412 Submenu Operating hours..........................................................414 Submenu Warning..................................................................415 Error submenu.....................................................................417 Working range limiter submenu.....................................................418 Driving submenu...................................................................420 10.1.10 SLI control unit..............................................................422 10.1.11 SLI display – main menu.......................................................424 10.1.12 SLI display – submenus........................................................425 Enter rigging mode submenu........................................................425 Monitoring submenu...............................................................426 Rigging mode monitoring submenu..................................................428 Lifting capacity table submenu....................................................429 Working range submenu.............................................................430 Error submenu.....................................................................431 Settings submenu..................................................................433 10.1.13 Hand-held control.............................................................434 Outriggers control panel.........................................................435 10.1.14 Outriggers control units......................................................436 Outriggers........................................................................437 Outrigger pressure display.......................................................437 Inclination indicator............................................................437 10.2 Short description of the operating elements..........................................439 10.2.1 Definition of information relating to directions of movement...................439 Basic rule........................................................................439 Switch............................................................................439 10.2.2 General rules for buttons and symbols on the display...........................440 10.2.3 Engine for crane operation.....................................................441 Side panel........................................................................441 ECOS display......................................................................441 10.2.4 Engine for driving.............................................................442 Side panel........................................................................442 Main menu.........................................................................442 Outriggers submenu...............................................................443 10.2.5 Seat contact switch and dead man's switch......................................444 10.2.6 ECOS crane control.............................................................445 Control unit......................................................................445 10.2.7 Outriggers.....................................................................448 Hand-held control.................................................................448 In the Outriggers submenu.........................................................449 In the settings submenu...........................................................450 On the Outriggers control units...................................................451 10.2.8 Inclination indicators.........................................................453 10.2.9 Outrigger pressure displays....................................................454 Outriggers submenu...............................................................454 Outriggers control units.........................................................454 10.2.10 Anemometer display............................................................454 10.2.11 Counterweight submenu.........................................................455 Counterweight submenu.............................................................455 10.2.12 Main hoist....................................................................457 10.2.13 Auxiliary hoist...............................................................459 10.2.14 Slewing gear..................................................................460 Submenu...........................................................................461 10.2.15 Derricking gear...............................................................463 10.2.16 Telescoping mechanism.........................................................464 Control panels....................................................................464 Submenu...........................................................................465 In the settings submenu...........................................................469 10.2.17 Hydraulic system..............................................................471 10.2.18 Houselock.....................................................................472 10.2.19 Safe load indicator (SLI).....................................................472 Control unit......................................................................472 Main menu.........................................................................475 Enter rigging mode submenu........................................................476 Monitoring submenu...............................................................479 Lifting capacity table submenu....................................................483 Working range submenu.............................................................483 Other.............................................................................484 10.2.20 Electrical system.............................................................485 10.2.21 Lighting, windscreen wiper/washing system.....................................485 Lighting..........................................................................485 Windscreen wiper/ washing system..................................................487 10.2.22 Hand-held control.............................................................488 Sockets for hand- held control....................................................488 Engine control panel..............................................................489 Horn..............................................................................489 Outriggers control panel.........................................................490 10.2.23 Windows, doors, keys..........................................................492 Windows...........................................................................492 Crane cab door....................................................................492 Keys..............................................................................493 10.2.24 Diagnostics...................................................................494 10.3 Short description of the operating elements – driving from the crane cab.............495 10.3.1 Driving submenu................................................................495 10.3.2 Engine for driving.............................................................496 10.3.3 Transmission...................................................................497 10.3.4 Axle drive.....................................................................498 10.3.5 Brakes.........................................................................499 Side panel........................................................................499 ECOS display......................................................................499 10.3.6 Steering.......................................................................500 Normal steering...................................................................501 Separate steering.................................................................501 11 Starting/Stopping the engine – for crane operation........................................505 11.1 Starting the engine – from the crane cab.............................................505 11.1.1 CHECKLIST: Starting the engine.................................................505 11.1.2 CHECKLIST: At low temperatures.................................................508 11.1.3 Refueling......................................................................508 11.1.4 Inspections before starting the engine.........................................510 On the hydraulic tank.............................................................510 Battery master switch.............................................................510 Checking the hand-held control....................................................511 11.1.5 Switching on the ignition......................................................511 11.1.6 Lamp test/equalisation of the switching states.................................512 Lamp test.........................................................................512 Equalisation of the switching states..............................................513 11.1.7 Setting the display brightness.................................................514 11.1.8 Starting the engine............................................................515 Without flame start system........................................................515 With flame start system...........................................................516 11.1.9 Inspections after starting the engine..........................................517 11.1.10 Monitoring submenu............................................................518 11.1.11 Setting the idling speed......................................................519 11.2 Starting the engine – with the hand-held control.....................................521 Prerequisites.........................................................................521 Starting the engine...................................................................521 11.3 Turning off the engine...............................................................523 11.3.1 During normal operation, with the ignition lock/with the hand- held control....523 After parking.....................................................................523 11.3.2 In emergencies, with the emergency stop switches...............................524 Resetting the emergency stop switch...............................................524 11.4 Air intake inhibitor.................................................................525 Releasing the air intake inhibitor....................................................525 12 Crane operation............................................................................529 12.1 Before crane operation...............................................................529 12.1.1 CHECKLIST: Inspections prior to crane operation................................529 12.1.2 Checking the condition of the truck crane......................................533 Tank for windscreen washing system................................................533 Visual inspection.................................................................533 Checking the position of the hoist ropes.........................................534 Checking the electrical system...................................................534 12.1.3 Adjusting the crane cab seat and front panel...................................535 Crane cab seat....................................................................535 Front panel.......................................................................536 12.1.4 Checking the safety devices....................................................537 Safe load indicator...............................................................537 Lifting limit switch..............................................................537 Emergency stop switch.............................................................538 Seat contact switch...............................................................539 12.1.5 Load, earthing.................................................................540 12.1.6 Preheating the hydraulic oil...................................................541 12.1.7 Locking/unlocking the turntable................................................542 Locking points....................................................................542 Locking the turntable............................................................543 Unlocking the turntable...........................................................543 12.1.8 Switching the houselock on/off.................................................544 Switching on the houselock........................................................544 Switching off the houselock.......................................................546 12.2 Operation of the safe load indicator.................................................547 12.2.1 Switching on the SLI...........................................................548 Switching on......................................................................548 Brightness of the displays........................................................550 12.2.2 Entering the rigging mode......................................................551 Entering individual components....................................................552 Entering the SLIcode.............................................................555 Entering the reeving.............................................................556 Accepting the rigging mode.......................................................556 12.2.3 Inspections prior to crane operation...........................................558 Opening the submenu..............................................................558 Checking..........................................................................559 12.2.4 Displays during crane operation................................................561 12.2.5 SLI early warning..............................................................564 12.2.6 SLI shutdown...................................................................564 Shutdown due to overload..........................................................564 12.2.7 Display in the event of errors.................................................566 12.2.8 SLI override...................................................................567 12.2.9 Displaying the lifting capacity tables.........................................568 12.2.10 Entering the time/date........................................................570 12.3 Crane operation with main boom.......................................................571 12.3.1 Checks during crane operation..................................................571 Horizontal alignment.............................................................571 Safe distances....................................................................571 Checking the wind speed...........................................................572 12.3.2 Permissible slewing ranges and working positions...............................573 360 slewing range................................................................573 Working position 0 to the rear...................................................573 180 to the front rigging position................................................574 Free-on-wheels working position...................................................574 12.3.3 Main hoist.....................................................................575 Switching on the main hoist.......................................................576 Lifting and lowering.............................................................576 Switching off the main hoist......................................................577 12.3.4 Auxiliary hoist................................................................578 Switching on the auxiliary hoist..................................................578 Lifting and lowering.............................................................579 Switching off the auxiliary hoist.................................................580 12.3.5 Lifting limit switch and lowering limit switch.................................581 Lifting limit switch..............................................................581 Lowering limit switch.............................................................583 12.3.6 Derricking gear................................................................584 Switching on the derricking gear..................................................584 Raising and lowering.............................................................585 Switching off the derricking gear.................................................586 Lowering the main boom to ahorizontal position..................................586 12.3.7 Telescoping mechanism..........................................................587 Overview..........................................................................588 Telescoping process..............................................................588 Assignment for display............................................................590 Fixed length, intermediate length, telescoping length............................592 Telescoping.......................................................................593 Telescoping sequence..............................................................593 Inspections prior to starting operations.........................................594 Switching on the telescoping mechanism...........................................595 Function of the control lever.....................................................595 Switching off the telescoping mechanism...........................................597 Manual telescoping...............................................................598 Checking the initial position....................................................598 Unlocking the telescoping cylinder..............................................601 Extending/ retracting the telescoping cylinder.................................603 Lock telescoping cylinder.........................................................604 Unlocking the telescopic section.................................................605 Telescoping the telescopic section................................................607 Locking the telescopic section...................................................608 Locking the telescopic section for on-road driving...............................609 Telescoping with teleautomation...................................................610 Telescoping the main boom in horizontal position................................615 12.3.8 High-speed mode................................................................616 Switch on function...............................................................616 Derricking gear/ Telescoping mechanism............................................616 Hoists............................................................................617 12.3.9 Slewing gear...................................................................618 Slewing gear brake................................................................618 Switching on the slewing gear.....................................................619 Releasing the slewing gear brake..................................................619 Engaging the slewing gear brake...................................................619 Slewing...........................................................................620 Slewing to 0 or 180 .............................................................622 Braking the slewing movement......................................................623 Slewing gear freewheel...........................................................623 Switching off the slewing gear....................................................624 12.3.10 Possible movement combinations................................................624 12.3.11 Hydraulic oil cooling.........................................................625 12.4 Settings and displays for crane operation............................................627 12.4.1 Inclining the crane cab........................................................627 12.4.2 Setting the idling speed.......................................................627 12.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................628 12.4.4 Limiting the power unit speeds.................................................628 12.4.5 Setting the characteristic curves for the control levers.......................630 12.4.6 Critical load control..........................................................631 Function..........................................................................631 Switching on andoff..............................................................631 12.4.7 Operation of the directional spotlights........................................632 12.4.8 Displaying the operating hours.................................................633 12.4.9 Warning submenu................................................................634 Meaning of the symbols............................................................634 Exiting the submenu..............................................................637 12.4.10 Error submenu.................................................................637 12.5 Working range limiter................................................................639 12.5.1 Opening the Working range limiter submenu......................................640 12.5.2 Viewing current settings.......................................................640 12.5.3 Entering limit values..........................................................642 Overall height/ Working radius....................................................642 Slewing angle.....................................................................643 Entering objects..................................................................645 12.5.4 Entering limit values/objects manually.........................................648 Limit values......................................................................648 Objects...........................................................................649 12.5.5 Switching monitoring functions on/off..........................................650 12.5.6 Shutdown by working range limiter..............................................651 12.6 Work break...........................................................................653 12.6.1 In case of short work breaks...................................................653 12.6.2 In case of work breaks of more than 8 hours....................................654 To secure the truck crane.........................................................654 12.7 Heating and air-conditioning system..................................................655 12.7.1 Standard heating system........................................................655 Switching on......................................................................655 Heating...........................................................................655 Air distribution..................................................................656 Switching off.....................................................................657 12.7.2 Air-conditioning system........................................................657 Warnings..........................................................................657 Switching on/off..................................................................658 Cooling...........................................................................658 Drying the air....................................................................659 12.7.3 Auxiliary water heating system.................................................659 Preheating the engine.............................................................660 Preheating the crane cab..........................................................660 Switching on......................................................................661 Setting the day and time..........................................................662 Storing the heating start........................................................663 Setting the heating period.......................................................664 Switching heating start on/off....................................................664 Switching off.....................................................................665 Setting the remaining run time....................................................665 12.7.4 Auxiliary air heater...........................................................666 Switching on......................................................................666 Temperature.......................................................................667 Switching off.....................................................................667 Other functions...................................................................667 13 Rigging work...............................................................................671 13.1 Rigging work checklists for crane operation with the main boom.......................671 13.1.1 CHECKLIST: Rigging.............................................................671 13.1.2 CHECKLIST: Unrigging...........................................................675 13.2 Choosing a suitable site.............................................................679 13.2.1 Determining the required ground bearing area...................................679 13.2.2 Safe distance from slopes and pits.............................................682 13.2.3 Earthing the truck crane.......................................................683 13.2.4 Safe distance from electrical cables...........................................684 13.3 Rigging work after driving with a trailer............................................687 13.3.1 Switching off the boom floating position.......................................687 13.3.2 Switching off the slewing gear freewheel.......................................688 Before slewing....................................................................688 13.3.3 Switching off boom pre-tensioning..............................................689 13.4 Connecting/disconnecting the hand-held control.......................................691 13.5 Starting the engine for driving for rigging work.....................................693 13.5.1 Starting/turning off the engine with the hand-held control.....................693 Prerequisites.....................................................................693 Starting the engine...............................................................694 Turning off the engine............................................................694 13.5.2 Starting/turning off the engine from the crane cab.............................695 Prerequisites.....................................................................695 Starting the engine...............................................................695 After starting the engine.........................................................696 Turning off the engine............................................................696 13.6 Outriggers...........................................................................697 13.6.1 CHECKLIST: Extending the outriggers............................................697 13.6.2 CHECKLIST: Retracting the outriggers...........................................699 13.6.3 Permissible outrigger spans....................................................700 13.6.4 Preparing the truck crane......................................................701 In the driver's cab...............................................................701 Outriggers controlunits..........................................................701 13.6.5 Setting the spans..............................................................702 For on-road driving..............................................................704 13.6.6 Extending/retracting outriggers................................................705 From the control units............................................................706 With the hand- held control.......................................................707 From the crane cab................................................................709 13.6.7 Moving the outrigger pads into working/driving position........................711 13.6.8 Enlarging the ground bearing area..............................................712 13.6.9 Extending/retracting supporting cylinders......................................713 From the control units............................................................714 With the hand- held control.......................................................715 From the crane cab................................................................716 13.6.10 Leveling the truck crane on outriggers horizontally...........................718 Inclination indicators...........................................................718 Prerequisites.....................................................................719 Manual alignment..................................................................720 Automatic alignment..............................................................721 13.6.11 Leveling the free-standing truck crane........................................723 13.6.12 Outrigger pressure display....................................................725 13.7 Rigging/unrigging the counterweight..................................................727 13.7.1 Counterweight sections.........................................................727 Basic version.....................................................................727 Additional version1..............................................................728 Additional version2..............................................................728 Additional version3..............................................................729 Additional version4..............................................................729 13.7.2 Identification.................................................................730 13.7.3 Slinging points on the counterweight sections..................................731 13.7.4 CHECKLIST: Rigging the counterweight...........................................733 13.7.5 CHECKLIST: Unrigging the counterweight.........................................735 13.7.6 Assembling counterweight combination...........................................737 Combinations on the turntable.....................................................738 Setting down the 2.5 t base plate.................................................739 Combinations for the basic version................................................741 Combinations with additional equipment............................................746 13.7.7 Counterweight hoist unit.......................................................757 Counterweight submenu.............................................................757 Extending/ retracting the lifting cylinders.....................................758 Locking/Unlocking counterweight...................................................760 13.7.8 Mounting/Dismounting the counterweight on the turntable........................761 Mounting..........................................................................761 Dismounting.......................................................................763 13.7.9 Assembling counterweight sections for driving the truck crane..................765 13.7.10 Slewing with rigged counterweight.............................................767 13.8 Rigging work on the main boom........................................................769 13.8.1 Hook block on the bumper.......................................................769 Picking up the hook block.........................................................769 Attaching the hook block..........................................................770 13.8.2 Hook block on a separate vehicle...............................................771 Picking up the hook block.........................................................772 Setting down the hook block.......................................................772 13.8.3 Reeving and unreeving the hoist rope...........................................774 Fastening the rope end clamp......................................................774 Reeving the hoist rope............................................................776 Unreeving hoist rope..............................................................779 13.8.4 Possible reeving methods on the main boom......................................780 With 7 head sheaves...............................................................780 With 8 head sheaves...............................................................783 13.8.5 Installing/removing the lifting limit switch...................................786 Installing the lifting limit switch..............................................786 Removing the lifting limit switch................................................789 13.8.6 Locking/Unlocking the lifting limit switch.....................................790 Locking...........................................................................790 Removing the lock.................................................................791 13.8.7 Anemometer and air traffic control light.......................................792 Mounting..........................................................................792 Dismounting.......................................................................793 13.9 Other rigging work...................................................................795 13.9.1 Rigging in free on wheels working position.....................................795 13.9.2 Mirror for crane operation.....................................................797 14 Driving with a rigged truck crane..........................................................801 14.1 Driving route........................................................................803 14.2 Before driving the rigged truck crane................................................803 14.2.1 check the tyre pressure and the wind speed.....................................803 14.3 Permissible rigging modes and axle loads.............................................805 14.3.1 Axle loads.....................................................................805 14.3.2 To drive without a load........................................................805 14.3.3 To drive with a load...........................................................806 14.4 Driving from the driver's cab........................................................807 14.4.1 Preparing to drive.............................................................807 Transmission......................................................................807 Switching on separate steering....................................................807 Connections.......................................................................807 14.4.2 While driving..................................................................808 14.5 Driving from the crane cab...........................................................809 14.5.1 Preparing to drive.............................................................809 14.5.2 Opening/closing the Driving mode submenu.......................................810 Automatic.........................................................................810 Manual............................................................................812 Closing...........................................................................812 14.5.3 Starting/turning off the engine for driving....................................813 Starting the engine...............................................................813 Turning off the engine............................................................814 14.5.4 Steering.......................................................................814 Switching on......................................................................814 Adjusting the steering direction..................................................814 Displays when steering............................................................815 Normal steering...................................................................815 Separate steering.................................................................816 14.5.5 Operating the transmission.....................................................817 Driving direction.................................................................818 Selecting the gear position.......................................................818 14.5.6 Starting.......................................................................819 14.5.7 While driving..................................................................819 14.5.8 Warning messages...............................................................820 14.5.9 Possible connections...........................................................821 Longitudinal/ transverse differential locks......................................822 14.5.10 After driving.................................................................823 14.6 Driving in combined operation........................................................825 14.6.1 Switching combined operation on/off............................................825 Prerequisites.....................................................................825 Switching on......................................................................826 Switching off.....................................................................826 14.6.2 Starting/turning off the engine................................................827 14.6.3 Preparing to drive.............................................................828 Transmission......................................................................828 Switching on separate steering...................................................828 Connections.......................................................................828 14.6.4 While driving..................................................................829 Without load......................................................................829 With load.........................................................................830 15 Malfunctions during crane operation........................................................833 15.1 Emergency stop switch................................................................833 15.2 What to do when malfunctions occur during craneoperation............................835 Load can be lowered..................................................................835 Load cannot be lowered................................................................835 15.3 Fuses................................................................................837 Information on replacing fuses........................................................837 15.3.1 Fuses on the turntable.........................................................838 Fuse groups F1/F2/F3..............................................................838 Fuses on the circuit board.......................................................839 15.3.2 Fuses in the crane cab.........................................................840 15.3.3 Fuses in the battery box.......................................................842 15.3.4 SLI fuses......................................................................843 15.4 Finding and eliminating malfunctions.................................................845 15.4.1 Malfunctions on the engine.....................................................845 15.4.2 Malfunctions on the main hoist/auxiliary hoist.................................847 15.4.3 Malfunctions on the derricking gear............................................848 15.4.4 Malfunctions in the telescoping mechanism......................................849 Telescoping mechanism error messages..............................................850 15.4.5 Malfunctions on the slewing gear...............................................852 15.4.6 Malfunctions on the counterweight hoist unit...................................853 15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................854 15.4.8 Malfunctions when inclining the crane cab......................................854 15.4.9 Malfunctions when operating with the hand-held control.........................855 15.4.10 Malfunctions when driving from the crane cab..................................856 15.4.11 Malfunctions of the outriggers................................................857 15.4.12 Troubleshooting the SLI.......................................................859 General malfunctions.............................................................859 Error messages in the monitoring submenu..........................................860 Displays in the Error submenu.....................................................862 Table of error codes..............................................................864 Switch off the sensor/tachogenerator............................................867 15.4.13 Malfunctions ECOS – superstructure............................................868 ECOS program version..............................................................868 General malfunctions.............................................................868 Error messages....................................................................869 Exiting the submenu...............................................................870 15.5 Emergency operations and programs....................................................871 15.5.1 Mechanical emergency operation for retracting..................................872 Prior to the emergency operation, check...........................................872 Procedure.........................................................................872 Mechanical emergency operation....................................................873 15.5.2 Telescoping emergency program..................................................875 Starting the emergency program....................................................875 Determining the type of error.....................................................876 If there is an error on the length indicator......................................877 If there is an error at a proximity switch........................................881 Terminating the emergency program.................................................882 Tables for approaching the locking points.........................................883 15.5.3 Entering the current telescoping...............................................885 15.5.4 Emergency operation with the hand-held control.................................887 Preparations......................................................................887 Operating a power unit............................................................888 Stopping movements...............................................................890 Stopping movements in emergencies................................................890 Turning off the engine............................................................890 15.5.5 Switching on emergency operation in coolant circuit............................891 15.6 Hydraulic emergency operation........................................................893 15.6.1 Operating principle............................................................893 15.6.2 Connecting/Disconnecting hoses.................................................894 Establishing connections.........................................................894 Disconnecting connections.........................................................895 15.6.3 Switching emergency operation on/off...........................................896 15.6.4 Establishing the hydraulic circuits required...................................897 Switching over valves.............................................................897 For lifting/ lowering............................................................899 For slewing.......................................................................900 15.6.5 Carrying out emergency operation...............................................901 Lifting/Lowering in emergency mode................................................901 Slewing in emergency mode.........................................................902 Raising/Lowering in emergency mode................................................903 15.6.6 After emergency operation......................................................904 Switch off emergency operation....................................................904 Switch over to crane operation....................................................904 Disconnecting the hoses.........................................................904 15.6.7 Emergency supply of another crane..............................................905 For emergency supply..............................................................905 After emergency supply............................................................905 16 Technical information about the superstructure.............................................909 16.1 Technical data.......................................................................909 16.1.1 Maximum lifting capacity (DIN/ISO/EN)..........................................909 16.1.2 Maximum lifting capacity (ASME B 30.5).........................................909 16.1.3 Dimensions and weights of the truck crane, axle loads..........................910 16.1.4 Dimensions and weights of removable parts......................................910 Hook blocks and hook tackle.......................................................910 Counterweight parts...............................................................911 Counterweight versions............................................................911 16.1.5 Superstructure.................................................................912 Engine............................................................................912 Main hoist........................................................................912 Auxiliary hoist...................................................................912 Slewing gears.....................................................................913 Derricking gear...................................................................913 Main boom.........................................................................913 Lattice extension.................................................................913 Operating speeds..................................................................914 17 Index......................................................................................917 A.........................................................................................919 B.........................................................................................919 C.........................................................................................919 D.........................................................................................921 E.........................................................................................923 F.........................................................................................925 H.........................................................................................925 I.........................................................................................926 K.........................................................................................926 L.........................................................................................926 M.........................................................................................927 O.........................................................................................928 P.........................................................................................929 R.........................................................................................929 S.........................................................................................930 T.........................................................................................932 V.........................................................................................933 W.........................................................................................933
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