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Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112638 – PDF DOWNLOAD
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Description
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112638 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112638 – PDF DOWNLOAD
Language : English
Pages : 926
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112638 – 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 3112638 – PDF DOWNLOAD
Additional pages.............................................................................. 3 Warning display STOP...................................................................... 3 SLI override.............................................................................. 5 New outriggers control units.............................................................. 17 New control unit...................................................................... 18 Old control unit...................................................................... 18 Outriggers............................................................................ 19 Outrigger pressure indicator.......................................................... 19 Inclination indicators................................................................ 19 9 sheave hook block....................................................................... 23 1 Overview.................................................................................... 29 1.1 Identification........................................................................ 29 1.2 EC Declaration of Conformity.......................................................... 33 1.3 Documentation supplied................................................................ 34 1.4 Information about the operating instructions.......................................... 35 1.4.1 What do the symbols used mean?.................................................. 35 1.4.2 How are the operating instructions structured?.................................. 37 Division.......................................................................... 37 Structure of the chapters......................................................... 37 Structure of the pages............................................................ 38 1.4.3 How do I find the information I need?........................................... 39 Cross-references example.......................................................... 40 1.4.4 What information is available for operations planning?.......................... 42 1.5 Conversion table for US measurements.................................................. 43 2 Basic safety instructions................................................................... 47 2.1 Intended use.......................................................................... 47 2.1.1 Improper use.................................................................... 48 2.2 Organisational measures............................................................... 49 2.3 Qualifications of the personnel....................................................... 51 2.4 Safety instructions for driving the truck crane....................................... 52 2.5 Safety instructions for crane operation............................................... 52 2.6 Information on transporting persons................................................... 54 Equipment for lifting persons......................................................... 54 Personnel............................................................................. 54 Operation............................................................................. 55 Truck crane........................................................................... 56 3 Operating elements for driving.............................................................. 59 3.1 Overview of the operating elements.................................................... 59 3.1.1 On the outside of the truck crane............................................... 60 3.1.2 Driver's cab.................................................................... 62 Overview.......................................................................... 62 Behind the cover.................................................................. 64 3.1.3 Instrument panel................................................................ 65 Left/right........................................................................ 65 Middle............................................................................ 66 3.1.4 Display, driver's cab........................................................... 68 3.1.5 Steering column/steering wheel.................................................. 69 3.1.6 Transmission operating elements................................................. 70 3.1.7 Tachograph...................................................................... 71 3.1.8 ECOS control unit............................................................... 72 3.1.9 ECOS display – main menu........................................................ 74 3.1.10 ECOS display – submenus........................................................ 76 Level adjustment system submenu................................................... 76 Settings submenu.................................................................. 78 Operating hours submenu........................................................... 79 Warning submenu................................................................... 79 Transmission emergency program submenu............................................ 80 Error submenu..................................................................... 81 3.1.11 Heating/Air-conditioning system................................................ 82 Standard heating system........................................................... 82 Auxiliary air heater – Version A.................................................. 83 Auxiliary air heater – Version B................................................. 84 Auxiliary water 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 Transfer case...................................................................101 3.2.9 Axle drive......................................................................102 3.2.10 Brakes.........................................................................103 Service brake.....................................................................103 Parking brake.....................................................................104 Additional brakes.................................................................105 3.2.11 Steering/separate steering.....................................................106 ECOS display......................................................................106 Driver's door.....................................................................106 3.2.12 Suspension.....................................................................107 3.2.13 Lighting/windscreen wipers/horn................................................108 Steering column...................................................................108 Instrument panel..................................................................108 Roof..............................................................................110 3.2.14 Level adjustment system........................................................110 3.2.15 Tachograph/speedometer.........................................................112 Tachograph........................................................................112 Speedometer.......................................................................112 3.2.16 Diagnostics....................................................................113 Displays/ submenu.................................................................113 3.2.17 On-board computer..............................................................114 3.2.18 Push-up roof...................................................................116 3.2.19 Windows, doors, keys...........................................................116 Window winder.....................................................................116 Doors.............................................................................117 Keys..............................................................................117 3.2.20 Front flap.....................................................................118 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 Transfer case – off-road gear on/off............................................208 Neutral position..................................................................208 5.4.2 Longitudinal and transverse differential locks..................................210 5.4.3 Operating the level adjustment system...........................................212 Opening the submenu..............................................................212 Setting the on-road level.........................................................213 Pre-selecting suspension struts...................................................213 Changing the vehicle level........................................................214 Viewing the current inclination...................................................214 Exiting the submenu...............................................................215 5.4.4 Freeing the truck crane stuck in terrain........................................216 Rocking the truck crane free......................................................216 Towing free forward..............................................................217 Towing free to the rear...........................................................217 5.4.5 Separate steering...............................................................218 Switching to separate steering....................................................218 Steering..........................................................................219 Switching to normal steering mode.................................................220 5.5 Heating and air-conditioning system...................................................221 5.5.1 Standard heating system.........................................................221 Switching on......................................................................221 Heating...........................................................................221 Air distribution..................................................................222 Examples..........................................................................223 Switching off.....................................................................223 5.5.2 Air-conditioning system.........................................................224 Warnings..........................................................................224 Switching on/off..................................................................224 Cooling...........................................................................225 Drying............................................................................225 5.5.3 Auxiliary air heater – Version A................................................226 Switching on......................................................................226 Temperature.......................................................................227 Setting the day and time..........................................................227 Storing the heating start........................................................228 Setting the heating period.......................................................229 Switching the heating start on and off............................................229 Switching off.....................................................................230 Setting the remaining run time...................................................230 5.5.4 Auxiliary air heater – Version B................................................231 Switching on......................................................................231 Setting the heating level.........................................................232 Setting the day and time..........................................................233 Setting the preselection time.....................................................233 Setting the heating period........................................................235 Deleting preselection times.......................................................235 Switching off.....................................................................235 5.5.5 Auxiliary water heater..........................................................236 Preheating the engine.............................................................236 Preheating the driver's cab.......................................................237 Switching on......................................................................237 Setting the day and time..........................................................238 Storing the heating start.........................................................239 Setting the heating period........................................................240 Switching heating start on / off..................................................240 Switching off.....................................................................241 Setting the remaining time........................................................241 5.6 Towing a trailer......................................................................243 Effects on the axle loads.............................................................243 Coupling the trailer..................................................................244 Connecting the supply lines...........................................................245 Removing supply lines.................................................................246 Uncoupling the trailer................................................................246 Checking the braking force...........................................................248 6 Driving modes...............................................................................251 6.1 Driving modes.........................................................................251 Information about the axle loads......................................................251 6.1.1 Information on how to use the tables............................................252 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs).............................253 For 14.00 R25 tyres...............................................................253 For 16.00 R25 tyres...............................................................254 For 20.5 R25 tyres...............................................................255 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)............256 6.2 Rigging work for driving with a trailer...............................................257 6.2.1 Switching on the slewing gear freewheel.........................................257 6.2.2 Switching on boom floating position.............................................259 6.2.3 Switching on boom pre-tensioning................................................260 6.2.4 Switching the superstructure driving lights on/off..............................262 Switching off.....................................................................262 Switching on......................................................................262 6.3 Rigging the main boom.................................................................263 Additional equipment required.........................................................263 6.3.1 CHECKLIST: Removing the main boom...............................................264 Prerequisites.....................................................................264 Checklist.........................................................................264 6.3.2 CHECKLIST: Mounting the main boom...............................................267 Prerequisites.....................................................................267 Checklist.........................................................................267 6.3.3 Slinging the main boom..........................................................270 6.3.4 Removing/attaching the clamp....................................................271 6.3.5 Hydraulic connection for the lattice extension..................................272 6.3.6 Switching the pressure relief on/off............................................273 6.3.7 Retracting/fitting the derricking cylinder head pin.............................274 Retracting the derricking cylinder head axle.....................................275 Fitting the derricking cylinder head axle........................................276 6.3.8 Retracting/extending the boom pivot pin.........................................277 Before retracting.................................................................277 After extension...................................................................277 Retracting/ extending the pivot pin...............................................278 6.3.9 Disconnecting the hydraulic/electrical connections..............................279 Lifting in front of the turntable.................................................279 Disconnecting.....................................................................280 6.3.10 Establishing the hydraulic/electrical connection...............................281 Lifting onto the turntable........................................................281 Establishing......................................................................282 6.3.11 Aligning the connecting points.................................................283 6.3.12 Securing/releasing the derricking cylinder.....................................283 6.3.13 Transporting the main boom.....................................................284 6.3.14 Inspections after main boom mounting...........................................285 7 Malfunctions in driving mode................................................................289 7.1 Emergency stop switch.................................................................289 7.2 What to do when a malfunction occurs in road traffic..................................291 7.3 Towing the truck crane................................................................293 7.3.1 Towing in the event of engine or transmission damage............................294 Compressed-air supply.............................................................294 Electric power supply.............................................................294 On the transmission..............................................................295 Axle drives.......................................................................296 Transfer case.....................................................................296 Parking brake.....................................................................296 Towing the truck crane out of the danger area.....................................297 7.3.2 Tow starting....................................................................298 7.4 Wheels and tyres......................................................................299 7.4.1 Wheel change....................................................................299 Removing a damaged wheel.........................................................300 On the spare wheel holder.........................................................300 Mounting a wheel..................................................................301 7.4.2 Filling the tyres yourself......................................................303 Connecting the filling hose.......................................................303 Filling the tyres.................................................................304 Removing the filling hose........................................................304 7.5 Fuses.................................................................................305 Information on replacing fuses........................................................305 7.5.1 Fuses in the driver's cab.......................................................306 F1 to F 41........................................................................306 A1 to A3..........................................................................308 7.5.2 Fuses in the battery box........................................................310 7.6 Troubleshooting.......................................................................311 7.6.1 Malfunctions on the engine......................................................311 7.6.2 Malfunctions to the transmission................................................313 7.6.3 Malfunctions of the transfer case...............................................314 7.6.4 Malfunctions of the service brake...............................................314 7.6.5 Malfunctions of the steering....................................................315 7.6.6 Differential lock malfunctions..................................................316 7.6.7 Malfunctions in the hydraulic system/hydraulic oil cooler.......................316 7.6.8 Malfunctions on the suspension..................................................317 7.6.9 Malfunctions of the level adjustment system.....................................317 7.6.10 Malfunctions on the ECOS carrier...............................................318 ECOS program version..............................................................318 General malfunctions.............................................................318 Error messages....................................................................319 Exiting the submenu..............................................................320 On the control units..............................................................321 7.7 Procedure in the event of malfunctions................................................323 7.7.1 Switching on emergency operation in coolant circuit.............................323 7.7.2 Procedure in the event of malfunctions to the transmission andengine...........324 Engine............................................................................324 Transmission......................................................................325 Transmission emergency program submenu..........................................326 Emergency compressed air supply...................................................329 ID number of the transmission.....................................................331 8 Technical Information on the carrier........................................................335 8.1 Technical data........................................................................335 8.1.1 Dimensions and weights of the truck crane, axle loads...........................336 Dimensions........................................................................337 Weight and axle loads.............................................................337 8.1.2 Dimensions and weights of removable parts.......................................338 Spare wheel.......................................................................338 Outriggers........................................................................338 Main boom.........................................................................338 8.1.3 Carrier.........................................................................339 Engine............................................................................339 Transmission......................................................................339 Transfer case.....................................................................339 Axle lines........................................................................339 Steering..........................................................................339 Tyres.............................................................................340 Outriggers........................................................................340 Electrical system.................................................................340 Tools.............................................................................341 Towing coupling...................................................................341 Driving speeds....................................................................341 Climbing ability..................................................................341 Turning circle radiuses..........................................................341 9 Index.......................................................................................345 A.........................................................................................347 B.........................................................................................347 C.........................................................................................347 D.........................................................................................349 E.........................................................................................351 F.........................................................................................353 H.........................................................................................353 I.........................................................................................354 K.........................................................................................354 L.........................................................................................355 M.........................................................................................355 O.........................................................................................356 P.........................................................................................357 R.........................................................................................357 S.........................................................................................358 T.........................................................................................360 V.........................................................................................361 W.........................................................................................362 Additional pages..............................................................................367 SLI override..............................................................................367 New outriggers control units..............................................................379 New control unit......................................................................380 Old control unit......................................................................380 Outriggers............................................................................381 Outrigger pressure indicator..........................................................381 Inclination indicators................................................................381 9 sheave hook block.......................................................................385 Warning display STOP......................................................................387 10 Operating elements for crane operation.....................................................393 10.1 Overview of the operating elements...................................................393 10.1.1 On the outside of the truck crane..............................................394 10.1.2 Crane cab......................................................................396 10.1.3 Front panel....................................................................398 10.1.4 Side panel.....................................................................399 Bottom............................................................................399 Top...............................................................................400 Standard heating system...........................................................403 Auxiliary water heating system....................................................404 Auxiliary air heater..............................................................405 10.1.5 Control panels.................................................................406 Left..............................................................................406 Right.............................................................................407 10.1.6 Control lever assignment.......................................................408 Version 1.........................................................................408 Version 2.........................................................................409 10.1.7 ECOS control unit..............................................................410 10.1.8 ECOS display – main menu.......................................................412 10.1.9 ECOS display – submenus........................................................414 Counterweight submenu.............................................................414 Slewing gear/ Houselock submenu..................................................415 Outriggers submenu...............................................................416 Telescoping submenu..............................................................418 Submenu Power unit speed..........................................................420 Monitoring submenu...............................................................421 Settings submenu..................................................................422 Submenu Operating hours..........................................................424 Submenu Warning..................................................................425 Error submenu.....................................................................427 Working range limiter submenu.....................................................428 Driving submenu...................................................................430 10.1.10 SLI control unit..............................................................432 10.1.11 Hand-held control.............................................................436 Outriggers control panel.........................................................437 10.1.12 Outriggers control units......................................................438 Outriggers........................................................................439 Outrigger pressure display.......................................................439 Inclination indicator............................................................439 10.2 Short description of the operating elements..........................................441 10.2.1 Definition of information relating to directions of movement...................441 Basic rule........................................................................441 Switch............................................................................441 10.2.2 General rules for buttons and symbols on the display...........................442 10.2.3 Engine for crane operation.....................................................443 Side panel........................................................................443 ECOS display......................................................................443 10.2.4 Engine for driving.............................................................444 Side panel........................................................................444 Main menu.........................................................................444 Outriggers submenu...............................................................445 10.2.5 Seat contact switch and dead man's switch......................................446 10.2.6 ECOS crane control.............................................................447 Control unit......................................................................447 10.2.7 Outriggers.....................................................................450 Hand-held control.................................................................450 In the Outriggers submenu.........................................................451 In the settings submenu...........................................................452 On the Outriggers control units...................................................453 10.2.8 Inclination indicators.........................................................455 10.2.9 Outrigger pressure displays....................................................456 Outriggers submenu...............................................................456 Outriggers control units.........................................................456 10.2.10 Anemometer display............................................................456 10.2.11 Counterweight submenu.........................................................457 Counterweight submenu.............................................................457 10.2.12 Main hoist....................................................................459 10.2.13 Auxiliary hoist...............................................................461 10.2.14 Slewing gear..................................................................462 Submenu...........................................................................463 10.2.15 Derricking gear...............................................................465 10.2.16 Telescoping mechanism.........................................................466 Control panels....................................................................466 Submenu...........................................................................467 In the settings submenu...........................................................471 10.2.17 Hydraulic system..............................................................473 10.2.18 Houselock.....................................................................474 10.2.19 Safe load indicator (SLI).....................................................475 Input elements with displays......................................................475 Display elements..................................................................477 On the front panel................................................................480 10.2.20 Electrical system.............................................................481 10.2.21 Lighting, windscreen wiper/washing system.....................................481 Lighting..........................................................................481 Windscreen wiper/ washing system..................................................483 10.2.22 Hand-held control.............................................................484 Sockets for hand- held control....................................................484 Engine control panel..............................................................485 Horn..............................................................................485 Outriggers control panel.........................................................486 10.2.23 Windows, doors, keys..........................................................488 Windows...........................................................................488 Crane cab door....................................................................488 Keys..............................................................................489 10.2.24 Diagnostics...................................................................490 10.3 Short description of the operating elements – driving from the crane cab.............491 10.3.1 Driving submenu................................................................491 10.3.2 Engine for driving.............................................................492 10.3.3 Transmission...................................................................493 10.3.4 Axle drive.....................................................................494 10.3.5 Brakes.........................................................................495 Side panel........................................................................495 ECOS display......................................................................495 10.3.6 Steering.......................................................................496 Normal steering...................................................................497 Separate steering.................................................................497 11 Starting/Stopping the engine – for crane operation........................................501 11.1 Starting the engine – from the crane cab.............................................501 11.1.1 CHECKLIST: Starting the engine.................................................501 11.1.2 CHECKLIST: At low temperatures.................................................504 11.1.3 Refueling......................................................................504 11.1.4 Inspections before starting the engine.........................................506 On the hydraulic tank.............................................................506 Battery master switch.............................................................506 Checking the hand-held control....................................................507 11.1.5 Switching on the ignition......................................................507 11.1.6 Lamp test/equalisation of the switching states.................................508 Lamp test.........................................................................508 Equalisation of the switching states..............................................509 11.1.7 Setting the display brightness.................................................510 11.1.8 Starting the engine............................................................511 Without flame start system........................................................511 With flame start system...........................................................512 11.1.9 Inspections after starting the engine..........................................513 11.1.10 Monitoring submenu............................................................514 11.1.11 Setting the idling speed......................................................515 11.2 Starting the engine – with the hand-held control.....................................517 Prerequisites.........................................................................517 Starting the engine...................................................................517 11.3 Turning off the engine...............................................................519 11.3.1 During normal operation, with the ignition lock/with the hand- held control....519 After parking.....................................................................519 11.3.2 In emergencies, with the emergency stop switches...............................520 Resetting the emergency stop switch...............................................520 11.4 Air intake inhibitor.................................................................521 Releasing the air intake inhibitor....................................................521 12 Crane operation............................................................................525 12.1 Before crane operation...............................................................525 12.1.1 CHECKLIST: Inspections prior to crane operation................................525 12.1.2 Checking the condition of the truck crane......................................529 Tank for windscreen washing system................................................529 Visual inspection.................................................................529 Checking the position of the hoist ropes.........................................530 Checking the electrical system...................................................530 12.1.3 Adjusting the crane cab seat and front panel...................................531 Crane cab seat....................................................................531 Front panel.......................................................................532 12.1.4 Checking the safety devices....................................................533 Safe load indicator...............................................................533 Lifting limit switch..............................................................533 Emergency stop switch.............................................................534 Seat contact switch...............................................................535 12.1.5 Load, earthing.................................................................536 12.1.6 Preheating the hydraulic oil...................................................537 12.1.7 Locking/unlocking the turntable................................................538 Locking points....................................................................538 Locking the turntable............................................................539 Unlocking the turntable...........................................................539 12.1.8 Switching the houselock on/off.................................................540 Switching on the houselock........................................................540 Switching off the houselock.......................................................542 12.2 Operation of the safe load indicator.................................................543 12.2.1 Switching on the SLI...........................................................544 Switching on......................................................................544 Lamp test on the SLI..............................................................546 Brightness of the displays........................................................546 12.2.2 Entering the rigging mode......................................................547 Entering the SLIcode.............................................................548 Entering the reeving.............................................................551 Entering individual components....................................................552 12.2.3 Inspections prior to crane operation...........................................555 12.2.4 Displays during crane operation................................................557 Continuous displays..............................................................557 Optional displays.................................................................559 12.2.5 SLI early warning..............................................................561 12.2.6 SLI shutdown...................................................................562 Shutdown due to overload..........................................................562 12.2.7 Error message..................................................................563 12.2.8 SLI override...................................................................564 12.2.9 Displaying and entering the time and date......................................565 Display...........................................................................565 Input.............................................................................566 12.3 Crane operation with main boom.......................................................567 12.3.1 Checks during crane operation..................................................567 Horizontal alignment.............................................................567 Safe distances....................................................................567 Checking the wind speed...........................................................568 12.3.2 Permissible slewing ranges and working positions...............................569 360 slewing range................................................................569 Working position 0 to the rear...................................................569 180 to the front rigging position................................................570 Free-on-wheels working position...................................................570 12.3.3 Main hoist.....................................................................571 Switching on the main hoist.......................................................572 Lifting and lowering.............................................................572 Switching off the main hoist......................................................573 12.3.4 Auxiliary hoist................................................................574 Switching on the auxiliary hoist..................................................574 Lifting and lowering.............................................................575 Switching off the auxiliary hoist.................................................576 12.3.5 Lifting limit switch and lowering limit switch.................................577 Lifting limit switch..............................................................577 Lowering limit switch.............................................................579 12.3.6 Derricking gear................................................................580 Switching on the derricking gear..................................................580 Raising and lowering.............................................................581 Switching off the derricking gear.................................................582 Lowering the main boom to ahorizontal position..................................582 12.3.7 Telescoping mechanism..........................................................583 Overview..........................................................................584 Telescoping process..............................................................584 Assignment for display............................................................586 Fixed length, intermediate length, telescoping length............................588 Telescoping.......................................................................589 Telescoping sequence..............................................................589 Inspections prior to starting operations.........................................590 Switching on the telescoping mechanism...........................................591 Function of the control lever.....................................................591 Switching off the telescoping mechanism...........................................593 Manual telescoping...............................................................594 Checking the initial position....................................................594 Unlocking the telescoping cylinder..............................................597 Extending/ retracting the telescoping cylinder.................................599 Lock telescoping cylinder.........................................................600 Unlocking the telescopic section.................................................601 Telescoping the telescopic section................................................603 Locking the telescopic section...................................................604 Locking the telescopic section for on-road driving...............................605 Telescoping with teleautomation...................................................606 Telescoping the main boom in horizontal position................................610 12.3.8 High-speed mode................................................................611 Switch on function...............................................................611 Derricking gear/ Telescoping mechanism............................................611 Hoists............................................................................612 12.3.9 Slewing gear...................................................................613 Slewing gear brake................................................................613 Switching on the slewing gear.....................................................614 Releasing the slewing gear brake..................................................614 Engaging the slewing gear brake...................................................614 Slewing...........................................................................615 Slewing to 0 or 180 .............................................................617 Braking the slewing movement......................................................618 Slewing gear freewheel...........................................................618 Switching off the slewing gear....................................................619 12.3.10 Possible movement combinations................................................619 12.3.11 Hydraulic oil cooling.........................................................620 12.4 Settings and displays for crane operation............................................621 12.4.1 Inclining the crane cab........................................................621 12.4.2 Setting the idling speed.......................................................621 12.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................622 12.4.4 Limiting the power unit speeds.................................................622 12.4.5 Setting the characteristic curves for the control levers.......................624 12.4.6 Critical load control..........................................................625 Function..........................................................................625 Switching on andoff..............................................................625 12.4.7 Operation of the directional spotlights........................................626 12.4.8 Displaying the operating hours.................................................627 12.4.9 Warning submenu................................................................628 Meaning of the symbols............................................................628 Exiting the submenu..............................................................631 12.4.10 Error submenu.................................................................631 12.5 Working range limiter................................................................633 12.5.1 Opening the Working range limiter submenu......................................634 12.5.2 Viewing current settings.......................................................634 12.5.3 Entering limit values..........................................................636 Overall height/ Working radius....................................................636 Slewing angle.....................................................................637 Entering objects..................................................................639 12.5.4 Entering limit values/objects manually.........................................642 Limit values......................................................................642 Objects...........................................................................643 12.5.5 Switching monitoring functions on/off..........................................644 12.5.6 Shutdown by working range limiter..............................................645 12.6 Work break...........................................................................647 12.6.1 In case of short work breaks...................................................647 12.6.2 In case of work breaks of more than 8 hours....................................648 To secure the truck crane.........................................................648 12.7 Heating and air-conditioning system..................................................649 12.7.1 Standard heating system........................................................649 Switching on......................................................................649 Heating...........................................................................649 Air distribution..................................................................650 Switching off.....................................................................651 12.7.2 Air-conditioning system........................................................651 Warnings..........................................................................651 Switching on/off..................................................................652 Cooling...........................................................................652 Drying the air....................................................................653 12.7.3 Auxiliary water heating system.................................................653 Preheating the engine.............................................................654 Preheating the crane cab..........................................................654 Switching on......................................................................655 Setting the day and time..........................................................656 Storing the heating start........................................................657 Setting the heating period.......................................................658 Switching heating start on/off....................................................658 Switching off.....................................................................659 Setting the remaining run time....................................................659 12.7.4 Auxiliary air heater...........................................................660 Switching on......................................................................660 Temperature.......................................................................661 Switching off.....................................................................661 Other functions...................................................................661 13 Rigging work...............................................................................665 13.1 Rigging work checklists for crane operation with the main boom.......................665 13.1.1 CHECKLIST: Rigging.............................................................665 13.1.2 CHECKLIST: Unrigging...........................................................669 13.2 Choosing a suitable site.............................................................673 13.2.1 Determining the required ground bearing area...................................673 13.2.2 Safe distance from slopes and pits.............................................676 13.2.3 Earthing the truck crane.......................................................677 13.2.4 Safe distance from electrical cables...........................................678 13.3 Rigging work after driving with a trailer............................................681 13.3.1 Switching off the boom floating position.......................................681 13.3.2 Switching off the slewing gear freewheel.......................................682 Before slewing....................................................................682 13.3.3 Switching off boom pre-tensioning..............................................683 13.4 Connecting/disconnecting the hand-held control.......................................685 13.5 Starting the engine for driving for rigging work.....................................687 13.5.1 Starting/turning off the engine with the hand-held control.....................687 Prerequisites.....................................................................687 Starting the engine...............................................................688 Turning off the engine............................................................688 13.5.2 Starting/turning off the engine from the crane cab.............................689 Prerequisites.....................................................................689 Starting the engine...............................................................689 After starting the engine.........................................................690 Turning off the engine............................................................690 13.6 Outriggers...........................................................................691 13.6.1 CHECKLIST: Extending the outriggers............................................691 13.6.2 CHECKLIST: Retracting the outriggers...........................................693 13.6.3 Permissible outrigger spans....................................................694 13.6.4 Preparing the truck crane......................................................695 In the driver's cab...............................................................695 Outriggers controlunits..........................................................695 13.6.5 Setting the spans..............................................................696 For on-road driving..............................................................698 13.6.6 Extending/retracting outriggers................................................699 From the control units............................................................700 With the hand- held control.......................................................701 From the crane cab................................................................703 13.6.7 Moving the outrigger pads into working/driving position........................705 13.6.8 Enlarging the ground bearing area..............................................706 13.6.9 Extending/retracting supporting cylinders......................................707 From the control units............................................................708 With the hand- held control.......................................................709 From the crane cab................................................................710 13.6.10 Leveling the truck crane on outriggers horizontally...........................712 Inclination indicators...........................................................712 Prerequisites.....................................................................713 Manual alignment..................................................................714 Automatic alignment..............................................................715 13.6.11 Leveling the free-standing truck crane........................................717 13.6.12 Outrigger pressure display....................................................719 13.7 Rigging/unrigging the counterweight..................................................721 13.7.1 Counterweight sections.........................................................721 Basic version.....................................................................721 Additional version1..............................................................722 Additional version2..............................................................722 Additional version3..............................................................723 Additional version4..............................................................723 13.7.2 Identification.................................................................724 13.7.3 Slinging points on the counterweight sections..................................725 13.7.4 CHECKLIST: Rigging the counterweight...........................................727 13.7.5 CHECKLIST: Unrigging the counterweight.........................................729 13.7.6 Assembling counterweight combination...........................................731 Combinations on the turntable.....................................................732 Setting down the 2.5 t base plate.................................................733 Combinations for the basic version................................................735 Combinations with additional equipment............................................740 13.7.7 Counterweight hoist unit.......................................................751 Counterweight submenu.............................................................751 Extending/ retracting the lifting cylinders.....................................752 Locking/Unlocking counterweight...................................................754 13.7.8 Mounting/Dismounting the counterweight on the turntable........................755 Mounting..........................................................................755 Dismounting.......................................................................757 13.7.9 Assembling counterweight sections for driving the truck crane..................759 13.7.10 Slewing with rigged counterweight.............................................761 13.8 Rigging work on the main boom........................................................763 13.8.1 Hook block on the bumper.......................................................763 Picking up the hook block.........................................................763 Attaching the hook block..........................................................764 13.8.2 Hook block on a separate vehicle...............................................765 Picking up the hook block.........................................................766 Setting down the hook block.......................................................766 13.8.3 Reeving and unreeving the hoist rope...........................................768 Fastening the rope end clamp......................................................768 Reeving the hoist rope............................................................770 Unreeving hoist rope..............................................................773 13.8.4 Possible reeving methods on the main boom......................................774 13.8.5 Installing/removing the lifting limit switch...................................778 Installing the lifting limit switch..............................................778 Removing the lifting limit switch................................................781 13.8.6 Locking/Unlocking the lifting limit switch.....................................782 Locking...........................................................................782 Removing the lock.................................................................783 13.8.7 Anemometer and air traffic control light.......................................784 Mounting..........................................................................784 Dismounting.......................................................................785 13.9 Other rigging work...................................................................787 13.9.1 Rigging in free on wheels working position.....................................787 13.9.2 Mirror for crane operation.....................................................789 14 Driving with a rigged truck crane..........................................................793 14.1 Driving route........................................................................795 14.2 Before driving the rigged truck crane................................................795 14.2.1 check the tyre pressure and the wind speed.....................................795 14.3 Permissible rigging modes and axle loads.............................................797 14.3.1 Axle loads.....................................................................797 14.3.2 To drive without a load........................................................797 14.3.3 To drive with a load...........................................................798 14.4 Driving from the driver's cab........................................................799 14.4.1 Preparing to drive.............................................................799 Transmission......................................................................799 Switching on separate steering....................................................799 Connections.......................................................................799 14.4.2 While driving..................................................................800 14.5 Driving from the crane cab...........................................................801 14.5.1 Preparing to drive.............................................................801 14.5.2 Opening/closing the Driving mode submenu.......................................802 Automatic.........................................................................802 Manual............................................................................804 Closing...........................................................................804 14.5.3 Starting/turning off the engine for driving....................................805 Starting the engine...............................................................805 Turning off the engine............................................................806 14.5.4 Steering.......................................................................806 Switching on......................................................................806 Adjusting the steering direction..................................................806 Displays when steering............................................................807 Normal steering...................................................................807 Separate steering.................................................................808 14.5.5 Operating the transmission.....................................................809 Driving direction.................................................................810 Selecting the gear position.......................................................810 14.5.6 Starting.......................................................................811 14.5.7 While driving..................................................................811 14.5.8 Warning messages...............................................................812 14.5.9 Possible connections...........................................................813 Longitudinal/ transverse differential locks......................................814 14.5.10 After driving.................................................................815 14.6 Driving in combined operation........................................................817 14.6.1 Switching combined operation on/off............................................817 Prerequisites.....................................................................817 Switching on......................................................................818 Switching off.....................................................................818 14.6.2 Starting/turning off the engine................................................819 14.6.3 Preparing to drive.............................................................820 Transmission......................................................................820 Switching on separate steering...................................................820 Connections.......................................................................820 14.6.4 While driving..................................................................821 Without load......................................................................821 With load.........................................................................822 15 Malfunctions during crane operation........................................................825 15.1 Emergency stop switch................................................................825 15.2 What to do when malfunctions occur during craneoperation............................827 Load can be lowered..................................................................827 Load cannot be lowered................................................................827 15.3 Fuses................................................................................829 Information on replacing fuses........................................................829 15.3.1 Fuses on the turntable.........................................................830 Fuse groups F1/F2/F3..............................................................830 Fuses on the circuit board.......................................................831 15.3.2 Fuses in the crane cab.........................................................832 15.3.3 Fuses in the battery box.......................................................834 15.3.4 SLI fuses......................................................................835 15.4 Finding and eliminating malfunctions.................................................837 15.4.1 Malfunctions on the engine.....................................................837 15.4.2 Malfunctions on the main hoist/auxiliary hoist.................................839 15.4.3 Malfunctions on the derricking gear............................................840 15.4.4 Malfunctions in the telescoping mechanism......................................841 Telescoping mechanism error messages..............................................842 15.4.5 Malfunctions on the slewing gear...............................................844 15.4.6 Malfunctions on the counterweight hoist unit...................................845 15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................846 15.4.8 Malfunctions when inclining the crane cab......................................846 15.4.9 Malfunctions when operating with the hand-held control.........................847 15.4.10 Malfunctions when driving from the crane cab..................................848 15.4.11 Malfunctions of the outriggers................................................849 15.4.12 Troubleshooting the SLI.......................................................851 General malfunctions.............................................................851 Error messages....................................................................852 Table of error codes..............................................................854 Switching off the sensor/tachogenerator..........................................857 15.4.13 Malfunctions ECOS – superstructure............................................858 ECOS program version..............................................................858 General malfunctions.............................................................858 Error messages....................................................................859 Exiting the submenu...............................................................860 15.5 Emergency operations and programs....................................................861 15.5.1 Mechanical emergency operation for retracting..................................862 Prior to the emergency operation, check...........................................862 Procedure.........................................................................862 Mechanical emergency operation....................................................863 15.5.2 Telescoping emergency program..................................................865 Starting the emergency program....................................................865 Determining the type of error.....................................................866 If there is an error on the length indicator......................................867 If there is an error at a proximity switch........................................871 Terminating the emergency program.................................................872 Tables for approaching the locking points.........................................873 15.5.3 Entering the current telescoping...............................................875 15.5.4 Emergency operation with the hand-held control.................................877 Preparations......................................................................877 Operating a power unit............................................................878 Stopping movements...............................................................880 Stopping movements in emergencies................................................880 Turning off the engine............................................................880 15.5.5 Switching on emergency operation in coolant circuit............................881 15.6 Hydraulic emergency operation........................................................883 15.6.1 Operating principle............................................................883 15.6.2 Connecting/Disconnecting hoses.................................................884 Establishing connections.........................................................884 Disconnecting connections.........................................................885 15.6.3 Switching emergency operation on/off...........................................886 15.6.4 Establishing the hydraulic circuits required...................................887 Switching over valves.............................................................887 For lifting/ lowering............................................................889 For slewing.......................................................................890 15.6.5 Carrying out emergency operation...............................................891 Lifting/Lowering in emergency mode................................................891 Slewing in emergency mode.........................................................892 Raising/Lowering in emergency mode................................................893 15.6.6 After emergency operation......................................................894 Switch off emergency operation....................................................894 Switch over to crane operation....................................................894 Disconnecting the hoses.........................................................894 15.6.7 Emergency supply of another crane..............................................895 For emergency supply..............................................................895 After emergency supply............................................................895 16 Technical information about the superstructure.............................................899 16.1 Technical data.......................................................................899 16.1.1 Maximum lifting capacity (DIN/ISO/EN)..........................................899 16.1.2 Maximum lifting capacity (ASME B 30.5).........................................899 16.1.3 Dimensions and weights of the truck crane, axle loads..........................900 16.1.4 Dimensions and weights of removable parts......................................900 Hook blocks and hook tackle.......................................................900 Counterweight parts...............................................................901 Counterweight versions............................................................901 16.1.5 Superstructure.................................................................902 Engine............................................................................902 Main hoist........................................................................902 Auxiliary hoist...................................................................902 Slewing gears.....................................................................903 Derricking gear...................................................................903 Main boom.........................................................................903 Lattice extension.................................................................903 Operating speeds..................................................................904 17 Index......................................................................................907 A.........................................................................................909 B.........................................................................................909 C.........................................................................................909 D.........................................................................................911 E.........................................................................................913 F.........................................................................................915 H.........................................................................................915 I.........................................................................................916 K.........................................................................................916 L.........................................................................................917 M.........................................................................................917 O.........................................................................................918 P.........................................................................................919 R.........................................................................................919 S.........................................................................................920 T.........................................................................................922 V.........................................................................................923 W.........................................................................................924
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