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Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112640 – PDF DOWNLOAD
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Description
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112640 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112640 – PDF DOWNLOAD
Language : English
Pages : 948
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112640 – 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.
The manufacturer is not liable for any damage caused by improper or unau-
thorized use of the GMK 5130-2 truck crane. The user alone bears the risk.
TABLE OF CONTENTS:
Grove Crane GMK 5130-2 Driving Operation Instruction Manual 3112640 – 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 Correction sheet – Accepting the telescope status ........................................ 25 1 Overview.................................................................................... 31 1.1 Identification........................................................................ 31 1.2 EC Declaration of Conformity.......................................................... 35 1.3 Documentation supplied................................................................ 36 1.4 Information about the operating instructions.......................................... 37 1.4.1 What do the symbols used mean?.................................................. 37 1.4.2 How are the operating instructions structured?.................................. 39 Division.......................................................................... 39 Structure of the chapters......................................................... 39 Structure of the pages............................................................ 40 1.4.3 How do I find the information I need?........................................... 41 Cross-references example.......................................................... 42 1.4.4 What information is available for operations planning?.......................... 44 1.5 Conversion table for US measurements.................................................. 45 2 Basic safety instructions................................................................... 49 2.1 Intended use.......................................................................... 49 2.1.1 Improper use.................................................................... 50 2.2 Organisational measures............................................................... 51 2.3 Qualifications of the personnel....................................................... 53 2.4 Safety instructions for driving the truck crane....................................... 54 2.5 Safety instructions for crane operation............................................... 55 2.6 Information on transporting persons................................................... 57 Equipment for lifting persons......................................................... 57 Personnel............................................................................. 58 Operation............................................................................. 58 Truck crane........................................................................... 59 3 Operating elements for driving.............................................................. 63 3.1 Overview of the operating elements.................................................... 63 3.1.1 On the outside of the truck crane............................................... 64 3.1.2 Driver's cab.................................................................... 66 Overview.......................................................................... 66 Behind the cover.................................................................. 68 3.1.3 Instrument panel................................................................ 69 Left/right........................................................................ 69 Middle............................................................................ 70 3.1.4 Display, driver's cab........................................................... 72 3.1.5 Steering column/steering wheel.................................................. 73 3.1.6 Transmission operating elements................................................. 74 3.1.7 Tachograph...................................................................... 75 3.1.8 ECOS control unit............................................................... 76 3.1.9 ECOS display – main menu........................................................ 78 3.1.10 ECOS display – submenus........................................................ 80 Level adjustment system submenu................................................... 80 Settings submenu.................................................................. 82 Operating hours submenu........................................................... 83 Warning submenu................................................................... 83 Transmission emergency program submenu............................................ 84 Error submenu..................................................................... 85 3.1.11 Heating/Air-conditioning system................................................ 86 Standard heating system........................................................... 86 Auxiliary air heater – Version A.................................................. 87 Auxiliary air heater – Version B................................................. 88 Auxiliary water heater............................................................ 89 3.1.12 Sockets for hand-held control.................................................. 90 3.1.13 Outrigger control units........................................................ 91 3.2 Short description of the operating elements........................................... 93 3.2.1 Definition of information relating to directions of movement.................... 93 Basic rule........................................................................ 93 Switches and buttons.............................................................. 94 3.2.2 General information on the operating elements................................... 94 3.2.3 General rules for buttons and symbols on the display............................ 95 3.2.4 Engine.......................................................................... 96 Steering column................................................................... 96 Multipurpose switch............................................................... 96 Instrument panel.................................................................. 97 Main menu......................................................................... 98 3.2.5 Electrical system............................................................... 99 3.2.6 ECOS crane control.............................................................. 99 Control unit...................................................................... 99 3.2.7 Transmission....................................................................102 Transmission display..............................................................102 ECOS display......................................................................102 Operating elements................................................................103 Instrument panel..................................................................104 3.2.8 Transfer case...................................................................105 3.2.9 Axle drive......................................................................106 3.2.10 Brakes.........................................................................107 Service brake.....................................................................107 Parking brake.....................................................................108 Additional brakes.................................................................109 3.2.11 Steering/separate steering.....................................................110 ECOS display......................................................................110 Driver's door.....................................................................110 3.2.12 Suspension.....................................................................111 3.2.13 Lighting/windscreen wipers/horn................................................112 Steering column...................................................................112 Instrument panel..................................................................112 Roof..............................................................................114 3.2.14 Level adjustment system........................................................114 3.2.15 Tachograph/speedometer.........................................................116 Tachograph........................................................................116 Speedometer.......................................................................116 3.2.16 Diagnostics....................................................................117 Displays/ submenu.................................................................117 3.2.17 On-board computer..............................................................118 3.2.18 Push-up roof...................................................................120 3.2.19 Windows, doors, keys...........................................................120 Window winder.....................................................................120 Doors.............................................................................121 Keys..............................................................................121 3.2.20 Front flap.....................................................................122 4 Starting/turning off the engine for driving.................................................125 4.1 Starting the engine from the driver's cab.............................................125 4.1.1 CHECKLIST: Starting the engine..................................................125 4.1.2 CHECKLIST: At low temperatures..................................................128 4.1.3 Ladders and access ladders......................................................129 Access ladders....................................................................129 Ladders...........................................................................129 4.1.4 Refueling.......................................................................131 4.1.5 Inspections before starting the engine..........................................132 On the hydraulic tank.............................................................132 Battery master switch.............................................................132 Checking the hand-held control....................................................133 4.1.6 Switch on the ignition..........................................................133 4.1.7 Lamp test/equalisation of the switching states..................................134 Lamp test.........................................................................134 Equalisation of the switching states..............................................135 4.1.8 Display – setting the brightness................................................136 4.1.9 Starting the engine.............................................................137 Without flame start system........................................................138 With flame start system...........................................................139 4.1.10 Inspections after starting the engine..........................................140 4.1.11 Monitoring elements............................................................141 Instrument panel..................................................................141 ECOS display......................................................................142 Driving display...................................................................142 4.1.12 Setting the idling speed.......................................................143 4.2 Turning off the engine................................................................145 4.2.1 On the ignition lock/with hand-held control.....................................145 After parking.....................................................................145 4.2.2 With emergency stop switches....................................................146 Resetting the emergency stop switch...............................................146 4.3 Air intake inhibitor..................................................................147 Releasing the air intake inhibitor....................................................147 5 Driving.....................................................................................151 5.1 Before driving........................................................................151 5.1.1 CHECKLIST: Checks before on-road driving........................................151 5.1.2 Checking the condition of the truck crane.......................................156 Windscreen washing system........................................................156 Electrical system.................................................................156 Adjusting the mirrors.............................................................157 Warning plates for vehicle width..................................................158 Displaying the vehicle height.....................................................158 Supply pressure...................................................................159 Parking brake.....................................................................160 5.1.3 Adjusting the seat and the steering column......................................161 Driver's seat.....................................................................161 Passenger's seat..................................................................162 Adjusting the steering column.....................................................163 5.1.4 Switching the suspension on/off.................................................164 Opening the submenu...............................................................164 Switching on the suspension.......................................................165 Switching off the suspension......................................................165 5.1.5 Adjusting the tachograph........................................................166 Prerequisites.....................................................................166 In the event of malfunctions......................................................166 Adjusting the tachograph..........................................................167 Additional displays...............................................................170 5.1.6 Displaying the operating hours..................................................171 5.1.7 Settings/displays with the on-board computer....................................173 Operation.........................................................................173 Overview..........................................................................174 Inspection information............................................................174 Error information.................................................................175 Alarm clock.......................................................................175 Language..........................................................................176 Settings..........................................................................176 Diagnostics.......................................................................177 5.2 Operating the transmission............................................................179 5.2.1 Switching on....................................................................179 5.2.2 Switching the transmission to neutral position..................................180 5.2.3 Changing the operating mode.....................................................180 Change-over to automatic mode.....................................................180 Change-over to manual mode........................................................180 5.2.4 Display of the selected gears...................................................181 5.2.5 Selecting the direction of travel and starting gear.............................181 Selecting the driving direction...................................................181 Selecting the starting gear.......................................................182 5.2.6 Starting........................................................................183 5.2.7 Driving and changing gears......................................................184 In automatic operating mode......................................................184 In manual operating mode.........................................................185 5.2.8 Changing the driving direction..................................................186 Quick change of gear..............................................................186 5.2.9 Stopping........................................................................187 Stopping for a long period of time................................................187 5.2.10 On the roller type dynamometer.................................................187 5.3 Driving and turning off the truck crane...............................................189 5.3.1 Checks while driving............................................................189 Immediately after you start to move...............................................189 While driving.....................................................................190 5.3.2 Tempomat........................................................................191 Switching on......................................................................191 Switching off.....................................................................192 5.3.3 Temposet........................................................................193 Switching on......................................................................193 Switching off.....................................................................193 5.3.4 Driving downhill................................................................194 Starting..........................................................................194 Checks when driving downhill.....................................................194 Downshifting......................................................................195 Additional brakes.................................................................196 5.3.5 Driving uphill..................................................................197 Starting..........................................................................197 Driving...........................................................................197 5.3.6 Warning submenu.................................................................198 Meaning of the symbols............................................................198 Exiting the submenu...............................................................199 5.3.7 Error submenu...................................................................200 5.3.8 Messages on the On-board computer display.......................................200 Warnings..........................................................................201 Warning messages..................................................................202 Error messages....................................................................203 Information.......................................................................205 5.3.9 Turning off the truck crane.....................................................208 Secure against rolling away.......................................................208 When stationary for more than 8hours.............................................209 5.4 Off-road driving......................................................................211 Adjustments to the transmission.......................................................211 Connections...........................................................................211 Changing the vehicle level............................................................211 Rocking the vehicle free and towing...................................................211 5.4.1 Transfer case – off-road gear on/off............................................212 Neutral position..................................................................212 5.4.2 Longitudinal and transverse differential locks..................................214 5.4.3 Operating the level adjustment system...........................................216 Opening the submenu..............................................................216 Setting the on-road level.........................................................217 Pre-selecting suspension struts...................................................217 Changing the vehicle level........................................................218 Viewing the current inclination...................................................218 Exiting the submenu...............................................................219 5.4.4 Freeing the truck crane stuck in terrain........................................220 Rocking the truck crane free......................................................220 Towing free forward..............................................................221 Towing free to the rear...........................................................221 5.4.5 Separate steering...............................................................222 Switching to separate steering....................................................222 Steering..........................................................................223 Switching to normal steering mode.................................................224 5.5 Heating and air-conditioning system...................................................225 5.5.1 Standard heating system.........................................................225 Switching on......................................................................225 Heating...........................................................................225 Air distribution..................................................................226 Examples..........................................................................227 Switching off.....................................................................227 5.5.2 Air-conditioning system.........................................................228 Warnings..........................................................................228 Switching on/off..................................................................228 Cooling...........................................................................229 Drying............................................................................229 5.5.3 Auxiliary air heater – Version A................................................230 Switching on......................................................................230 Temperature.......................................................................231 Setting the day and time..........................................................231 Storing the heating start........................................................232 Setting the heating period.......................................................233 Switching the heating start on and off............................................233 Switching off.....................................................................234 Setting the remaining run time...................................................234 5.5.4 Auxiliary air heater – Version B................................................235 Switching on......................................................................235 Setting the heating level.........................................................236 Setting the day and time..........................................................237 Setting the preselection time.....................................................237 Setting the heating period........................................................239 Deleting preselection times.......................................................239 Switching off.....................................................................239 5.5.5 Auxiliary water heater..........................................................240 Preheating the engine.............................................................240 Preheating the driver's cab.......................................................241 Switching on......................................................................241 Setting the day and time..........................................................242 Storing the heating start.........................................................243 Setting the heating period........................................................244 Switching heating start on / off..................................................244 Switching off.....................................................................245 Setting the remaining time........................................................245 5.6 Towing a trailer......................................................................247 Effects on the axle loads.............................................................247 Coupling the trailer..................................................................248 Connecting the supply lines...........................................................249 Removing supply lines.................................................................250 Uncoupling the trailer................................................................250 Checking the braking force...........................................................252 6 Driving modes...............................................................................255 6.1 Driving modes.........................................................................255 Information about the axle loads......................................................255 6.1.1 Information on how to use the tables............................................256 6.1.2 Tables for a maximum axle load of 12 t (26,500 lbs).............................257 For 14.00 R25 tyres...............................................................257 For 16.00 R25 tyres...............................................................258 For 20.5 R25 tyres...............................................................259 6.1.3 Maximum permitted speeds with an axle load of over 12t (26,500lbs)............260 6.2 Rigging work for driving with a trailer...............................................261 6.2.1 Switching on the slewing gear freewheel.........................................261 6.2.2 Switching on boom floating position.............................................263 6.2.3 Switching on boom pre-tensioning................................................264 6.2.4 Switching the superstructure driving lights on/off..............................266 Switching off.....................................................................266 Switching on......................................................................266 6.3 Rigging the main boom.................................................................267 Additional equipment required.........................................................267 6.3.1 CHECKLIST: Removing the main boom...............................................268 Prerequisites.....................................................................268 Checklist.........................................................................268 6.3.2 CHECKLIST: Mounting the main boom...............................................271 Prerequisites.....................................................................271 Checklist.........................................................................271 6.3.3 Slinging the main boom..........................................................274 6.3.4 Removing/attaching the clamp....................................................275 6.3.5 Hydraulic connection for the lattice extension..................................276 6.3.6 Switching the pressure relief on/off............................................277 6.3.7 Retracting/fitting the derricking cylinder head pin.............................278 Retracting the derricking cylinder head axle.....................................279 Fitting the derricking cylinder head axle........................................280 6.3.8 Retracting/extending the boom pivot pin.........................................281 Before retracting.................................................................281 After extension...................................................................281 Retracting/ extending the pivot pin...............................................282 6.3.9 Disconnecting the hydraulic/electrical connections..............................283 Lifting in front of the turntable.................................................283 Disconnecting.....................................................................284 6.3.10 Establishing the hydraulic/electrical connection...............................285 Lifting onto the turntable........................................................285 Establishing......................................................................286 6.3.11 Aligning the connecting points.................................................287 6.3.12 Securing/releasing the derricking cylinder.....................................287 6.3.13 Transporting the main boom.....................................................288 6.3.14 Inspections after main boom mounting...........................................289 7 Malfunctions in driving mode................................................................293 7.1 Emergency stop switch.................................................................293 7.2 What to do when a malfunction occurs in road traffic..................................295 7.3 Towing the truck crane................................................................297 7.3.1 Towing in the event of engine or transmission damage............................298 Compressed-air supply.............................................................298 Electric power supply.............................................................298 On the transmission..............................................................299 Axle drives.......................................................................300 Transfer case.....................................................................300 Parking brake.....................................................................300 Towing the truck crane out of the danger area.....................................301 7.3.2 Tow starting....................................................................302 7.4 Wheels and tyres......................................................................303 7.4.1 Wheel change....................................................................303 Removing a damaged wheel.........................................................304 On the spare wheel holder.........................................................304 Mounting a wheel..................................................................305 7.4.2 Filling the tyres yourself......................................................307 Connecting the filling hose.......................................................307 Filling the tyres.................................................................308 Removing the filling hose........................................................308 7.5 Fuses.................................................................................309 Information on replacing fuses........................................................309 7.5.1 Fuses in the driver's cab.......................................................310 F1 to F 41........................................................................310 A1 to A3..........................................................................312 7.5.2 Fuses in the battery box........................................................314 7.6 Troubleshooting.......................................................................315 7.6.1 Malfunctions on the engine......................................................315 7.6.2 Malfunctions to the transmission................................................317 7.6.3 Malfunctions of the transfer case...............................................318 7.6.4 Malfunctions of the service brake...............................................318 7.6.5 Malfunctions of the steering....................................................319 7.6.6 Differential lock malfunctions..................................................320 7.6.7 Malfunctions in the hydraulic system/hydraulic oil cooler.......................320 7.6.8 Malfunctions on the suspension..................................................321 7.6.9 Malfunctions of the level adjustment system.....................................321 7.6.10 Malfunctions on the ECOS carrier...............................................322 ECOS program version..............................................................322 General malfunctions.............................................................322 Error messages....................................................................323 Exiting the submenu..............................................................324 On the control units..............................................................325 7.7 Procedure in the event of malfunctions................................................327 7.7.1 Switching on emergency operation in coolant circuit.............................327 7.7.2 Procedure in the event of malfunctions to the transmission andengine...........328 Engine............................................................................328 Transmission......................................................................329 Transmission emergency program submenu..........................................330 Emergency compressed air supply...................................................333 ID number of the transmission.....................................................335 8 Technical Information on the carrier........................................................339 8.1 Technical data........................................................................339 8.1.1 Dimensions and weights of the truck crane, axle loads...........................340 Dimensions........................................................................341 Weight and axle loads.............................................................341 8.1.2 Dimensions and weights of removable parts.......................................342 Spare wheel.......................................................................342 Outriggers........................................................................342 Main boom.........................................................................342 8.1.3 Carrier.........................................................................343 Engine............................................................................343 Transmission......................................................................343 Transfer case.....................................................................343 Axle lines........................................................................343 Steering..........................................................................343 Tyres.............................................................................344 Outriggers........................................................................344 Electrical system.................................................................344 Tools.............................................................................345 Towing coupling...................................................................345 Driving speeds....................................................................345 Climbing ability..................................................................345 Turning circle radiuses..........................................................345 9 Index.......................................................................................349 A.........................................................................................351 B.........................................................................................351 C.........................................................................................351 D.........................................................................................353 E.........................................................................................355 F.........................................................................................357 H.........................................................................................357 I.........................................................................................358 K.........................................................................................358 L.........................................................................................359 M.........................................................................................359 O.........................................................................................360 P.........................................................................................361 R.........................................................................................361 S.........................................................................................362 T.........................................................................................364 V.........................................................................................366 W.........................................................................................366 Additional pages..............................................................................371 SLI override..............................................................................371 New outriggers control units..............................................................383 New control unit......................................................................384 Old control unit......................................................................384 Outriggers............................................................................385 Outrigger pressure indicator..........................................................385 Inclination indicators................................................................385 9 sheave hook block.......................................................................389 Correction sheet – Accepting the telescope status ........................................391 Warning display STOP......................................................................393 10 Operating elements for crane operation.....................................................399 10.1 Overview of the operating elements...................................................399 10.1.1 On the outside of the truck crane..............................................400 10.1.2 Crane cab......................................................................402 10.1.3 Front panel....................................................................404 10.1.4 Side panel.....................................................................405 Bottom............................................................................405 Top...............................................................................406 Standard heating system...........................................................409 Auxiliary water heating system....................................................410 Auxiliary air heater..............................................................411 10.1.5 Control panels.................................................................412 Left..............................................................................412 Right.............................................................................413 10.1.6 Control lever assignment.......................................................414 Version 1.........................................................................414 Version 2.........................................................................415 10.1.7 ECOS control unit..............................................................416 10.1.8 ECOS display – main menu.......................................................418 10.1.9 ECOS display – submenus........................................................420 Counterweight submenu.............................................................420 Slewing gear/ Houselock submenu..................................................421 Outriggers submenu...............................................................422 Telescoping submenu..............................................................424 Submenu Power unit speed..........................................................426 Monitoring submenu...............................................................427 Settings submenu..................................................................428 Submenu Operating hours..........................................................430 Submenu Warning..................................................................431 Error submenu.....................................................................433 Working range limiter submenu.....................................................434 Driving submenu...................................................................436 10.1.10 SLI control unit..............................................................438 10.1.11 SLI display – main menu.......................................................440 10.1.12 SLI display – submenus........................................................441 Enter rigging mode submenu........................................................441 Monitoring submenu...............................................................442 Rigging mode monitoring submenu..................................................444 Lifting capacity table submenu....................................................445 Working range submenu.............................................................446 Error submenu.....................................................................447 Settings submenu..................................................................449 10.1.13 Hand-held control.............................................................450 Outriggers control panel.........................................................451 10.1.14 Outriggers control units......................................................452 Outriggers........................................................................453 Outrigger pressure display.......................................................453 Inclination indicator............................................................453 10.2 Short description of the operating elements..........................................455 10.2.1 Definition of information relating to directions of movement...................455 Basic rule........................................................................455 Switch............................................................................455 10.2.2 General rules for buttons and symbols on the display...........................456 10.2.3 Engine for crane operation.....................................................457 Side panel........................................................................457 ECOS display......................................................................457 10.2.4 Engine for driving.............................................................458 Side panel........................................................................458 Main menu.........................................................................458 Outriggers submenu...............................................................459 10.2.5 Seat contact switch and dead man's switch......................................460 10.2.6 ECOS crane control.............................................................461 Control unit......................................................................461 10.2.7 Outriggers.....................................................................464 Hand-held control.................................................................464 In the Outriggers submenu.........................................................465 In the settings submenu...........................................................466 On the Outriggers control units...................................................467 10.2.8 Inclination indicators.........................................................469 10.2.9 Outrigger pressure displays....................................................470 Outriggers submenu...............................................................470 Outriggers control units.........................................................470 10.2.10 Anemometer display............................................................470 10.2.11 Counterweight submenu.........................................................471 Counterweight submenu.............................................................471 10.2.12 Main hoist....................................................................473 10.2.13 Auxiliary hoist...............................................................475 10.2.14 Slewing gear..................................................................476 Submenu...........................................................................477 10.2.15 Derricking gear...............................................................479 10.2.16 Telescoping mechanism.........................................................480 Control panels....................................................................480 Submenu...........................................................................481 In the settings submenu...........................................................485 10.2.17 Hydraulic system..............................................................487 10.2.18 Houselock.....................................................................488 10.2.19 Safe load indicator (SLI).....................................................489 Control unit......................................................................489 Main menu.........................................................................491 Enter rigging mode submenu........................................................492 Monitoring submenu...............................................................495 Lifting capacity table submenu....................................................499 Working range submenu.............................................................500 Other.............................................................................500 10.2.20 Electrical system.............................................................501 10.2.21 Lighting, windscreen wiper/washing system.....................................501 Lighting..........................................................................501 Windscreen wiper/ washing system..................................................503 10.2.22 Hand-held control.............................................................504 Sockets for hand- held control....................................................504 Engine control panel..............................................................505 Horn..............................................................................505 Outriggers control panel.........................................................506 10.2.23 Windows, doors, keys..........................................................508 Windows...........................................................................508 Crane cab door....................................................................508 Keys..............................................................................509 10.2.24 Diagnostics...................................................................510 10.3 Short description of the operating elements – driving from the crane cab.............511 10.3.1 Driving submenu................................................................511 10.3.2 Engine for driving.............................................................512 10.3.3 Transmission...................................................................513 10.3.4 Axle drive.....................................................................514 10.3.5 Brakes.........................................................................515 Side panel........................................................................515 ECOS display......................................................................515 10.3.6 Steering.......................................................................516 Normal steering...................................................................517 Separate steering.................................................................517 11 Starting/Stopping the engine – for crane operation........................................521 11.1 Starting the engine – from the crane cab.............................................521 11.1.1 CHECKLIST: Starting the engine.................................................521 11.1.2 CHECKLIST: At low temperatures.................................................524 11.1.3 Refueling......................................................................524 11.1.4 Inspections before starting the engine.........................................526 On the hydraulic tank.............................................................526 Battery master switch.............................................................526 Checking the hand-held control....................................................527 11.1.5 Switching on the ignition......................................................527 11.1.6 Lamp test/equalisation of the switching states.................................528 Lamp test.........................................................................528 Equalisation of the switching states..............................................529 11.1.7 Setting the display brightness.................................................530 11.1.8 Starting the engine............................................................531 Without flame start system........................................................531 With flame start system...........................................................532 11.1.9 Inspections after starting the engine..........................................533 11.1.10 Monitoring submenu............................................................534 11.1.11 Setting the idling speed......................................................535 11.2 Starting the engine – with the hand-held control.....................................537 Prerequisites.........................................................................537 Starting the engine...................................................................537 11.3 Turning off the engine...............................................................539 11.3.1 During normal operation, with the ignition lock/with the hand- held control....539 After parking.....................................................................539 11.3.2 In emergencies, with the emergency stop switches...............................540 Resetting the emergency stop switch...............................................540 11.4 Air intake inhibitor.................................................................541 Releasing the air intake inhibitor....................................................541 12 Crane operation............................................................................545 12.1 Before crane operation...............................................................545 12.1.1 CHECKLIST: Inspections prior to crane operation................................545 12.1.2 Checking the condition of the truck crane......................................549 Tank for windscreen washing system................................................549 Visual inspection.................................................................549 Checking the position of the hoist ropes.........................................550 Checking the electrical system...................................................550 12.1.3 Adjusting the crane cab seat and front panel...................................551 Crane cab seat....................................................................551 Front panel.......................................................................552 12.1.4 Checking the safety devices....................................................553 Safe load indicator...............................................................553 Lifting limit switch..............................................................553 Emergency stop switch.............................................................554 Seat contact switch...............................................................555 12.1.5 Load, earthing.................................................................556 12.1.6 Preheating the hydraulic oil...................................................557 12.1.7 Locking/unlocking the turntable................................................558 Locking points....................................................................558 Locking the turntable............................................................559 Unlocking the turntable...........................................................559 12.1.8 Switching the houselock on/off.................................................560 Switching on the houselock........................................................560 Switching off the houselock.......................................................562 12.2 Operation of the safe load indicator.................................................563 12.2.1 Switching on the SLI...........................................................564 Switching on......................................................................564 Brightness of the displays........................................................566 12.2.2 Entering the rigging mode......................................................567 Entering individual components....................................................568 Entering the SLIcode.............................................................571 Entering the reeving.............................................................572 Accepting the rigging mode.......................................................572 12.2.3 Inspections prior to crane operation...........................................574 Opening the submenu..............................................................574 Checking..........................................................................575 12.2.4 Displays during crane operation................................................577 12.2.5 SLI early warning..............................................................580 12.2.6 SLI shutdown...................................................................580 Shutdown due to overload..........................................................580 12.2.7 Display in the event of errors.................................................582 12.2.8 SLI override...................................................................583 12.2.9 Displaying the lifting capacity tables.........................................584 12.2.10 Entering the time/date........................................................586 12.3 Crane operation with main boom.......................................................587 12.3.1 Checks during crane operation..................................................587 Horizontal alignment.............................................................587 Safe distances....................................................................587 Checking the wind speed...........................................................588 12.3.2 Permissible slewing ranges and working positions...............................589 360 slewing range................................................................589 Working position 0 to the rear...................................................589 180 to the front rigging position................................................590 Free-on-wheels working position...................................................590 12.3.3 Main hoist.....................................................................591 Switching on the main hoist.......................................................592 Lifting and lowering.............................................................592 Switching off the main hoist......................................................593 12.3.4 Auxiliary hoist................................................................594 Switching on the auxiliary hoist..................................................594 Lifting and lowering.............................................................595 Switching off the auxiliary hoist.................................................596 12.3.5 Lifting limit switch and lowering limit switch.................................597 Lifting limit switch..............................................................597 Lowering limit switch.............................................................599 12.3.6 Derricking gear................................................................600 Switching on the derricking gear..................................................600 Raising and lowering.............................................................601 Switching off the derricking gear.................................................602 Lowering the main boom to ahorizontal position..................................602 12.3.7 Telescoping mechanism..........................................................603 Overview..........................................................................604 Telescoping process..............................................................604 Assignment for display............................................................606 Fixed length, intermediate length, telescoping length............................608 Telescoping.......................................................................609 Telescoping sequence..............................................................609 Inspections prior to starting operations.........................................610 Switching on the telescoping mechanism...........................................611 Function of the control lever.....................................................611 Switching off the telescoping mechanism...........................................613 Manual telescoping...............................................................614 Checking the initial position....................................................614 Unlocking the telescoping cylinder..............................................617 Extending/ retracting the telescoping cylinder.................................619 Lock telescoping cylinder.........................................................620 Unlocking the telescopic section.................................................621 Telescoping the telescopic section................................................623 Locking the telescopic section...................................................624 Locking the telescopic section for on-road driving...............................625 Telescoping with teleautomation...................................................626 Telescoping the main boom in horizontal position................................630 12.3.8 High-speed mode................................................................631 Switch on function...............................................................631 Derricking gear/ Telescoping mechanism............................................631 Hoists............................................................................632 12.3.9 Slewing gear...................................................................633 Slewing gear brake................................................................633 Switching on the slewing gear.....................................................634 Releasing the slewing gear brake..................................................634 Engaging the slewing gear brake...................................................634 Slewing...........................................................................635 Slewing to 0 or 180 .............................................................637 Braking the slewing movement......................................................638 Slewing gear freewheel...........................................................638 Switching off the slewing gear....................................................639 12.3.10 Possible movement combinations................................................639 12.3.11 Hydraulic oil cooling.........................................................640 12.4 Settings and displays for crane operation............................................641 12.4.1 Inclining the crane cab........................................................641 12.4.2 Setting the idling speed.......................................................641 12.4.3 Adjusting the wiper stroke interval of the windscreen wiper....................642 12.4.4 Limiting the power unit speeds.................................................642 12.4.5 Setting the characteristic curves for the control levers.......................644 12.4.6 Critical load control..........................................................645 Function..........................................................................645 Switching on andoff..............................................................645 12.4.7 Operation of the directional spotlights........................................646 12.4.8 Displaying the operating hours.................................................647 12.4.9 Warning submenu................................................................648 Meaning of the symbols............................................................648 Exiting the submenu..............................................................651 12.4.10 Error submenu.................................................................651 12.5 Working range limiter................................................................653 12.5.1 Opening the Working range limiter submenu......................................654 12.5.2 Viewing current settings.......................................................654 12.5.3 Entering limit values..........................................................656 Overall height/ Working radius....................................................656 Slewing angle.....................................................................657 Entering objects..................................................................659 12.5.4 Entering limit values/objects manually.........................................662 Limit values......................................................................662 Objects...........................................................................663 12.5.5 Switching monitoring functions on/off..........................................664 12.5.6 Shutdown by working range limiter..............................................665 12.6 Work break...........................................................................667 12.6.1 In case of short work breaks...................................................667 12.6.2 In case of work breaks of more than 8 hours....................................668 To secure the truck crane.........................................................668 12.7 Heating and air-conditioning system..................................................669 12.7.1 Standard heating system........................................................669 Switching on......................................................................669 Heating...........................................................................669 Air distribution..................................................................670 Switching off.....................................................................671 12.7.2 Air-conditioning system........................................................671 Warnings..........................................................................671 Switching on/off..................................................................672 Cooling...........................................................................672 Drying the air....................................................................673 12.7.3 Auxiliary water heating system.................................................673 Preheating the engine.............................................................674 Preheating the crane cab..........................................................674 Switching on......................................................................675 Setting the day and time..........................................................676 Storing the heating start........................................................677 Setting the heating period.......................................................678 Switching heating start on/off....................................................678 Switching off.....................................................................679 Setting the remaining run time....................................................679 12.7.4 Auxiliary air heater...........................................................680 Switching on......................................................................680 Temperature.......................................................................681 Switching off.....................................................................681 Other functions...................................................................681 13 Rigging work...............................................................................685 13.1 Rigging work checklists for crane operation with the main boom.......................685 13.1.1 CHECKLIST: Rigging.............................................................685 13.1.2 CHECKLIST: Unrigging...........................................................689 13.2 Choosing a suitable site.............................................................693 13.2.1 Determining the required ground bearing area...................................693 13.2.2 Safe distance from slopes and pits.............................................696 13.2.3 Earthing the truck crane.......................................................697 13.2.4 Safe distance from electrical cables...........................................698 13.3 Rigging work after driving with a trailer............................................701 13.3.1 Switching off the boom floating position.......................................701 13.3.2 Switching off the slewing gear freewheel.......................................702 Before slewing....................................................................702 13.3.3 Switching off boom pre-tensioning..............................................703 13.4 Connecting/disconnecting the hand-held control.......................................705 13.5 Starting the engine for driving for rigging work.....................................707 13.5.1 Starting/turning off the engine with the hand-held control.....................707 Prerequisites.....................................................................707 Starting the engine...............................................................708 Turning off the engine............................................................708 13.5.2 Starting/turning off the engine from the crane cab.............................709 Prerequisites.....................................................................709 Starting the engine...............................................................709 After starting the engine.........................................................710 Turning off the engine............................................................710 13.6 Outriggers...........................................................................711 13.6.1 CHECKLIST: Extending the outriggers............................................711 13.6.2 CHECKLIST: Retracting the outriggers...........................................713 13.6.3 Permissible outrigger spans....................................................714 13.6.4 Preparing the truck crane......................................................715 In the driver's cab...............................................................715 Outriggers controlunits..........................................................715 13.6.5 Setting the spans..............................................................716 For on-road driving..............................................................718 13.6.6 Extending/retracting outriggers................................................719 From the control units............................................................720 With the hand- held control.......................................................721 From the crane cab................................................................723 13.6.7 Moving the outrigger pads into working/driving position........................725 13.6.8 Enlarging the ground bearing area..............................................726 13.6.9 Extending/retracting supporting cylinders......................................727 From the control units............................................................728 With the hand- held control.......................................................729 From the crane cab................................................................730 13.6.10 Leveling the truck crane on outriggers horizontally...........................732 Inclination indicators...........................................................732 Prerequisites.....................................................................733 Manual alignment..................................................................734 Automatic alignment..............................................................735 13.6.11 Leveling the free-standing truck crane........................................737 13.6.12 Outrigger pressure display....................................................739 13.7 Rigging/unrigging the counterweight..................................................741 13.7.1 Counterweight sections.........................................................741 Basic version.....................................................................741 Additional version1..............................................................742 Additional version2..............................................................742 Additional version3..............................................................743 Additional version4..............................................................743 13.7.2 Identification.................................................................744 13.7.3 Slinging points on the counterweight sections..................................745 13.7.4 CHECKLIST: Rigging the counterweight...........................................747 13.7.5 CHECKLIST: Unrigging the counterweight.........................................749 13.7.6 Assembling counterweight combination...........................................751 Combinations on the turntable.....................................................752 Setting down the 2.5 t base plate.................................................753 Combinations for the basic version................................................755 Combinations with additional equipment............................................760 13.7.7 Counterweight hoist unit.......................................................771 Counterweight submenu.............................................................771 Extending/ retracting the lifting cylinders.....................................772 Locking/Unlocking counterweight...................................................774 13.7.8 Mounting/Dismounting the counterweight on the turntable........................775 Mounting..........................................................................775 Dismounting.......................................................................777 13.7.9 Assembling counterweight sections for driving the truck crane..................779 13.7.10 Slewing with rigged counterweight.............................................781 13.8 Rigging work on the main boom........................................................783 13.8.1 Hook block on the bumper.......................................................783 Picking up the hook block.........................................................783 Attaching the hook block..........................................................784 13.8.2 Hook block on a separate vehicle...............................................785 Picking up the hook block.........................................................786 Setting down the hook block.......................................................786 13.8.3 Reeving and unreeving the hoist rope...........................................788 Fastening the rope end clamp......................................................788 Reeving the hoist rope............................................................790 Unreeving hoist rope..............................................................793 13.8.4 Possible reeving methods on the main boom......................................794 13.8.5 Installing/removing the lifting limit switch...................................798 Installing the lifting limit switch..............................................798 Removing the lifting limit switch................................................801 13.8.6 Locking/Unlocking the lifting limit switch.....................................802 Locking...........................................................................802 Removing the lock.................................................................803 13.8.7 Anemometer and air traffic control light.......................................804 Mounting..........................................................................804 Dismounting.......................................................................805 13.9 Other rigging work...................................................................807 13.9.1 Rigging in free on wheels working position.....................................807 13.9.2 Mirror for crane operation.....................................................809 14 Driving with a rigged truck crane..........................................................813 14.1 Driving route........................................................................815 14.2 Before driving the rigged truck crane................................................815 14.2.1 check the tyre pressure and the wind speed.....................................815 14.3 Permissible rigging modes and axle loads.............................................817 14.3.1 Axle loads.....................................................................817 14.3.2 To drive without a load........................................................817 14.3.3 To drive with a load...........................................................818 14.4 Driving from the driver's cab........................................................819 14.4.1 Preparing to drive.............................................................819 Transmission......................................................................819 Switching on separate steering....................................................819 Connections.......................................................................819 14.4.2 While driving..................................................................820 14.5 Driving from the crane cab...........................................................821 14.5.1 Preparing to drive.............................................................821 14.5.2 Opening/closing the Driving mode submenu.......................................822 Automatic.........................................................................822 Manual............................................................................824 Closing...........................................................................824 14.5.3 Starting/turning off the engine for driving....................................825 Starting the engine...............................................................825 Turning off the engine............................................................826 14.5.4 Steering.......................................................................826 Switching on......................................................................826 Adjusting the steering direction..................................................826 Displays when steering............................................................827 Normal steering...................................................................827 Separate steering.................................................................828 14.5.5 Operating the transmission.....................................................829 Driving direction.................................................................830 Selecting the gear position.......................................................830 14.5.6 Starting.......................................................................831 14.5.7 While driving..................................................................831 14.5.8 Warning messages...............................................................832 14.5.9 Possible connections...........................................................833 Longitudinal/ transverse differential locks......................................834 14.5.10 After driving.................................................................835 14.6 Driving in combined operation........................................................837 14.6.1 Switching combined operation on/off............................................837 Prerequisites.....................................................................837 Switching on......................................................................838 Switching off.....................................................................838 14.6.2 Starting/turning off the engine................................................839 14.6.3 Preparing to drive.............................................................840 Transmission......................................................................840 Switching on separate steering...................................................840 Connections.......................................................................840 14.6.4 While driving..................................................................841 Without load......................................................................841 With load.........................................................................842 15 Malfunctions during crane operation........................................................845 15.1 Emergency stop switch................................................................845 15.2 What to do when malfunctions occur during craneoperation............................847 Load can be lowered..................................................................847 Load cannot be lowered................................................................847 15.3 Fuses................................................................................849 Information on replacing fuses........................................................849 15.3.1 Fuses on the turntable.........................................................850 Fuse groups F1/F2/F3..............................................................850 Fuses on the circuit board.......................................................851 15.3.2 Fuses in the crane cab.........................................................852 15.3.3 Fuses in the battery box.......................................................854 15.3.4 SLI fuses......................................................................855 15.4 Finding and eliminating malfunctions.................................................857 15.4.1 Malfunctions on the engine.....................................................857 15.4.2 Malfunctions on the main hoist/auxiliary hoist.................................859 15.4.3 Malfunctions on the derricking gear............................................860 15.4.4 Malfunctions in the telescoping mechanism......................................861 Telescoping mechanism error messages..............................................862 15.4.5 Malfunctions on the slewing gear...............................................864 15.4.6 Malfunctions on the counterweight hoist unit...................................865 15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler......................866 15.4.8 Malfunctions when inclining the crane cab......................................866 15.4.9 Malfunctions when operating with the hand-held control.........................867 15.4.10 Malfunctions when driving from the crane cab..................................868 15.4.11 Malfunctions of the outriggers................................................869 15.4.12 Troubleshooting the SLI.......................................................871 General malfunctions.............................................................871 Error messages in the monitoring submenu..........................................872 Displays in the Error submenu.....................................................874 Table of error codes..............................................................876 Switch off the sensor/tachogenerator............................................879 15.4.13 Malfunctions ECOS – superstructure............................................880 ECOS program version..............................................................880 General malfunctions.............................................................880 Error messages....................................................................881 Exiting the submenu...............................................................882 15.5 Emergency operations and programs....................................................883 15.5.1 Mechanical emergency operation for retracting..................................884 Prior to the emergency operation, check...........................................884 Procedure.........................................................................884 Mechanical emergency operation....................................................885 15.5.2 Telescoping emergency program..................................................887 Starting the emergency program....................................................887 Determining the type of error.....................................................888 If there is an error on the length indicator......................................889 If there is an error at a proximity switch........................................893 Terminating the emergency program.................................................894 Tables for approaching the locking points.........................................895 15.5.3 Entering the current telescoping...............................................897 15.5.4 Emergency operation with the hand-held control.................................899 Preparations......................................................................899 Operating a power unit............................................................900 Stopping movements...............................................................902 Stopping movements in emergencies................................................902 Turning off the engine............................................................902 15.5.5 Switching on emergency operation in coolant circuit............................903 15.6 Hydraulic emergency operation........................................................905 15.6.1 Operating principle............................................................905 15.6.2 Connecting/Disconnecting hoses.................................................906 Establishing connections.........................................................906 Disconnecting connections.........................................................907 15.6.3 Switching emergency operation on/off...........................................908 15.6.4 Establishing the hydraulic circuits required...................................909 Switching over valves.............................................................909 For lifting/ lowering............................................................911 For slewing.......................................................................912 15.6.5 Carrying out emergency operation...............................................913 Lifting/Lowering in emergency mode................................................913 Slewing in emergency mode.........................................................914 Raising/Lowering in emergency mode................................................915 15.6.6 After emergency operation......................................................916 Switch off emergency operation....................................................916 Switch over to crane operation....................................................916 Disconnecting the hoses.........................................................916 15.6.7 Emergency supply of another crane..............................................917 For emergency supply..............................................................917 After emergency supply............................................................917 16 Technical information about the superstructure.............................................921 16.1 Technical data.......................................................................921 16.1.1 Maximum lifting capacity (DIN/ISO/EN)..........................................921 16.1.2 Maximum lifting capacity (ASME B 30.5).........................................921 16.1.3 Dimensions and weights of the truck crane, axle loads..........................922 16.1.4 Dimensions and weights of removable parts......................................922 Hook blocks and hook tackle.......................................................922 Counterweight parts...............................................................923 Counterweight versions............................................................923 16.1.5 Superstructure.................................................................924 Engine............................................................................924 Main hoist........................................................................924 Auxiliary hoist...................................................................924 Slewing gears.....................................................................925 Derricking gear...................................................................925 Main boom.........................................................................925 Lattice extension.................................................................925 Operating speeds..................................................................926 17 Index......................................................................................929 A.........................................................................................931 B.........................................................................................931 C.........................................................................................931 D.........................................................................................933 E.........................................................................................935 F.........................................................................................937 H.........................................................................................937 I.........................................................................................938 K.........................................................................................938 L.........................................................................................939 M.........................................................................................939 O.........................................................................................940 P.........................................................................................941 R.........................................................................................941 S.........................................................................................942 T.........................................................................................944 V.........................................................................................946 W.........................................................................................946
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