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Grove Crane GMK 5170-1 Driving Operating Manual SN 3113043 – PDF DOWNLOAD
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Description
Grove Crane GMK 5170-1 Driving Operating Manual SN 3113043 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5170-1 Driving Operating Manual SN 3113043 – PDF DOWNLOAD
Language : English
Pages : 894
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Grove Crane GMK 5170-1 Driving Operating Manual SN 3113043 – PDF DOWNLOAD
Intended use:
The GMK 5170 truck crane is constructed in accordance with the latest tech- nology and the
recognised 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 5170 truck crane may only be used when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - Without the corresponding special equipment, the GMK 5170 truck crane may only be operated within
the permitted temperature range; à Technical
data, p. 1 – 7. - The GMK 5170 truck crane is designed solely for lifting loads which are within the permitted GMK
5170 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 5170 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 5170.
The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK
5170 truck crane. The user alone bears the
risk.
TABLE OF CONTENTS:
Grove Crane GMK 5170-1 Driving Operating Manual SN 3113043 – PDF DOWNLOAD
1 Overview................................................................................................. 7 1.1 Accidents.......................................................................................... 7 1.2 Branch offices..................................................................................... 9 1.2.1 Manitowoc Crane Care......................................................................... 9 1.2.2 Dealer list.................................................................................. 9 1.3 Warranty specifications............................................................................ 9 1.4 Terms used......................................................................................... 10 1.5 Technical data..................................................................................... 13 1.5.1 Maximum lifting capacity (DIN/ISO/EN)........................................................ 13 1.5.2 Maximum lifting capacity (ASME B 30.5)....................................................... 13 1.5.3 Dimensions and weights of the truck crane, axle loads........................................ 14 Dimensions..................................................................................... 15 Weight and axle loads.......................................................................... 15 1.5.4 Dimensions and weights of removable parts.................................................... 16 Spare wheel.................................................................................... 16 Outriggers..................................................................................... 16 Hook blocks and hook tackle.................................................................... 17 Counterweight parts............................................................................ 17 Main boom...................................................................................... 18 1.5.5 Carrier...................................................................................... 19 Engine......................................................................................... 19 Gears.......................................................................................... 19 Transfer case.................................................................................. 19 Axle lines..................................................................................... 20 Steering....................................................................................... 20 Tyres.......................................................................................... 20 Outriggers..................................................................................... 21 Vehicle electrical system...................................................................... 21 Tool........................................................................................... 21 Towing couplings............................................................................... 21 Driving speeds................................................................................. 22 Climbing ability............................................................................... 22 Turning radii.................................................................................. 22 1.5.6 Superstructure............................................................................... 23 Engine......................................................................................... 23 Main hoist..................................................................................... 23 Auxiliary hoist................................................................................ 23 Slewing gears.................................................................................. 24 Derricking gear................................................................................ 24 Main boom...................................................................................... 24 Lattice extension.............................................................................. 24 Operating speeds............................................................................... 25 1.6 Documentation supplied............................................................................. 27 1.6.1 Questions on documentation................................................................... 28 1.7 Notes on the operating instructions................................................................ 29 1.7.1 What do the symbols used mean?............................................................... 29 1.7.2 How are the operating instructions structured?............................................... 31 Division....................................................................................... 31 Structure of the chapters...................................................................... 31 Structure of the pages......................................................................... 32 1.7.3 How do I find the information I need?........................................................ 33 Cross-references example....................................................................... 34 1.7.4 What information is available for operations planning?....................................... 36 1.8 Conversion table for US measuring units............................................................ 37 1.9 Training – Information............................................................................. 39 1.10 Identification.................................................................................... 40 1.11 EC Declaration of Conformity...................................................................... 42 2 Basic safety instructions................................................................................ 45 2.1 Intended use....................................................................................... 45 2.1.1 Improper use................................................................................. 46 2.2 Organisational measures............................................................................ 47 2.3 Personnel qualifications........................................................................... 49 2.4 Safety instructions for driving the truck crane.................................................... 50 2.5 Safety instructions for crane operation............................................................ 51 2.6 Notes on transporting persons...................................................................... 53 Equipment for lifting persons...................................................................... 53 Personnel.......................................................................................... 53 Operation.......................................................................................... 54 Truck crane........................................................................................ 55 3 Operating elements for driving........................................................................... 59 3.1 Overview of the operating elements................................................................. 59 3.1.1 On the outside of the truck crane............................................................ 60 3.1.2 In the driver's cab.......................................................................... 62 Top view of driver's cab....................................................................... 62 Below in the driver's cab...................................................................... 64 Overhead in the driver's cab................................................................... 65 Behind the cover............................................................................... 66 3.1.3 Front instrument panel....................................................................... 67 Left........................................................................................... 67 Middle......................................................................................... 68 Right.......................................................................................... 69 3.1.4 ECOS control unit............................................................................ 70 3.1.5 ECOS display – main menu..................................................................... 72 3.1.6 ECOS display – submenus...................................................................... 74 Level adjustment system submenu................................................................ 74 Settings submenu............................................................................... 76 Monitoring submenu............................................................................. 77 Warning submenu................................................................................ 78 Operating hours submenu........................................................................ 80 Errors submenu................................................................................. 81 3.1.7 Side instrument panel........................................................................ 82 Standard heating............................................................................... 83 Auxiliary water heater......................................................................... 84 Auxiliary air heater........................................................................... 85 3.1.8 Gears........................................................................................ 86 3.1.9 Steering column.............................................................................. 87 3.1.10 Sockets for hand-held control............................................................... 88 3.1.11 Outrigger control units..................................................................... 89 3.2 Short description of the operating elements........................................................ 91 3.2.1 Definition of direction information.......................................................... 91 Basic rule..................................................................................... 91 Switches and buttons........................................................................... 92 3.2.2 General notes on the operating elements...................................................... 92 3.2.3 General rules for buttons and symbols on the display......................................... 93 3.2.4 Engine....................................................................................... 94 Steering column................................................................................ 94 Multipurpose switch............................................................................ 94 Instrument panels.............................................................................. 95 3.2.5 DEF system................................................................................... 96 Instrument panel............................................................................... 96 3.2.6 Electrical system/electronics................................................................ 97 Electrical system.............................................................................. 97 3.2.7 ECOS crane control........................................................................... 97 Control unit................................................................................... 97 Instrument panel...............................................................................100 3.2.8 Transmission.................................................................................101 ECOS display...................................................................................101 Side instrument panel..........................................................................102 3.2.9 Reverse camera...............................................................................105 Submenu for reverse camera.....................................................................105 3.2.10 Transfer case...............................................................................106 3.2.11 Final drive.................................................................................107 3.2.12 Brakes......................................................................................109 Service brake..................................................................................109 Parking brake..................................................................................110 Additional brakes..............................................................................111 3.2.13 Normal steering mode/separate steering......................................................112 Instrument panels..............................................................................112 ECOS display...................................................................................113 Driver's door..................................................................................114 3.2.14 Suspension..................................................................................115 3.2.15 Lighting/windscreen wipers/horn.............................................................116 Steering column................................................................................116 Instrument panels..............................................................................116 Overhead in the driver's cab...................................................................118 3.2.16 Level adjustment system.....................................................................119 3.2.17 Tachograph/speedometer......................................................................121 Tachograph.....................................................................................121 Speedometer....................................................................................121 3.2.18 Roof ventilator.............................................................................122 3.2.19 Diagnostics.................................................................................123 Connections/ buttons...........................................................................123 Displays/ submenu..............................................................................123 3.2.20 Windows, doors, keys........................................................................124 Windows........................................................................................124 Doors..........................................................................................125 Keys...........................................................................................126 3.2.21 Front flap..................................................................................126 4 Starting/turning off the engine for driving..............................................................129 4.1 Starting the engine from the driver's cab..........................................................129 4.1.1 CHECKLIST: Starting the engine...............................................................129 4.1.2 CHECKLIST: At low temperatures...............................................................132 4.1.3 Access ladders and ladders...................................................................132 Access ladders.................................................................................132 Ladders........................................................................................133 4.1.4 Refuel.......................................................................................135 Fuel tank......................................................................................135 DEF tank.......................................................................................136 Tank – auxiliary heater........................................................................137 4.1.5 Checks before starting the engine............................................................138 On hydraulic tank..............................................................................138 Battery master switch..........................................................................138 Checking hand- held control....................................................................139 4.1.6 Switching on the ignition....................................................................139 4.1.7 Lamp test/switching state equalisation.......................................................140 Lamp test......................................................................................140 Equalisation of the switching states...........................................................141 4.1.8 Adjusting display brightness.................................................................142 4.1.9 Starting the engine..........................................................................143 Without flame start system.....................................................................144 With flame start system........................................................................145 4.1.10 Checks after starting the engine............................................................146 Checking in the main menu......................................................................146 Checking the instrument panels.................................................................147 4.1.11 Monitoring submenu..........................................................................148 4.1.12 Setting idling speed........................................................................149 4.2 Turning off the engine.............................................................................151 4.2.1 During normal operation, with the ignition lock/with the hand- held control..................151 Hand-held control not connected................................................................151 Hand-held control connected....................................................................151 After turning off..............................................................................151 4.2.2 With emergency stop switches in emergencies..................................................152 Resetting the emergency stop switch............................................................152 4.3 Air intake inhibitor...............................................................................153 Releasing the air intake inhibitor.................................................................153 5 Driving..................................................................................................157 5.1 Before driving.....................................................................................157 5.1.1 CHECKLIST: Checks before on-road driving.....................................................157 5.1.2 Checking the condition of the truck crane....................................................163 Warning plates for vehicle width...............................................................163 Electrical system..............................................................................163 Adjusting the mirrors..........................................................................164 Reverse camera.................................................................................165 Checking the vehicle height....................................................................165 Checking the compressed air and brake systems..................................................166 5.1.3 Adjusting the seat and the steering column...................................................168 Driver's seat..................................................................................168 Passenger's seat...............................................................................169 Steering column................................................................................170 5.1.4 Switching the suspension on/off..............................................................171 Opening the submenu............................................................................171 Switching on the suspension....................................................................172 Switching off the suspension...................................................................172 5.1.5 Setting the tachograph.......................................................................173 Prerequisites..................................................................................173 Display of error messages......................................................................173 Setting the tachograph.........................................................................174 5.1.6 Displaying the operating hours...............................................................178 5.2 Operating the transmission.........................................................................179 5.2.1 Switching on.................................................................................179 5.2.2 Switching the transmission to neutral position...............................................180 While driving..................................................................................180 5.2.3 Changing the driving mode....................................................................181 5.2.4 Selecting the driving direction..............................................................181 5.2.5 Changing highest gear/starting gear..........................................................183 5.2.6 Starting.....................................................................................183 5.2.7 Driving and changing gears...................................................................184 5.2.8 Changing the driving direction...............................................................185 5.2.9 Stopping.....................................................................................185 Stopping for a long period of time.............................................................185 5.2.10 On the roller type dynamometer..............................................................186 5.2.11 Oil level gauge.............................................................................186 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.....................................................................................193 Switching on the Tempomat......................................................................193 Driving with the Tempomat......................................................................193 Switching off the Tempomat.....................................................................194 5.3.3 Temposet.....................................................................................195 Switching Temposet on..........................................................................195 Driving with the Temposet......................................................................195 Switching Temposet off.........................................................................195 5.3.4 Driving downhill.............................................................................196 Starting.......................................................................................196 Checks when driving downhill...................................................................196 Shifting down from the highest gear............................................................197 Additional brakes..............................................................................198 5.3.5 Driving uphill...............................................................................199 Starting.......................................................................................199 Driving........................................................................................199 5.3.6 Warning submenu..............................................................................200 Opening the submenu............................................................................200 Meaning of the symbols.........................................................................201 Exiting the submenu............................................................................204 5.3.7 Overriding torque reduction..................................................................205 5.3.8 Error submenu................................................................................206 5.3.9 Turning off the truck crane..................................................................206 Securing the truck crane against moving unintentionally........................................207 When stationary for more than 8hours..........................................................208 5.3.10 Folding berth...............................................................................209 5.4 Off-road driving...................................................................................211 Adjustments to the transmission....................................................................211 Connections........................................................................................211 Changing the vehicle level.........................................................................211 Rocking the vehicle free andtowing................................................................211 5.4.1 Transfer case – switching the off-road gear on/off...........................................212 Prerequisites..................................................................................212 Switching on...................................................................................212 Switching off..................................................................................213 Neutral position...............................................................................213 5.4.2 Longitudinal and transverse differential locks...............................................214 5.4.3 Operating the level adjustment system........................................................216 Opening the submenu............................................................................216 Setting the onroad 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 truck crane stuck in terrain.........................................................220 Rocking the truck crane free...................................................................220 Towing free forwards...........................................................................221 Towing free in reverse gear....................................................................221 5.5 Separate steering..................................................................................223 5.5.1 Switching on separate steering...............................................................224 5.5.2 Steering with separate steering..............................................................225 Manual.........................................................................................225 Automatic......................................................................................225 5.5.3 Switching off separate steering..............................................................226 5.6 Heating and ventilating the driver's cab...........................................................227 5.6.1 Standard heating system......................................................................227 Switching the heater on and off................................................................227 Setting the temperature........................................................................227 Setting recirculated air/fresh air.............................................................228 Setting the air distribution...................................................................228 Ventilating the driver's cab...................................................................229 5.6.2 Auxiliary water heater.......................................................................230 Preheating the engine..........................................................................230 Preheating the driver's cab....................................................................230 Switching on the auxiliary heater..............................................................231 Switching off the auxiliary heater.............................................................232 Setting time and weekday.......................................................................232 Saving automatic heating start.................................................................233 Setting the heating period.....................................................................234 Switching the automatic heating start on and off...............................................234 Setting the remaining time.....................................................................235 5.6.3 Auxiliary air heater with timer..............................................................236 Switching on the auxiliary heater..............................................................236 Setting the temperature........................................................................237 Switching off the auxiliary heater.............................................................237 Other functions................................................................................237 5.6.4 Air-conditioning system......................................................................238 Switching on...................................................................................238 Setting the air distribution...................................................................238 Switching off..................................................................................239 For pleasant air conditioning..................................................................239 Drying the air in the driver's cab.............................................................240 5.7 Towing a trailer...................................................................................241 Effects on the axle loads..........................................................................241 Coupling the trailer...............................................................................242 Connecting the supply lines........................................................................243 Removing the supply lines..........................................................................244 Uncoupling the trailer.............................................................................244 Checking the braking force.........................................................................246 6 Driving modes and rigging for on-road driving............................................................249 6.1 Driving modes......................................................................................249 Information about the axle loads...................................................................249 6.1.1 Information on how to use the tables.........................................................250 6.1.2 Tables for maximum axle load 12t (26,500lbs)...............................................251 For tyres 385/95 R25...........................................................................251 For yres 445/95 R25 525 /80 R25................................................................253 6.2 Rigging work for driving with a trailer............................................................255 6.2.1 Switching on the slewing gear freewheel......................................................255 6.2.2 Switching on boom floating position..........................................................257 6.2.3 Switching on boom pre-tensioning.............................................................258 6.2.4 Switching the superstructure driving lights on/off...........................................260 Switching off..................................................................................260 Switching on...................................................................................260 6.3 Rigging the main boom..............................................................................261 Additional equipment required......................................................................261 6.3.1 CHECKLIST: Removing the main boom............................................................262 Prerequisites..................................................................................262 Checklist......................................................................................262 6.3.2 CHECKLIST: Mounting the main boom............................................................265 Prerequisites..................................................................................265 Checklist......................................................................................265 6.3.3 Slinging the main boom.......................................................................268 6.3.4 Removing/attaching the clamps................................................................269 6.3.5 Switching the pressure relief on/off.........................................................271 6.3.6 Retracting/fitting the derricking cylinder head pin..........................................272 Derricking cylinder support....................................................................272 Operating the lifting device...................................................................272 Retracting the derricking cylinder head axle...................................................273 Fitting the derricking cylinder head axle......................................................274 6.3.7 Retracting/extending the boom pivot pin......................................................275 Before retracting..............................................................................275 After extending................................................................................275 Retracting/ extending the pivot pin............................................................276 6.3.8 Disconnecting the hydraulic/electrical connections...........................................277 Lifting in front of the turntable..............................................................277 Disconnecting..................................................................................278 6.3.9 Establishing the hydraulic/electrical connection.............................................279 Lifting onto the turntable.....................................................................279 Establishing...................................................................................280 6.3.10 Aligning the connecting points..............................................................281 6.3.11 Securing/releasing the derricking cylinder..................................................281 6.3.12 Transporting the main boom..................................................................282 6.3.13 Inspections after main boom mounting........................................................283 6.4 Rigging the outrigger beams........................................................................285 6.4.1 CHECKLIST: Removing the outrigger beams......................................................286 6.4.2 CHECKLIST: Installing the outrigger beams....................................................288 6.4.3 Preparing the truck crane....................................................................291 Prerequisites..................................................................................291 For removal...................................................................................291 6.4.4 Removing/attaching outrigger pads............................................................292 Removing the outrigger pads....................................................................292 Attaching the outrigger pads...................................................................293 6.4.5 Disconnecting/establishing the hydraulic connection..........................................294 6.4.6 Separating/establishing the electrical connection............................................295 6.4.7 Unscrewing/screwing in the spacers...........................................................296 Unscrewing.....................................................................................296 Screwing in....................................................................................297 6.4.8 Separating/establishing the connections to the outrigger box.................................298 6.4.9 Extending/retracting the outrigger beam......................................................298 Extending the outrigger beam...................................................................298 Inserting the outrigger beam...................................................................300 6.4.10 Transporting the outrigger beams............................................................302 7 Malfunctions in driving mode.............................................................................305 7.1 Emergency stop devices.............................................................................305 7.2 What to do when a malfunction occurs in road traffic...............................................307 7.3 Towing the truck crane.............................................................................309 7.3.1 Towing after engine/transmission damage......................................................309 Compressed-air supply..........................................................................310 Electric power supply..........................................................................310 Axle drives....................................................................................310 Transmission...................................................................................310 Transfer case..................................................................................311 Parking brake..................................................................................311 Towing the truck crane out of the danger area.................................................312 7.3.2 Tow starting.................................................................................312 7.4 Wheels and tyres...................................................................................313 7.4.1 Wheel change.................................................................................313 Removing adamaged wheel.......................................................................314 On the spare wheel holder......................................................................314 Mounting a wheel...............................................................................315 7.4.2 Inflating the tyres yourself.................................................................317 Connecting the filling hose....................................................................317 Inflating the tyres............................................................................318 Removing the filling hose......................................................................318 7.5 Fuses on the carrier...............................................................................319 Notes on changing fuses............................................................................319 7.5.1 Fuses in the driver's cab....................................................................320 7.5.2 Fuses in the battery box.....................................................................324 7.5.3 Fuses on I/O circuit boards..................................................................325 7.6 Troubleshooting....................................................................................327 7.6.1 Malfunctions on the engine for driving.......................................................327 7.6.2 Faults on the DEF system.....................................................................329 7.6.3 Differential lock malfunctions...............................................................330 7.6.4 Malfunctions in the transmission.............................................................331 7.6.5 Transfer case malfunctions...................................................................332 7.6.6 Malfunctions of the service brake............................................................332 7.6.7 Malfunctions of the steering.................................................................333 7.6.8 Malfunctions on the suspension...............................................................334 7.6.9 Malfunctions of the level adjustment system..................................................334 7.6.10 Malfunctions of the reverse camera..........................................................335 7.6.11 Malfunctions in the hydraulic system/hydraulic oil cooler...................................335 7.6.12 Malfunctions on the ECOS carrier............................................................337 ECOS program version...........................................................................337 General malfunctions...........................................................................337 Error messages.................................................................................338 Exiting the submenu............................................................................339 Error display on the control units.............................................................340 7.7 Procedure in the event of malfunctions.............................................................341 7.7.1 Switching on emergency operation in coolant circuit..........................................341 7.7.2 Malfunctions on the engine...................................................................342 7.7.3 Malfunctions in the transmission.............................................................343 General malfunctions...........................................................................343 Display E......................................................................................343 Transmission malfunction.......................................................................344 Reading out error codes........................................................................345 7.8 Emergency operation................................................................................347 7.8.1 External starting socket.....................................................................347 Performing a jump start........................................................................348 7.8.2 Battery charger..............................................................................348 8 Index....................................................................................................351 A......................................................................................................353 B......................................................................................................353 C......................................................................................................354 D......................................................................................................355 E......................................................................................................357 F......................................................................................................359 G......................................................................................................359 H......................................................................................................360 I......................................................................................................361 K......................................................................................................361 L......................................................................................................361 M......................................................................................................362 O......................................................................................................363 P......................................................................................................364 R......................................................................................................364 S......................................................................................................365 T......................................................................................................366 V......................................................................................................368 W......................................................................................................368 9 Operating elements for crane operation...................................................................379 9.1 Overview of the operating elements.................................................................379 9.1.1 Exterior of the truck crane..................................................................380 9.1.2 Crane cab....................................................................................384 9.1.3 Front panel..................................................................................386 9.1.4 Side panel...................................................................................387 Below..........................................................................................387 Top............................................................................................388 Console, rear..................................................................................390 Standard heating system........................................................................391 Auxiliary water heater.........................................................................392 Auxiliary air heater...........................................................................393 9.1.5 Control panels...............................................................................394 Left-hand control panel........................................................................394 Right-hand control panel.......................................................................395 9.1.6 Control lever configuration..................................................................396 Version 1......................................................................................396 Version 2......................................................................................397 9.1.7 ECOS control unit............................................................................398 9.1.8 ECOS display – main menu.....................................................................400 9.1.9 ECOS display – submenus......................................................................402 Counterweight submenu..........................................................................402 Slewing gear/ houselock submenu................................................................403 Outriggers submenu.............................................................................404 Telescoping submenu............................................................................406 Power unit speeds submenu......................................................................408 Monitoring submenu.............................................................................409 Settings submenu...............................................................................410 Warning submenu................................................................................412 Operating hours submenu........................................................................414 Error submenu..................................................................................415 Working range limiter submenu.................................................................416 9.1.10 RCL control unit............................................................................418 9.1.11 RCL display – main menu.....................................................................420 9.1.12 RCL display – submenus......................................................................421 Submenu Rigging mode entry.....................................................................421 Monitoring submenu.............................................................................422 Rigging mode monitoring submenu................................................................424 Submenu Lifting capacity table.................................................................425 Working range submenu..........................................................................426 Error submenu..................................................................................427 Settings submenu...............................................................................429 9.1.13 Hand-held control...........................................................................430 Outrigger control panel........................................................................431 9.1.14 Outrigger control units.....................................................................432 Outrigger......................................................................................433 Outrigger pressure display.....................................................................433 Inclination indicator..........................................................................433 9.2 Short description of the operating elements........................................................435 9.2.1 Definition of direction information..........................................................435 Basic rule.....................................................................................435 Switches.......................................................................................435 9.2.2 General rules for buttons and symbols on the display.........................................436 9.2.3 Engine for crane operation...................................................................437 Side panel.....................................................................................437 ECOS display...................................................................................438 9.2.4 DEF system...................................................................................438 ECOS display...................................................................................438 9.2.5 Engine for driving...........................................................................439 Outriggers submenu.............................................................................439 9.2.6 Seat contact switch and dead man's switch....................................................440 9.2.7 ECOS crane control...........................................................................441 Control unit...................................................................................441 9.2.8 Outrigger....................................................................................444 Hand-held control..............................................................................444 In the Outrigger submenu.......................................................................445 In the Settings submenu........................................................................446 On the outrigger control units.................................................................447 9.2.9 Inclination indicators.......................................................................449 9.2.10 Outrigger pressure displays.................................................................450 Outriggers submenu.............................................................................450 Outrigger control units........................................................................450 9.2.11 Anemometer displays.........................................................................450 9.2.12 Counterweight submenu.......................................................................451 Counterweight submenu..........................................................................451 9.2.13 Main hoist..................................................................................454 9.2.14 Auxiliary hoist.............................................................................455 9.2.15 Slewing gear................................................................................456 Control panels.................................................................................456 Submenu........................................................................................457 9.2.16 Derricking gear.............................................................................458 9.2.17 Telescoping mechanism.......................................................................459 Control panels.................................................................................459 Submenu........................................................................................460 In the Settings submenu........................................................................464 9.2.18 Hydraulic system............................................................................466 9.2.19 Houselock...................................................................................467 9.2.20 Rated capacity limiter (RCL)................................................................469 Control unit...................................................................................469 Main menu......................................................................................471 Submenu Rigging mode entry.....................................................................472 Monitoring submenu.............................................................................476 Submenu Lifting capacity table.................................................................479 Working range submenu..........................................................................480 RCL override..................................................................................481 External displays..............................................................................482 9.2.21 Electrical system...........................................................................483 9.2.22 Lighting, windscreen wiper/washing system...................................................483 Lighting.......................................................................................483 Windscreen wiper/washing system................................................................485 9.2.23 Hand-held control...........................................................................486 Hand-held control sockets......................................................................486 Engine control panel...........................................................................487 Horn...........................................................................................487 Outriggers control panel.......................................................................488 9.2.24 Diagnostics.................................................................................490 9.2.25 Windows, doors, keys........................................................................491 Windows........................................................................................491 Crane cab door.................................................................................491 Keys...........................................................................................492 10 Starting/stopping the engine – for crane operation......................................................495 10.1 Starting the engine – from the crane cab..........................................................495 10.1.1 CHECKLIST: Starting the engine..............................................................495 10.1.2 CHECKLIST: At low temperatures..............................................................498 10.1.3 Refuel......................................................................................499 Fuel tank......................................................................................499 DEF tank.......................................................................................500 Tank – auxiliary heater........................................................................501 10.1.4 Checks before starting the engine...........................................................502 On hydraulic tank..............................................................................502 Battery master switch..........................................................................502 Checking the hand-held control.................................................................503 10.1.5 Switching on the ignition...................................................................503 10.1.6 Lamp test...................................................................................504 Lamp test......................................................................................504 10.1.7 Adjusting display brightness................................................................506 10.1.8 Starting the engine.........................................................................507 Without flame start system.....................................................................507 With flame start system........................................................................508 10.1.9 Checks after starting the engine............................................................509 At the ECOS control unit.......................................................................509 On the side panel..............................................................................509 10.1.10 Monitoring submenu.........................................................................511 10.1.11 Setting idling speed.......................................................................512 10.2 Starting the engine – with the hand-held control..................................................513 Prerequisites......................................................................................513 Starting the engine................................................................................513 10.3 Turning off the engine............................................................................515 10.3.1 During normal operation, with the ignition lock/with the handheld control..................515 Hand-held control not connected................................................................515 Hand-held control connected....................................................................515 After turning off..............................................................................515 10.3.2 In emergencies, with the emergency stop switches............................................516 Resetting the emergency stop switch............................................................516 10.4 Air intake inhibitor..............................................................................517 Releasing the air intake inhibitor.................................................................517 11 Crane operation.........................................................................................521 11.1 Before operating the crane........................................................................521 11.1.1 CHECKLIST: Checks before operating the crane................................................521 11.1.2 Checking the condition of the truck crane...................................................525 Visual inspection..............................................................................525 Checking the position of the hoist ropes.......................................................525 Checking the electrical system.................................................................526 11.1.3 Adjusting the crane cab seat and front control panel........................................526 Crane cab seat.................................................................................526 Adjusting the front panel......................................................................527 11.1.4 Checking the safety equipment...............................................................528 Rated capacity limiter.........................................................................528 Lifting limit switch...........................................................................528 Emergency stop switch..........................................................................529 Seat contact switch and dead man's switch......................................................530 11.1.5 Earthing the load...........................................................................531 11.1.6 Preheating the hydraulic oil................................................................532 11.1.7 Locking/unlocking the turntable.............................................................533 11.1.8 Switching the houselock on/off..............................................................534 Switching on the houselock.....................................................................534 Switching off the houselock....................................................................536 11.2 Operation of the rated capacity limiter...........................................................537 11.2.1 Switching on the RCL........................................................................538 Switching on...................................................................................538 Brightness of the displays.....................................................................540 11.2.2 Enter rigging mode..........................................................................541 Entering individual components.................................................................542 Entering the RCL code..........................................................................546 Entering the reeving...........................................................................547 Accepting the rigging mode.....................................................................547 11.2.3 Checks before operating the crane...........................................................549 Opening the submenu............................................................................549 Checks.........................................................................................550 11.2.4 Displays during crane operation.............................................................552 11.2.5 RCL early warning...........................................................................555 11.2.6 RCL shutdown................................................................................555 Shutdown due to overload.......................................................................555 11.2.7 Display in the event of errors..............................................................557 11.2.8 RCL override – version A....................................................................558 11.2.9 RCL override – version B....................................................................559 Overview status display........................................................................559 When rigging...................................................................................560 To raise the boom..............................................................................561 In emergency...................................................................................562 11.2.10 Displaying the lifting capacity tables.....................................................563 11.2.11 Entering the time/date.....................................................................565 11.3 Crane operation with main boom....................................................................567 11.3.1 Checks during crane operation...............................................................567 Horizontal alignment...........................................................................567 Safe distances.................................................................................567 Checking the wind speed........................................................................568 11.3.2 Permissible slewing ranges and working positions for crane operation........................569 360 slewing range.............................................................................569 Working position 0 to the rear................................................................569 180 to the front rigging position.............................................................569 11.3.3 Main hoist..................................................................................571 Switching on the main hoist....................................................................572 Lifting and lowering...........................................................................573 Switching off the main hoist...................................................................573 11.3.4 Auxiliary hoist.............................................................................574 Switching on the auxiliary hoist...............................................................575 Lifting and lowering...........................................................................576 Switching off the auxiliary hoist..............................................................576 11.3.5 Lifting limit switch and lowering limit switch..............................................577 Lifting limit switch...........................................................................577 Lowering limit switch..........................................................................579 11.3.6 Derricking gear.............................................................................580 Switching on the derricking gear...............................................................580 Raising and lowering...........................................................................581 Re-enable raising function.....................................................................582 Switching off the derricking gear..............................................................582 Lowering the main boom to ahorizontal position................................................583 11.3.7 Telescoping mechanism.......................................................................585 Overview.......................................................................................586 Telescoping process............................................................................586 Assignment for display.........................................................................588 Fixed length, intermediate length, telescoping length..........................................590 Telescoping....................................................................................591 Telescoping sequence...........................................................................591 Checks before starting work....................................................................592 Switching on the telescoping mechanism.........................................................593 Function of the control lever..................................................................593 Switching off the telescoping mechanism........................................................595 Manual telescoping.............................................................................596 Checking the initial position..................................................................596 Unlocking the telescoping cylinder.............................................................599 Extending/ retracting the telescoping cylinder.................................................601 Lock telescoping cylinder......................................................................602 Unlocking the telescopic section...............................................................603 Telescoping the telescopic section.............................................................605 Locking the telescopic section.................................................................606 Locking the telescopic section for on-road driving.............................................607 Telescoping with teleautomation................................................................608 Telescoping the main boom when horizontal......................................................612 11.3.8 High-speed mode.............................................................................613 Switch on function.............................................................................613 Derricking gear/ telescoping mechanism.........................................................613 Hoists.........................................................................................614 11.3.9 Slewing gear................................................................................615 Switching on the slewing gear..................................................................615 Slew...........................................................................................616 Braking the slewing movement...................................................................618 Slewing gear freewheel.........................................................................618 Switching off the slewing gear.................................................................618 11.3.10 Possible movement combinations.............................................................619 11.3.11 Hydraulic oil cooling......................................................................620 11.4 Settings and displays for crane operation.........................................................621 11.4.1 Limiting the power unit speeds..............................................................621 11.4.2 Setting the characteristic curves for the control levers....................................623 11.4.3 Inclining the crane cab.....................................................................624 11.4.4 Setting idling speed........................................................................624 11.4.5 Critical load control.......................................................................625 Function.......................................................................................625 Switching on and off...........................................................................625 11.4.6 Adjusting the wiper stroke interval of the windscreen wiper.................................626 11.4.7 Using the slewable spotlights...............................................................627 11.4.8 Displaying the operating hours..............................................................628 11.4.9 Warning submenu.............................................................................629 Opening the submenu............................................................................629 Meaning of the symbols.........................................................................629 Exiting the submenu............................................................................632 11.4.10 Overriding torque reduction................................................................633 11.4.11 Error submenu..............................................................................634 11.5 Working range limiter.............................................................................635 11.5.1 Opening the working range limiter submenu...................................................636 11.5.2 Viewing current settings....................................................................636 11.5.3 Entering limit values.......................................................................638 Overall height/ Working radius.................................................................638 Slewing angle..................................................................................639 Entering objects...............................................................................641 11.5.4 Entering limit values/objects manually......................................................644 Limit values...................................................................................644 Objects........................................................................................645 11.5.5 Switching monitoring functions on/off.......................................................646 11.5.6 Shutdown by working range limiter...........................................................647 11.6 Work break........................................................................................649 11.6.1 In case of short work breaks................................................................649 11.6.2 In case of work breaks of more than 8 hours.................................................650 Securing the truck crane against unauthorised use..............................................650 11.7 Heating and air-conditioning system...............................................................651 11.7.1 Standard heating system.....................................................................651 Switching on...................................................................................651 Heating........................................................................................651 Air distribution...............................................................................652 Switching off..................................................................................653 Warnings.......................................................................................653 Switching on/off...............................................................................654 Cooling........................................................................................654 Drying the air.................................................................................655 11.7.3 Auxiliary water heater......................................................................655 Preheating the engine..........................................................................656 Preheating the crane cab.......................................................................656 Switching on...................................................................................657 Setting the day and time.......................................................................658 Storing the heating start......................................................................659 Setting the heating period.....................................................................660 Switching heating start on/off.................................................................660 Switching off..................................................................................661 Setting the remaining time.....................................................................661 11.7.4 Auxiliary air heater........................................................................662 Switching on...................................................................................662 Temperature....................................................................................663 Switching off..................................................................................663 Other functions................................................................................663 11.8 CraneSTAR system..................................................................................665 11.8.1 Overview....................................................................................665 11.8.2 Position of the components..................................................................665 12 Rigging work............................................................................................669 12.1 Rigging work checklists for crane operation with the main boom....................................669 12.1.1 CHECKLIST: Rigging..........................................................................669 12.1.2 CHECKLIST: Unrigging........................................................................673 12.2 Choosing a suitable site..........................................................................677 12.2.1 Determining the required ground bearing area................................................677 12.2.2 Safe distance from slopes and pits..........................................................680 12.2.3 Earthing the truck crane....................................................................681 12.2.4 Safe distance from electrical cables........................................................682 12.3 Rigging work after driving with a trailer.........................................................685 12.3.1 Switching off the slewing gear freewheel....................................................686 Before slewing.................................................................................686 12.3.2 Switching off the boom floating position....................................................687 12.3.3 Switching off boom pre-tensioning...........................................................688 12.4 Connecting/disconnecting the hand-held control....................................................689 12.5 Starting the engine for driving for rigging work..................................................691 12.5.1 Starting/turning off the engine with the hand-held control..................................691 Prerequisites..................................................................................691 Starting the engine............................................................................692 Turning off the engine.........................................................................692 12.5.2 Starting/turning off the engine from the crane cab..........................................693 Prerequisites..................................................................................693 Starting the engine............................................................................693 After starting the engine......................................................................694 Turning off the engine.........................................................................694 12.6 Outrigger.........................................................................................695 12.6.1 CHECKLIST: Extending the outriggers.........................................................695 12.6.2 CHECKLIST: Retracting the outriggers........................................................697 12.6.3 Permissible outrigger spans.................................................................698 12.6.4 Preparing the truck crane...................................................................699 In the driver's cab............................................................................699 Outrigger control units........................................................................699 12.6.5 Setting the outrigger spans.................................................................700 For on-road driving............................................................................702 12.6.6 Extending/retracting outrigger beams........................................................703 From the control units.........................................................................703 With the handheld control.....................................................................705 From the crane cab.............................................................................707 12.6.7 Moving the outrigger pads into working/driving position.....................................709 12.6.8 Enlarging the ground bearing area...........................................................710 12.6.9 Extending/retracting supporting cylinders...................................................711 From the control units.........................................................................712 With the handheld control.....................................................................713 From the crane cab.............................................................................714 12.6.10 Level the truck crane on outriggers........................................................716 Inclination indicators.........................................................................716 Prerequisites..................................................................................717 Manual alignment...............................................................................718 Automatic alignment............................................................................719 12.6.11 Outrigger pressure display.................................................................721 12.7 Rigging/unrigging the counterweight...............................................................723 12.7.1 Counterweight sections......................................................................723 Version A......................................................................................723 Version B......................................................................................724 12.7.2 Identification..............................................................................725 12.7.3 Slinging points.............................................................................727 12.7.4 CHECKLIST: Rigging the counterweight........................................................728 12.7.5 CHECKLIST: Unrigging the counterweight......................................................729 12.7.6 Assembling counterweight combination........................................................730 With version A.................................................................................732 With version B.................................................................................734 12.7.7 Counterweight hoist unit....................................................................736 Counterweight submenu..........................................................................736 Extending/ retracting the lifting cylinders....................................................737 Automatic mode, rigging........................................................................738 Automatic mode, unrigging......................................................................740 Cancel automatic mode..........................................................................742 12.7.8 Screwing the counterweight section to the turntable.........................................743 12.7.9 Slewing with rigged counterweight...........................................................744 12.7.10 Assembling counterweight sections for driving..............................................746 12.8 Rigging work on the main boom.....................................................................747 12.8.1 Hook block on the bumper....................................................................747 Picking up the hook block......................................................................747 Attaching the hook block.......................................................................748 12.8.2 Hook block on a separate vehicle............................................................749 Picking up the hook block......................................................................750 Setting down the hook block....................................................................750 12.8.3 Reeving and unreeving the hoist rope........................................................752 Rope end fitting...............................................................................752 Fastening the rope end clamp...................................................................753 Reeving the hoist rope.........................................................................755 Unreeving the hoist rope.......................................................................758 12.8.4 Possible reeving methods on the main boom...................................................759 With 8 head sheaves............................................................................759 12.8.5 Installing/removing the lifting limit switch................................................763 Installing the lifting limit switch............................................................763 Removing the lifting limit switch..............................................................766 12.8.6 Locking/unlocking the lifting limit switch..................................................768 Locking........................................................................................768 Removing the lock..............................................................................768 12.8.7 Anemometer and air traffic control light....................................................769 Installing.....................................................................................769 Removing.......................................................................................770 12.9 Other rigging works............................................................................... 0 12.9.1 Folding mirrors in/out and adjusting........................................................ 0 12.9.2 Cameras for crane operation.................................................................772 Cameras on the hoists..........................................................................772 Camera on main boom............................................................................772 Turning the monitor on/off and switching.......................................................774 13 Driving with rigged truck crane.........................................................................777 13.1 Driving distance..................................................................................777 13.2 Permissible rigging modes and axle loads..........................................................779 Axle load table....................................................................................779 13.3 Before driving....................................................................................781 13.3.1 Secure the counterweight to the turntable...................................................781 13.3.2 Securing the superstructure against slewing.................................................781 13.3.3 Checking tyre pressure and wind speed.......................................................782 13.3.4 Putting the truck crane on the wheels.......................................................783 13.3.5 Gears/connections...........................................................................785 Gears..........................................................................................785 Connections....................................................................................785 13.4 While driving.....................................................................................786 13.5 After driving.....................................................................................787 13.5.1 Restoring to its original condition.........................................................787 13.5.2 Supporting the truck crane..................................................................787 13.5.3 Releasing counterweight.....................................................................788 14 Malfunctions during crane operation.....................................................................791 14.1 Emergency stop devices............................................................................791 14.2 What to do when malfunctions occur during crane operation.........................................793 Load can be lowered................................................................................793 Load cannot be lowered.............................................................................793 14.3 Fuses on the superstructure.......................................................................795 Notes on changing fuses............................................................................795 14.3.1 Fuses on the turntable......................................................................796 Fuse groups F1/F2..............................................................................796 Fuses on the circuit board.....................................................................798 Fuses on I/O circuit boards....................................................................798 14.3.2 Fuses in the crane cab......................................................................799 14.3.3 Fuses in the battery box....................................................................801 14.3.4 RCL fuses...................................................................................803 14.4 Finding and eliminating malfunctions..............................................................805 14.4.1 Malfunctions on the engine for crane operation..............................................805 14.4.2 Faults on the DEF system....................................................................807 14.4.3 Malfunctions when operating with the hand-held control......................................807 14.4.4 Malfunctions on the main hoist/auxiliary hoist..............................................808 14.4.5 Malfunctions in the hoist cameras...........................................................809 14.4.6 Malfunctions in the main boom camera........................................................810 14.4.7 Malfunctions on the derricking gear.........................................................811 14.4.8 Malfunctions on the slewing gear............................................................812 14.4.9 Malfunctions on the counterweight hoist unit................................................813 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler..................................814 14.4.11 Malfunctions when inclining the crane cab..................................................814 14.4.12 Malfunctions in the telescoping mechanism..................................................815 Telescoping mechanism error messages...........................................................817 14.4.13 Malfunctions of the outriggers.............................................................818 14.4.14 Troubleshooting the RCL....................................................................819 General malfunctions...........................................................................819 Error messages in the Monitoring submenu.......................................................820 Displays in the Error submenu..................................................................822 Table of error codes..........................................................................824 Switching off thesensor/ tachogenerator.......................................................827 14.4.15 Malfunctions ECOS – superstructure.........................................................828 ECOS programme version.........................................................................828 General malfunctions...........................................................................828 Error messages.................................................................................829 Exiting the submenu............................................................................830 14.4.16 Malfunctions on the CraneSTAR system.......................................................831 14.5 Emergency operations and programmes...............................................................835 14.5.1 Mechanical emergency activation for retracting..............................................836 Prior to the emergency operation, check........................................................836 Procedure......................................................................................836 Mechanical emergency activation................................................................837 14.5.2 Telescoping emergency programme.............................................................839 Starting the emergency program.................................................................839 Determining the error type.....................................................................840 Error on length indicator......................................................................841 If there is an error at a proximity switch.....................................................845 Terminating the emergency program..............................................................846 Tables for approaching the locking points......................................................847 14.5.3 Entering the current telescoping............................................................849 14.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....851 Preparations...................................................................................851 Operating a power unit.........................................................................852 Stopping movements.............................................................................854 Stopping movements in emergencies..............................................................854 Turning off the engine.........................................................................854 14.5.5 Switching on emergency operation in coolant circuit.........................................855 14.6 Hydraulic emergency operation.....................................................................857 14.7 Other emergency operations........................................................................869 14.7.1 External starting socket....................................................................869 Performing a jump start........................................................................870 14.7.2 Battery charger.............................................................................870 15 Index...................................................................................................873 A......................................................................................................875 B......................................................................................................875 C......................................................................................................876 D......................................................................................................877 E......................................................................................................879 F......................................................................................................881 G......................................................................................................881 H......................................................................................................882 I......................................................................................................883 K......................................................................................................883 L......................................................................................................883 M......................................................................................................884 O......................................................................................................885 P......................................................................................................886 R......................................................................................................886 S......................................................................................................887 T......................................................................................................888 V......................................................................................................890 W......................................................................................................890
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