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Grove Crane GMK-5170 Part1 Driving Operating Instructions Manual 3112582 – PDF DOWNLOAD
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Description
Grove Crane GMK-5170 Part1 Driving Operating Instructions Manual 3112582 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK-5170 Part1 Driving Operating Instructions Manual 3112582 – PDF DOWNLOAD
Language : English
Pages : 894
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK-5170 Part1 Driving Operating Instructions Manual 3112582 – PDF DOWNLOAD
Intended use:
- The GMK 5170 is a state-of-the-art truck crane, designed in accordance with
approved safety regulations. Nevertheless, the operator or third parties can
still be endangered and the crane or other property put at risk while using it.
The truck crane may only be modified with the consent of Manitowoc Crane
Group Germany GmbH. - The GMK 5170 truck crane may only be used in a perfect technical condition
as intended and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately.
The GMK 5170 truck crane may only be operated without the corresponding
special equipment within the permitted temperature range; àTechnical
Information on the carrier, p. 8 – 1. - 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.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK-5170 Part1 Driving Operating Instructions Manual 3112582 – PDF DOWNLOAD
Additional page............................................................................................ 3 SLI override........................................................................................... 3 Stop at 0° or 180°..................................................................................... 15 New outriggers control units........................................................................... 17 New control unit................................................................................... 18 Old control unit................................................................................... 18 Outriggers......................................................................................... 19 Outrigger pressure indicator....................................................................... 19 Inclination indicators............................................................................. 19 Correction sheet........................................................................................... 23 Fuses.................................................................................................. 23 Accepting the telescope status......................................................................... 25 1 Overview................................................................................................. 31 1.1 Identification..................................................................................... 31 1.2 EC Declaration of Conformity....................................................................... 35 1.3 Documentation supplied............................................................................. 36 1.4 Information about the operating instructions....................................................... 37 1.4.1 What do the symbols used mean?............................................................... 37 1.4.2 How are the operating instructions structured?............................................... 39 Division....................................................................................... 39 Structure of the chapters...................................................................... 39 Structure of the pages......................................................................... 40 1.4.3 How do I find the information I need?........................................................ 41 Cross-references example....................................................................... 42 1.4.4 What information is available for operations planning?....................................... 44 1.5 Conversion table for US measurements............................................................... 45 2 Basic safety instructions................................................................................ 49 2.1 Intended use....................................................................................... 49 2.1.1 Improper use................................................................................. 50 2.2 Organisational measures............................................................................ 51 2.3 Qualifications of the personnel.................................................................... 53 2.4 Safety instructions for driving the truck crane.................................................... 54 2.5 Safety instructions for crane operation............................................................ 55 3 Operating elements for driving........................................................................... 59 3.1 Overview of the operating elements................................................................. 59 3.1.1 On the outside of the truck crane............................................................ 60 3.1.2 Driver's cab................................................................................. 62 Overview....................................................................................... 62 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 Tachograph Version 1........................................................................... 68 Middle......................................................................................... 69 Right.......................................................................................... 70 3.1.4 ECOS control unit............................................................................ 72 3.1.5 ECOS display – main menu..................................................................... 74 3.1.6 ECOS display – submenus...................................................................... 76 Level adjustment system submenu................................................................ 76 Settings submenu............................................................................... 78 Monitoring submenu............................................................................. 79 Operating hours submenu........................................................................ 80 Warning submenu................................................................................ 80 Error submenu.................................................................................. 81 3.1.7 Side instrument panel........................................................................ 82 Standard heating system........................................................................ 83 Auxiliary water heater......................................................................... 84 Auxiliary air heater........................................................................... 85 3.1.8 Transmission operating elements.............................................................. 86 3.1.9 Steering column/steering wheel............................................................... 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 information relating to directions of movement................................. 91 Basic rule..................................................................................... 91 Switches and buttons........................................................................... 92 3.2.2 General information 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 Main menu...................................................................................... 95 3.2.5 Electrical system/electronics................................................................ 96 Electrical system.............................................................................. 96 3.2.6 ECOS crane control........................................................................... 96 Control unit................................................................................... 96 Instrument panel............................................................................... 99 3.2.7 Transmission.................................................................................100 ECOS display...................................................................................100 Side instrument panel..........................................................................101 3.2.8 Transfer case................................................................................104 3.2.9 Axle drive...................................................................................105 3.2.10 Brakes......................................................................................106 Service brake..................................................................................106 Parking brake..................................................................................107 Additional brakes..............................................................................108 3.2.11 Normal steering mode/separate steering......................................................109 Instrument panels..............................................................................109 ECOS display...................................................................................110 Driver's door..................................................................................111 3.2.12 Suspension..................................................................................112 3.2.13 Lighting/windscreen wipers/horn.............................................................113 Steering column................................................................................113 Instrument panels..............................................................................113 Overhead in the driver's cab...................................................................115 3.2.14 Level adjustment system.....................................................................116 3.2.15 Tachograph/speedometer......................................................................118 Tachograph.....................................................................................118 Speedometer....................................................................................118 3.2.16 Roof ventilator.............................................................................119 3.2.17 Diagnostics.................................................................................120 Connections/ buttons...........................................................................120 Displays/ submenu..............................................................................120 3.2.18 Windows, doors, keys........................................................................121 Windows........................................................................................121 Doors..........................................................................................121 Keys...........................................................................................122 3.2.19 Front flap..................................................................................123 3.2.20 Storage compartment.........................................................................123 4 Starting/turning off the engine for driving..............................................................127 4.1 Starting the engine from the driver's cab..........................................................127 4.1.1 CHECKLIST: Starting the engine...............................................................127 4.1.2 CHECKLIST: At low temperatures...............................................................130 4.1.3 Access ladders and ladders...................................................................130 Access ladders.................................................................................130 Ladders........................................................................................131 4.1.4 Refuelling...................................................................................133 4.1.5 Checks before starting the engine............................................................134 Valves on hydraulic tank.......................................................................134 Battery master switch..........................................................................135 Checking the hand-held control.................................................................135 4.1.6 Switch on the ignition.......................................................................135 4.1.7 Lamp test/equalisation of the switching states...............................................136 Lamp test......................................................................................136 Equalisation of the switching states...........................................................137 4.1.8 Adjusting the brightness of the display......................................................139 4.1.9 Starting the engine..........................................................................140 Without flame start system.....................................................................141 With flame start system........................................................................142 4.1.10 Checks after starting the engine............................................................143 Checking in the main menu......................................................................143 Checking the instrument panels.................................................................144 4.1.11 Monitoring submenu..........................................................................145 4.1.12 Setting the idling speed....................................................................146 4.2 Turning off the engine.............................................................................147 4.2.1 During normal operation, with the ignition lock/with the hand- held control..................147 Hand-held control not connected................................................................147 Hand-held control connected....................................................................147 After turning off..............................................................................147 4.2.2 With emergency stop switches in emergencies..................................................148 Resetting the emergency stop switch............................................................148 4.3 Air intake inhibitor...............................................................................149 Releasing the air intake inhibitor.................................................................149 5 Driving..................................................................................................153 5.1 Before driving.....................................................................................153 5.1.1 CHECKLIST: Checks before on-road driving.....................................................153 5.1.2 Checking the condition of the truck crane....................................................159 Windscreen washing system......................................................................159 Warning plates for vehicle width...............................................................159 Electrical system..............................................................................160 Adjusting the mirrors..........................................................................160 Checking the vehicle height....................................................................161 Supply pressure................................................................................162 Parking brake..................................................................................163 5.1.3 Adjusting the seat and the steering column...................................................164 Adjusting the driver's seat....................................................................164 Adjusting the passenger seat...................................................................165 Adjusting the steering column..................................................................166 5.1.4 Switching the suspension on/off..............................................................167 Opening the submenu............................................................................167 Switching on the suspension....................................................................168 Switching off the suspension...................................................................168 5.1.5 Setting the tachograph – version 1...........................................................169 Prerequisites..................................................................................169 Display of error messages......................................................................169 Adjusting the tachograph.......................................................................170 5.1.6 Displaying the operating hours...............................................................174 5.2 Operating the transmission.........................................................................175 5.2.1 Switching on.................................................................................175 5.2.2 Switching the transmission to neutral position...............................................176 While driving..................................................................................176 5.2.3 Changing the driving mode....................................................................177 5.2.4 Selecting the driving direction..............................................................178 5.2.5 Selecting highest gear/starting gear.........................................................179 5.2.6 Starting.....................................................................................179 5.2.7 Driving and changing gears...................................................................180 5.2.8 Changing the driving direction...............................................................181 5.2.9 Stopping.....................................................................................182 Stopping for a longer period of time...........................................................182 5.2.10 On the roller type dynamometer..............................................................182 5.2.11 Oil level gauge.............................................................................183 5.3 Driving and turning off the truck crane............................................................185 5.3.1 Checks while driving.........................................................................185 Immediately after you start to move............................................................185 While driving..................................................................................186 5.3.2 Tempomat.....................................................................................189 Switching on the Tempomat......................................................................189 Driving with the Tempomat......................................................................189 Switching off the Tempomat.....................................................................190 5.3.3 Temposet.....................................................................................191 Switching Temposet on..........................................................................191 Driving with the Temposet......................................................................191 Switching Temposet off.........................................................................191 5.3.4 Driving downhill.............................................................................192 Starting.......................................................................................192 Checks when driving downhill...................................................................192 Shifting down from the highest gear............................................................193 Additional brakes..............................................................................194 5.3.5 Driving uphill...............................................................................195 Starting.......................................................................................195 Driving........................................................................................195 5.3.6 Warning submenu..............................................................................196 Opening the submenu............................................................................196 Meaning of the symbols.........................................................................197 Exiting the submenu............................................................................200 5.3.7 Error submenu................................................................................200 5.3.8 Turning off the truck crane..................................................................201 Secure against rolling away....................................................................202 When stationary for more than 8hours..........................................................203 5.3.9 Folding berth................................................................................204 5.4 Off-road driving...................................................................................205 Adjustments to the transmission....................................................................205 Connections........................................................................................205 Changing the vehicle level.........................................................................205 Rocking the vehicle free and towing................................................................205 5.4.1 Transfer case – switching the off-road gear on/off...........................................206 Prerequisites..................................................................................206 Switching on...................................................................................206 Switching off..................................................................................207 Neutral position...............................................................................207 5.4.2 Longitudinal and transverse differential locks...............................................207 5.4.3 Operating the level adjustment system........................................................209 Opening the submenu............................................................................209 Setting the on-road level......................................................................210 Pre-selecting suspension struts................................................................210 Changing the vehicle level.....................................................................211 Viewing the current inclination................................................................211 Exiting the submenu............................................................................212 5.4.4 Freeing the truck crane stuck in terrain.....................................................213 Rocking the truck crane free...................................................................213 Towing free forwards...........................................................................214 Towing free in reverse gear....................................................................214 5.5 Separate steering..................................................................................215 5.5.1 Switching on separate steering...............................................................216 Manually.......................................................................................216 Automatically..................................................................................217 5.5.3 Switching off separate steering..............................................................218 5.6 Heating and ventilating the driver's cab...........................................................219 5.6.1 Standard heating system......................................................................219 Switching the heater on and off................................................................219 Setting the temperature........................................................................219 Setting recirculated air/fresh air.............................................................220 Setting the air distribution...................................................................220 Ventilating the driver's cab...................................................................221 5.6.2 Auxiliary water heater.......................................................................222 Preheating the engine..........................................................................222 Preheating the driver's cab....................................................................222 Switching on the auxiliary heater..............................................................223 Switching off the auxiliary heater.............................................................224 Setting time and weekday.......................................................................224 Saving automatic heating start.................................................................225 Setting the heating period.....................................................................226 Switching the automatic heating start on and off...............................................226 Setting the remaining time.....................................................................227 5.6.3 Auxiliary air heater with timer..............................................................228 Switching on the auxiliary heater..............................................................228 Setting the temperature........................................................................229 Switching off the auxiliary heater.............................................................229 Other functions................................................................................229 5.6.4 Switching the air-conditioning system on/off.................................................230 Switching on...................................................................................230 Setting the air distribution...................................................................230 Switching off..................................................................................231 For pleasant air conditioning in the crane cab.................................................231 Drying the air in the driver's cab.............................................................232 5.7 Towing a trailer...................................................................................233 Effects on the axle loads..........................................................................233 Coupling the trailer...............................................................................234 Connecting the supply lines........................................................................235 Removing the supply lines..........................................................................236 Uncoupling the trailer.............................................................................236 Checking the braking force.........................................................................238 6 Driving modes and rigging for on-road driving............................................................241 6.1 Driving modes......................................................................................241 Information about the axle loads...................................................................241 6.1.1 Information on how to use the tables.........................................................242 6.1.2 Tables for maximum axle load 12t............................................................243 For 14.00 R25 tyres............................................................................243 For 16.00 R25/ 20.5R25 tyres..................................................................244 6.2 Rigging work for driving with a trailer............................................................245 6.2.1 Switching on the slewing gear freewheel......................................................245 Prerequisites..................................................................................245 6.2.2 Switching on boom floating position..........................................................247 6.2.3 Switching on boom pre-tensioning.............................................................248 6.2.4 Switching the superstructure driving lights on/off...........................................249 Switching off..................................................................................249 Switching on...................................................................................249 6.3 Rigging the main boom..............................................................................251 Additional equipment required......................................................................251 6.3.1 CHECKLIST: Removing the main boom............................................................252 Prerequisites..................................................................................252 Checklist......................................................................................252 6.3.2 CHECKLIST: Mounting the main boom............................................................255 Prerequisites..................................................................................255 Checklist......................................................................................255 6.3.3 Slinging the main boom.......................................................................258 6.3.4 Removing/attaching the clamp.................................................................259 6.3.5 Switching the pressure relief on/off.........................................................260 6.3.6 Retracting/fitting the derricking cylinder head pin..........................................261 Derricking cylinder............................................................................261 Operation of the lifting device................................................................261 Retracting the derricking cylinder head axle...................................................262 Fitting the derricking cylinder head axle......................................................263 6.3.7 Retracting/extending the boom pivot pin......................................................264 Before retracting..............................................................................264 After extension................................................................................264 Retracting/ extending the pivot pin............................................................265 6.3.8 Disconnecting the hydraulic/electrical connection............................................266 Lifting in front of the turntable..............................................................266 Disconnecting..................................................................................267 6.3.9 Establishing the hydraulic/electrical connection.............................................268 Lifting onto the turntable.....................................................................268 Establishing...................................................................................269 6.3.10 Aligning the connecting points..............................................................270 6.3.11 Securing/releasing the derricking cylinder..................................................270 6.3.12 Transporting the main boom..................................................................271 6.3.13 Inspections after main boom mounting........................................................272 6.4 Installing/removing supports.......................................................................273 6.4.1 CHECKLIST: Removing the outrigger beams......................................................274 6.4.2 CHECKLIST: Installing the outrigger beams....................................................276 6.4.3 Preparing the truck crane....................................................................278 Prerequisites..................................................................................278 For removal....................................................................................278 6.4.4 Removing/attaching outrigger pads............................................................279 Removing the outrigger pads....................................................................279 Attaching the outrigger pads...................................................................280 6.4.5 Disconnecting/establishing the hydraulic connection..........................................281 6.4.6 Establishing/disconnecting the electrical connection.........................................282 6.4.7 Unscrewing/screwing in the spacers...........................................................283 Unscrewing.....................................................................................283 Screwing in....................................................................................284 6.4.8 Disconnecting/establishing the connections to the outrigger box..............................285 6.4.9 Extending/Retracting the outrigger beam......................................................285 Extending the outrigger beam...................................................................285 Inserting the outrigger beam...................................................................287 6.4.10 Transporting the outrigger beams............................................................289 7 Malfunctions in driving mode.............................................................................293 7.1 Emergency stop devices.............................................................................293 7.2 What to do when a malfunction occurs in road traffic...............................................295 7.3 Towing the truck crane.............................................................................297 7.3.1 Towing in the event of engine or transmission damage.........................................297 Compressed-air supply..........................................................................298 Electric power supply..........................................................................298 Axle drives....................................................................................298 Transmission...................................................................................298 Transfer case..................................................................................299 Parking brake..................................................................................299 Towing the truck crane out of the danger area..................................................300 7.3.2 Tow starting.................................................................................300 7.4 Wheels and tyres...................................................................................301 7.4.1 Wheel change.................................................................................301 Removing a damaged wheel.......................................................................302 On the spare wheel holder......................................................................302 Mounting a wheel...............................................................................303 7.4.2 Filling the tyres yourself...................................................................305 Connecting the filling hose....................................................................305 Filling the tyres..............................................................................306 Remove the filling hose........................................................................306 7.5 Fuses on the carrier...............................................................................307 Information on replacing fuses.....................................................................307 7.5.1 Fuses in the driver's cab....................................................................308 7.5.2 Fuses in the battery box.....................................................................312 7.5.3 Fuses on I/O circuit boards..................................................................313 7.6 Troubleshooting....................................................................................315 7.6.1 Malfunctions on the engine for driving.......................................................315 7.6.2 Differential lock malfunctions...............................................................317 7.6.3 Malfunctions to the transmission.............................................................318 7.6.4 Transfer case malfunctions...................................................................319 7.6.5 Malfunctions of the service brake............................................................319 7.6.6 Malfunctions of the steering.................................................................320 7.6.7 Malfunctions on the suspension...............................................................321 7.6.8 Malfunctions of the level adjustment system..................................................321 7.6.9 Malfunctions in the hydraulic system/hydraulic oil cooler....................................322 7.6.10 Malfunctions on the ECOS carrier............................................................323 ECOS program version...........................................................................323 General malfunctions...........................................................................323 Error messages.................................................................................324 Exiting the submenu............................................................................325 Error display on the control units.............................................................326 7.7 Procedure in the event of malfunctions.............................................................327 7.7.1 Switching on emergency operation in coolant circuit..........................................327 7.7.2 Malfunctions on the engine...................................................................328 7.7.3 Malfunctions to the transmission.............................................................329 General malfunctions...........................................................................329 Display E......................................................................................329 Transmission malfunction.......................................................................330 Reading out error codes........................................................................331 8 Technical Information on the carrier.....................................................................335 8.1 Technical data.....................................................................................335 8.1.1 Dimensions and weights of the truck crane, axle loads........................................336 Dimensions.....................................................................................337 Weight and axle loads..........................................................................337 8.1.2 Dimensions and weights of removable parts....................................................338 Spare wheel....................................................................................338 Outriggers.....................................................................................338 Main boom......................................................................................339 Auxiliary hoist................................................................................339 8.1.3 Carrier......................................................................................339 Engine.........................................................................................339 Transmission...................................................................................339 Transfer case..................................................................................339 Axle lines.....................................................................................340 Steering.......................................................................................340 Tyres..........................................................................................340 Vehicle electrical system......................................................................341 Tools..........................................................................................341 Towing coupling...............................................................................341 Outriggers.....................................................................................341 Driving speeds.................................................................................342 Climbing ability...............................................................................342 Turning circle radiuses........................................................................342 9 Index....................................................................................................345 A......................................................................................................347 B......................................................................................................347 C......................................................................................................348 D......................................................................................................349 E......................................................................................................351 F......................................................................................................352 H......................................................................................................353 I......................................................................................................354 K......................................................................................................354 L......................................................................................................354 M......................................................................................................355 O......................................................................................................355 P......................................................................................................357 R......................................................................................................357 S......................................................................................................358 T......................................................................................................360 V......................................................................................................361 W......................................................................................................361 Additional page............................................................................................367 SLI override...........................................................................................367 Stop at 0° or 180°.....................................................................................379 New outriggers control units...........................................................................381 New control unit...................................................................................382 Old control unit...................................................................................382 Outriggers.........................................................................................383 Outrigger pressure indicator.......................................................................383 Inclination indicators.............................................................................383 Correction sheet...........................................................................................387 Fuses..................................................................................................387 Accepting the telescope status.........................................................................389 10 Operating elements for crane operation..................................................................395 10.1 Overview of the operating elements................................................................395 10.1.1 On the outside of the truck crane...........................................................396 10.1.2 Crane cab...................................................................................398 10.1.3 Front panel.................................................................................400 10.1.4 Side panel..................................................................................401 Bottom.........................................................................................401 Top............................................................................................402 Standard heating system........................................................................405 Auxiliary water heating system.................................................................406 Auxiliary air heater...........................................................................407 10.1.5 Control panels..............................................................................408 Left...........................................................................................408 Right..........................................................................................409 10.1.6 Control lever configuration.................................................................410 Version 1......................................................................................410 Version 2......................................................................................411 10.1.7 ECOS control unit...........................................................................412 10.1.8 ECOS display – main menu....................................................................414 10.1.9 ECOS display – submenus.....................................................................416 Counterweight submenu..........................................................................416 Slewing gear/ Houselock submenu................................................................417 Outriggers submenu.............................................................................418 Telescoping submenu............................................................................420 Power unit speeds submenu......................................................................422 Monitoring submenu.............................................................................423 Settings submenu...............................................................................424 Operating hours submenu........................................................................426 Warning submenu................................................................................426 Error submenu..................................................................................429 Working range limitation submenu...............................................................430 10.1.10 SLI control unit...........................................................................432 10.1.11 SLI display – main menu....................................................................434 10.1.12 SLI display – submenus.....................................................................435 Enter rigging mode submenu.....................................................................435 Monitoring submenu.............................................................................436 Rigging mode monitoring submenu................................................................438 Lifting capacity table submenu.................................................................439 Working range submenu..........................................................................440 Error submenu..................................................................................441 Settings submenu...............................................................................443 10.1.13 Hand-held control..........................................................................444 Outriggers control panel.......................................................................445 10.1.14 Outriggers control units...................................................................446 Outriggers.....................................................................................447 Outrigger pressure display.....................................................................447 Inclination indicator..........................................................................447 10.2 Short description of the operating elements.......................................................449 10.2.1 Definition of information relating to directions of movement................................449 Basic rule.....................................................................................449 Switch.........................................................................................450 10.2.2 General rules for buttons and symbols on the display........................................450 10.2.3 Engine for crane operation..................................................................451 Side panel.....................................................................................451 10.2.4 Engine for driving..........................................................................452 Side panel.....................................................................................452 Outriggers submenu.............................................................................452 10.2.5 Seat contact switch and dead man's switch...................................................453 10.2.6 ECOS crane control..........................................................................454 Control unit...................................................................................454 10.2.7 Outriggers..................................................................................457 Hand-held control..............................................................................457 In the Outriggers submenu......................................................................458 In the settings submenu........................................................................459 On the Outriggers control units................................................................460 10.2.8 Inclination indicators......................................................................462 10.2.9 Outrigger pressure displays.................................................................463 Outriggers submenu.............................................................................463 Outriggers control units.......................................................................463 10.2.10 Anemometer display.........................................................................463 10.2.11 Counterweight submenu......................................................................464 Counterweight submenu..........................................................................464 10.2.12 Main hoist.................................................................................467 10.2.13 Auxiliary hoist............................................................................469 10.2.14 Slewing gear...............................................................................470 Control panels.................................................................................470 Submenu........................................................................................471 10.2.15 Derricking gear............................................................................473 10.2.16 Telescoping mechanism......................................................................474 Control panels.................................................................................474 Submenu........................................................................................475 In the settings submenu........................................................................479 10.2.17 Hydraulic system...........................................................................481 10.2.18 Houselock..................................................................................482 10.2.19 Safe load indicator (SLI)..................................................................483 Control unit...................................................................................483 Main menu......................................................................................485 Enter rigging mode submenu.....................................................................486 Monitoring submenu.............................................................................489 Lifting capacity table submenu.................................................................493 Working range submenu..........................................................................493 Other..........................................................................................494 10.2.20 Electrical system..........................................................................495 10.2.21 Lighting, windscreen wiper/washing system..................................................495 Lighting.......................................................................................495 Windscreen wiper/washing system................................................................497 10.2.22 Hand-held control..........................................................................498 Sockets for hand- held control.................................................................498 Engine control panel...........................................................................499 Horn...........................................................................................499 Outriggers control panel.......................................................................500 10.2.23 Diagnostics................................................................................502 10.2.24 Windows, doors, keys.......................................................................503 Windows........................................................................................503 Crane cab door.................................................................................503 Keys...........................................................................................504 11 Starting/turning off the engine – for crane operation...................................................507 11.1 Starting the engine – from the crane cab..........................................................507 11.1.1 CHECKLIST: Starting the engine..............................................................507 11.1.2 CHECKLIST: At low temperatures..............................................................510 11.1.3 Refuelling..................................................................................510 11.1.4 Inspections before starting the engine......................................................512 Valve on hydraulic tank........................................................................512 Battery master switch..........................................................................512 Checking the hand-held control.................................................................513 11.1.5 Switch on the ignition......................................................................513 11.1.6 Lamp test...................................................................................515 Lamp test......................................................................................515 11.1.7 Adjusting the brightness of the display.....................................................517 11.1.8 Starting the engine.........................................................................518 Without flame start system.....................................................................518 With flame start system........................................................................519 11.1.9 Inspections after starting the engine.......................................................520 11.1.10 Monitoring submenu.........................................................................521 11.1.11 Setting the idling speed...................................................................522 11.2 Starting the engine – with the hand-held control..................................................523 Prerequisites......................................................................................523 Starting the engine................................................................................523 11.3 Turning off the engine............................................................................525 11.3.1 During normal operation, with the ignition lock/with the hand- held control.................525 Hand-held control not connected................................................................525 Hand-held control connected....................................................................525 After parking..................................................................................525 11.3.2 In emergencies, with the emergency stop switches............................................526 Resetting the emergency stop switch............................................................526 11.4 Air intake inhibitor..............................................................................527 Releasing the air intake inhibitor.................................................................527 12 Crane operation.........................................................................................531 12.1 Before crane operation............................................................................531 12.1.1 CHECKLIST: Inspections prior to crane operation.............................................531 12.1.2 Checking the condition of the truck crane...................................................535 Tank for windscreen washing system.............................................................535 Auxiliary heater...............................................................................535 Visual inspection..............................................................................536 Checking the position of the hoist ropes.......................................................536 Checking the electrical system.................................................................537 12.1.3 Adjusting the crane cab bracket and front panel.............................................537 Adjusting the crane cab bracket................................................................537 Front panel....................................................................................538 12.1.4 Checking the safety devices.................................................................539 Safe load indicator............................................................................539 Lifting limit switch...........................................................................539 Emergency stop switch..........................................................................540 Seat contact switch............................................................................541 12.1.5 Earthing load...............................................................................542 12.1.6 Preheating the hydraulic oil................................................................543 12.1.7 Switching the houselock on/off..............................................................544 Switching on the houselock.....................................................................544 Switching off the houselock....................................................................546 12.2 Operation of the safe load indicator..............................................................547 12.2.1 Switching on the SLI........................................................................548 Switching on...................................................................................548 Brightness of the displays.....................................................................550 12.2.2 Entering the rigging mode...................................................................551 Entering individual components.................................................................552 Entering the SLI code..........................................................................555 Entering the reeving...........................................................................556 Accepting the rigging mode.....................................................................556 12.2.3 Inspections prior to crane operation........................................................558 Opening the submenu............................................................................558 Checking.......................................................................................559 12.2.4 Displays during crane operation.............................................................561 12.2.5 SLI early warning...........................................................................564 12.2.6 SLI shutdown................................................................................564 Shutdown due to overload.......................................................................564 12.2.7 Display in the event of errors..............................................................566 12.2.8 SLI override................................................................................567 12.2.9 Displaying the lifting capacity tables......................................................568 12.2.10 Entering the time/date.....................................................................570 12.3 Crane operation with main boom....................................................................571 12.3.1 Checks during crane operation...............................................................571 Horizontal alignment...........................................................................571 Safe distances.................................................................................571 Checking the wind speed........................................................................572 12.3.2 Permissible slewing ranges and working positions for crane operation........................573 360 slewing range.............................................................................573 Working position 0 to the rear................................................................573 180 to the front rigging position.............................................................573 12.3.3 Main hoist..................................................................................575 Switching on the main hoist....................................................................576 Lifting and lowering...........................................................................576 Switching off the main hoist...................................................................577 12.3.4 Auxiliary hoist.............................................................................578 Switching on the auxiliary hoist...............................................................578 Lifting and lowering...........................................................................579 Switching off the auxiliary hoist..............................................................580 12.3.5 Lifting limit switch and lowering limit switch..............................................581 Lifting limit switch...........................................................................581 Lowering limit switch..........................................................................583 12.3.6 Derricking gear.............................................................................584 Switching on the derricking gear...............................................................584 Raising and lowering...........................................................................584 Switching off the derricking gear..............................................................585 Lowering the main boom to a horizontal position................................................586 12.3.7 Telescoping mechanism.......................................................................587 Overview.......................................................................................588 Telescoping process............................................................................588 Assignment for display.........................................................................590 Fixed length, intermediate length, telescoping length..........................................592 Telescoping....................................................................................593 Telescoping sequence...........................................................................593 Inspections prior to starting operations.......................................................594 Switching on the telescoping mechanism.........................................................595 Function of the control lever..................................................................595 Switching off the telescoping mechanism.......................................................597 Manual telescoping.............................................................................598 Checking the initial position..................................................................598 Unlocking the telescoping cylinder............................................................601 Extending/retracting the telescoping cylinder..................................................603 Lock telescoping cylinder......................................................................604 Unlocking the telescopic section..............................................................605 Telescoping the telescopic section.............................................................607 Locking the telescopic section.................................................................608 Locking the telescopic section for on-road driving.............................................609 Telescoping with teleautomation................................................................610 Telescoping the main boom in horizontal position...............................................615 12.3.8 High-speed mode.............................................................................616 Derricking gear/ telescoping mechanism........................................................616 Hoisting gears.................................................................................617 12.3.9 Slewing gear................................................................................618 Slewing gear brake.............................................................................618 Switching on the slewing gear..................................................................619 Releasing the slewing gear brake...............................................................619 Engaging the slewing gear brake................................................................619 Slewing........................................................................................620 Slewing to 0 or 180 ..........................................................................622 Braking the slewing movement...................................................................623 Slewing gear freewheel.........................................................................623 Switching off the slewing gear.................................................................624 12.3.10 Possible movement combinations.............................................................624 12.3.11 Hydraulic oil cooling......................................................................625 12.4 Settings and displays for crane operation.........................................................627 12.4.1 Inclining the crane cab.....................................................................627 12.4.2 Setting the idling speed....................................................................627 12.4.3 Adjusting the wiper stroke interval of the windscreen wiper.................................628 12.4.4 Limiting the power unit speeds..............................................................628 12.4.5 Setting the characteristic curve for the control levers.....................................630 12.4.6 Critical load control.......................................................................631 Function.......................................................................................631 Switching on and off...........................................................................631 12.4.7 Slewable spotlights.........................................................................632 12.4.8 Displaying the operating hours..............................................................633 12.4.9 Warning submenu.............................................................................634 Meaning of the symbols.........................................................................634 Exiting the submenu............................................................................638 12.4.10 Error submenu..............................................................................638 12.5 Working range limiter.............................................................................639 12.5.1 Opening the Working range limiter submenu...................................................640 12.5.2 Viewing current settings....................................................................640 12.5.3 Entering limit values.......................................................................642 Overall height/ Working radius.................................................................642 Slewing angle..................................................................................643 Entering objects...............................................................................645 12.5.4 Entering limit values/objects manually......................................................648 Limit values...................................................................................648 Objects........................................................................................649 12.5.5 Switching monitoring functions on/off.......................................................650 12.5.6 Shutdown by working range limiter...........................................................651 12.6 Work break........................................................................................653 12.6.1 In case of short work breaks................................................................653 12.6.2 In case of work breaks of more than 8 hours.................................................654 Securing the truck crane against unauthorised use..............................................654 12.7 Heating and air-conditioning system...............................................................655 12.7.1 Standard heating system.....................................................................655 Switching on...................................................................................655 Heating........................................................................................655 Air distribution...............................................................................656 Switching off..................................................................................657 Notes..........................................................................................657 Switching on/off...............................................................................658 Cooling........................................................................................658 Drying the air.................................................................................659 12.7.3 Auxiliary water heating system..............................................................659 Preheating the engine..........................................................................660 Preheating the crane cab.......................................................................660 Switching on...................................................................................661 Setting the day and time.......................................................................662 Storing the heating start......................................................................663 Setting the heating period.....................................................................664 Switching heating start on/off.................................................................664 Switching off..................................................................................665 Setting the remaining run time.................................................................665 12.7.4 Auxiliary air heater........................................................................666 Switching on...................................................................................666 Temperature....................................................................................667 Switching off..................................................................................667 Other functions................................................................................667 13 Rigging work............................................................................................671 13.1 Rigging work checklists for crane operation with the main boom....................................671 13.1.1 CHECKLIST: Rigging..........................................................................671 13.1.2 CHECKLIST: Unrigging........................................................................675 13.2 Choosing a suitable site..........................................................................679 13.2.1 Determining the required ground bearing area................................................679 13.2.2 Safe distance from slopes and pits..........................................................682 13.2.3 Earthing the truck crane....................................................................683 13.2.4 Safe distance from electrical cables........................................................684 13.3 Rigging work after driving with a trailer.........................................................687 13.3.1 Switching off the boom floating position....................................................687 13.3.2 Switching off the slewing gear freewheel....................................................688 Before slewing.................................................................................688 13.3.3 Switching off boom pre-tensioning...........................................................689 13.4 Connecting/disconnecting the hand-held control....................................................690 13.5 Starting the engine for driving for rigging work..................................................691 13.5.1 Starting/turning off the engine with the hand-held control..................................691 Prerequisites..................................................................................691 Starting the engine............................................................................692 Turning off the engine.........................................................................692 13.5.2 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 13.6 Outriggers........................................................................................695 13.6.1 CHECKLIST: Extending the outriggers.........................................................695 13.6.2 CHECKLIST: Retracting the outriggers........................................................697 13.6.3 Permissible outrigger spans.................................................................698 13.6.4 Preparing the truck crane...................................................................699 In the driver's cab............................................................................699 Outriggers control units.......................................................................699 13.6.5 Setting the spans...........................................................................700 For on-road driving............................................................................702 13.6.6 Extending/retracting supports...............................................................703 From the control units.........................................................................703 With the hand- held control....................................................................705 From the crane cab.............................................................................707 13.6.7 Moving the outrigger pads into working/driving position.....................................709 13.6.8 Enlarging the ground bearing area...........................................................710 13.6.9 Extending/retracting supporting cylinders...................................................711 From the control units.........................................................................712 With the hand- held control....................................................................713 From the crane cab.............................................................................714 13.6.10 Levelling the truck crane on outriggers horizontally.......................................716 Inclination indicators.........................................................................716 Prerequisites..................................................................................717 Manual alignment..............................................................................718 Automatic alignment............................................................................719 13.6.11 Outrigger pressure display.................................................................721 13.7 Counterweight.....................................................................................723 Version A..........................................................................................723 Version B..........................................................................................724 13.7.2 Identification..............................................................................724 13.7.3 Slinging points.............................................................................725 13.7.4 CHECKLIST: Rigging the counterweight........................................................726 13.7.5 CHECKLIST: Unrigging the counterweight......................................................727 13.7.6 Assembling counterweight combination........................................................728 With version A.................................................................................730 With version B.................................................................................732 13.7.7 Counterweight hoist unit....................................................................734 Counterweight submenu..........................................................................734 Extending/retracting the lifting cylinders.....................................................735 Automatic mode rigging.........................................................................736 Automatic mode unrigging.......................................................................737 Cancel automatic mode..........................................................................739 13.7.8 Screwing the counterweight section to the turntable.........................................740 13.7.9 Slewing with rigged counterweight...........................................................741 13.7.10 Assembling counterweight sections for driving..............................................743 13.8 Rigging work on the main boom.....................................................................744 13.8.1 Hook block on the bumper....................................................................744 Picking up the hook block......................................................................744 Attaching the hook block.......................................................................745 13.8.2 Hook block on a separate vehicle............................................................746 Picking up the hook block......................................................................747 Setting down the hook block....................................................................747 13.8.3 Reeving and unreeving the hoist rope........................................................749 Rope end clamp.................................................................................749 Rope end fitting...............................................................................751 Reeving the hoist rope........................................................................752 Unreeving hoist rope...........................................................................755 13.8.4 Possible reevings with 8 head sheaves.......................................................756 13.8.5 Installing/removing the lifting limit switch................................................760 Installing the lifting limit switch............................................................760 Removing the lifting limit switch..............................................................763 13.8.6 Locking/Unlocking the lifting limit switch..................................................765 Locking........................................................................................765 Removing the lock..............................................................................766 13.8.7 Anemometer and air traffic control light....................................................767 Mounting.......................................................................................767 Removing.......................................................................................768 13.9 Other rigging works...............................................................................770 13.9.1 Mirror for crane operation..................................................................770 14 Rigged truck crane, driving.............................................................................773 14.1 Driving distance..................................................................................775 14.2 Before driving the rigged truck crane.............................................................775 14.2.1 Checking the tyre pressure and the wind speed...............................................775 14.3 Permissible rigging modes and axle loads..........................................................777 Axle load table...................................................................................777 14.4 Before driving....................................................................................779 14.4.1 Secure the counterweight to the turntable...................................................779 14.5 Driving...........................................................................................783 Transmission.......................................................................................783 Connections........................................................................................783 14.5.2 While driving...............................................................................783 14.5.3 After driving...............................................................................784 14.6 Driving in combined operation.....................................................................785 14.6.1 Switching combined operation on/off.........................................................785 Prerequisites..................................................................................785 Switching on...................................................................................786 Switching off..................................................................................786 14.6.2 Starting/turning off the engine.............................................................787 14.6.3 While driving...............................................................................788 14.6.4 After driving...............................................................................788 15 Malfunctions during crane operation.....................................................................791 15.1 Emergency stop switch.............................................................................791 15.2 What to do when malfunctions occur during crane operation.........................................793 Load can be lowered................................................................................793 Load cannot be lowered.............................................................................793 15.3 Fuses on the superstructure.......................................................................795 Information on replacing fuses.....................................................................795 15.3.1 Fuses on the turntable......................................................................796 Fuse groups F1/F2..............................................................................796 Fuses on the circuit board.....................................................................798 Fuses on I/O circuit boards....................................................................798 15.3.2 Fuses in the crane cab......................................................................799 15.3.3 Fuses in the battery box....................................................................801 15.3.4 SLI fuses...................................................................................802 15.4 Finding and eliminating malfunctions..............................................................805 15.4.1 Malfunctions on the engine..................................................................805 15.4.2 Malfunctions when operating with the hand-held control......................................807 15.4.3 Malfunctions on the main hoist/auxiliary hoist..............................................808 15.4.4 Malfunctions on the derricking gear.........................................................809 15.4.5 Malfunctions on the slewing gear............................................................810 15.4.6 Malfunctions on the counterweight hoist unit................................................811 15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler...................................812 15.4.8 Malfunctions when inclining the crane cab...................................................812 15.4.9 Malfunctions in the telescoping mechanism...................................................813 Telescoping mechanism error messages...........................................................815 15.4.10 Malfunctions of the outriggers.............................................................816 15.4.11 Troubleshooting the SLI....................................................................817 General malfunctions...........................................................................817 Error messages in the monitoring submenu.......................................................818 Displays in the Error submenu..................................................................820 Table of error codes...........................................................................822 Switching off the sensor/tachogenerator........................................................825 15.4.12 Malfunctions ECOS – superstructure.........................................................826 ECOS program version...........................................................................826 General malfunctions...........................................................................826 Error messages.................................................................................827 Exiting the submenu............................................................................828 15.5 Emergency operations and programs.................................................................829 15.5.1 Mechanical emergency operation for retracting...............................................830 Prior to the emergency operation, check........................................................830 Procedure......................................................................................830 Mechanical emergency operation.................................................................831 15.5.2 Telescoping emergency program...............................................................833 Starting the emergency program.................................................................833 Determining the type of error..................................................................834 If there is an error on the length indicator...................................................835 If there is an error at a proximity switch.....................................................839 Terminating the emergency program..............................................................840 Tables for approaching the locking points......................................................841 15.5.3 Entering the current telescoping............................................................843 15.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....845 Preparations...................................................................................845 Operating a power unit.........................................................................846 Stopping movements.............................................................................848 Stopping movements in emergencies..............................................................848 Turning off the engine.........................................................................848 15.5.5 Switching on emergency operation in coolant circuit.........................................849 15.6 Hydraulic emergency operation.....................................................................851 15.6.1 Operating principle.........................................................................851 15.6.2 Connecting/disconnecting hoses..............................................................853 Establishing connections.......................................................................853 Disconnecting connections......................................................................854 15.6.3 Switching emergency operation on/off........................................................855 15.6.4 Establishing the hydraulic circuits required................................................856 Switching over valves..........................................................................856 For lifting/lowering...........................................................................858 For slewing....................................................................................859 15.6.5 Carrying out emergency operation............................................................860 Lifting/Lowering in emergency mode.............................................................860 Slewing in emergency mode......................................................................861 Raising/Lowering in emergency mode.............................................................862 15.6.6 After emergency operation...................................................................863 Switching off emergency operation..............................................................863 Switching over to crane operation..............................................................863 Disconnecting the hoses........................................................................863 15.6.7 Emergency supply of another crane...........................................................864 For emergency supply...........................................................................864 After emergency supply.........................................................................864 16 Technical information about the superstructure..........................................................867 16.1 Technical data....................................................................................867 16.1.1 Maximum lifting capacity (DIN/ISO/EN).......................................................867 16.1.2 Dimensions and weights of the truck crane, axle loads.......................................868 16.1.3 Dimensions and weights of removable parts...................................................868 Hook blocks and hook tackle....................................................................868 Counterweight parts............................................................................869 Auxiliary hoist................................................................................869 16.1.4 Superstructure..............................................................................870 Engine.........................................................................................870 Main hoist.....................................................................................870 Auxiliary hoist................................................................................870 Slewing gears..................................................................................871 Derricking gear................................................................................871 Main boom......................................................................................871 Lattice extension..............................................................................871 Operating speeds...............................................................................872 17 Index...................................................................................................875 A......................................................................................................877 B......................................................................................................877 C......................................................................................................878 D......................................................................................................879 E......................................................................................................881 F......................................................................................................882 H......................................................................................................883 I......................................................................................................884 K......................................................................................................884 L......................................................................................................884 M......................................................................................................885 O......................................................................................................885 P......................................................................................................887 R......................................................................................................887 S......................................................................................................888 T......................................................................................................890 V......................................................................................................891 W......................................................................................................891
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