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Grove Crane GMK 5200 Driving Operating Instructions Manual 2084814 – PDF DOWNLOAD
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Description
Grove Crane GMK 5200 Driving Operating Instructions Manual 2084814 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5200 Driving Operating Instructions Manual 2084814 – PDF DOWNLOAD
Language : English
Pages : 800
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5200 Driving Operating Instructions Manual 2084814 – PDF DOWNLOAD
Overview:
1.1 Vehicle identification:
These operating instructions are intended only for the truck crane whose serial number is specified on the front cover.
The following plates and numbers have been fitted to the truck crane for identification:
1 the chassis number on the front right-hand side behind the first axle line,
2 the model plate on the passenger seat console containing the chassis number and designation of the crane model,
3 the name plate at the front of the crane operator’s cab containing serial number and designation of the crane model,
4 the CE mark on the name plate.
The location of ID numbers for removable rigging parts (e.g. counterweights, lattice extension, auxiliary hoist) is specified in the corresponding chapters.
Overview and contents of truck crane user information:
1.3.1 Operating Instructions:
These operating instructions contain information required to operate the truck crane.
- The operating instructions are divided into two parts. Part 1 with chapters 1 to 10 contains the
Description of the vehicle section of the truck crane; Part 2 with chapters 11 to 18 contains the
Description of the crane section. - In Chapter 2 you will find Basic safety instructions. Please read and observe these instructions,
even if you are familiar with the safety manual. The Basic safety instructions are contained in
this chapter only. Special safety instruc- tions that relate to specific hazards are described in
the section containing the operation with which the hazard is associated. - Chapter 3 contains Information for applications engineering. It is intended pri- marily for the
truck crane operator and those responsible for applications engineering.
This chapter contains
– the required qualifications of those involved in applications engineering,
– special safety instructions,
– information that is relevant to applications engineering.
- In Chapter 4 to 6 you will find information required for Driving the truck crane: a description of
all structural and operational components, clearly de- fined checklists for rigging modes and work,
and the operating instructions for on-road and off-road driving and the removal and installation of
the aux- iliary hoist. - Rigging for on-road driving is described in Chapter 7.
- In Chapter 8, there is information on Troubleshooting on the vehicle section of the truck crane.
- Chapter 9 contains the Technical description of the individual parts and func- tional elements of
the vehicle parts as well as the Technical data. - Chapter 10 contains the Index. This helps you when you are looking for cer-
tain procedures and terms in the operating instructions.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 5200 Driving Operating Instructions Manual 2084814 – PDF DOWNLOAD
Operating instructions Part 1 Driving............................................................................... 1 Correction sheets – Drives...................................................................................... 3 Important information....................................................................................... 5 Validity................................................................................................ 5 Reason for these correction sheets...................................................................... 5 Information............................................................................................. 5 Correction.................................................................................................. 6 9.1.3 Drive units....................................................................................... 6 Axle lines.......................................................................................... 6 Additional pages - Emergency operation/Emergency program telescoping ........................................... 9 1 Overview...................................................................................................... 13 1.1 Vehicle identification.................................................................................. 15 1.2 EC declaration of conformity............................................................................ 18 1.3 Overview and contents of truck crane user information................................................... 19 1.3.1 Operating Instructions............................................................................ 19 1.3.2 Lattice extension operating manual (additional equipment)......................................... 20 1.3.3 Maintenance manual................................................................................ 20 1.3.4 Lifting capacity table............................................................................ 21 1.3.5 Outrigger load table.............................................................................. 21 1.3.6 Safety manual..................................................................................... 21 1.3.7 Circuit diagrams.................................................................................. 21 1.3.8 Spare parts list.................................................................................. 22 1.4 Instructions for use of this document................................................................... 22 1.4.1 How are the operating instructions laid out?...................................................... 22 1.4.2 How are the pages of the operating manual formatted?.............................................. 23 1.4.3 How can I find the necessary information quickly and easily?...................................... 24 Example of cross- reference usage................................................................... 25 Explanations of how to use the index............................................................... 30 1.4.4 Definition of direction information............................................................... 30 Basic rule.......................................................................................... 30 Buttons and switches............................................................................... 30 1.4.5 Conversion table for US measurements.............................................................. 31 2 Fundamental safety instructions for crane operators.......................................................... 33 2.1 Warnings and symbols.................................................................................... 35 2.2 Proper use.............................................................................................. 36 2.3 Organisational measures................................................................................. 38 2.4 Personnel qualifications................................................................................ 40 2.5 Safety instructions that apply to truck crane driving................................................... 41 2.6 Safety instructions for truck crane work................................................................ 41 3 Information for applications engineering...................................................................... 43 3.1 Safety instructions..................................................................................... 45 3.1.1 Proper use........................................................................................ 45 3.1.2 Organizational measures........................................................................... 45 3.1.3 Personnel qualifications.......................................................................... 47 3.2 Applications engineering................................................................................ 48 3.2.1 Application engineering requirements.............................................................. 48 3.2.2 Details about applications engineering contained in the user information......................... 49 4 Description of the truck crane – vehicle section.............................................................. 51 4.1 Overview of the operating and display instruments....................................................... 53 4.1.1 Overview of the vehicle........................................................................... 53 4.1.2 Overview of driver’s cab.......................................................................... 56 Over the windscreen................................................................................. 58 4.1.3 Front instrument panel............................................................................ 60 4.1.4 Side instrument panel............................................................................. 68 4.2 Functional description of the display and operating instruments........................................ 75 4.2.1 On the instrument panels.......................................................................... 75 Vehicle engine...................................................................................... 75 Automatic gearbox.................................................................................. 76 Axle drive.......................................................................................... 78 Brakes.............................................................................................. 79 Suspension.......................................................................................... 81 Hydraulics.......................................................................................... 82 Steering............................................................................................ 82 Electrical system................................................................................... 83 Level adjustment.................................................................................... 85 Driver’s cab heating system........................................................................ 87 Driver’s cab heating system........................................................................ 87 Auxiliary heater with timer (additional equipment).................................................. 89 Air-conditioning system (additional equipment)...................................................... 90 Cab lighting........................................................................................ 92 Other operating instruments........................................................................ 92 4.2.2 Other operating instruments in the vehicle section................................................ 94 Keys, doors, windows................................................................................ 94 Access ladders...................................................................................... 95 Ladders............................................................................................. 96 Vehicle engine diagnostic plug...................................................................... 97 Fire extinguisher (additional equipment)........................................................... 98 Folding bunk (additional equipment)................................................................. 98 5 Vehicle engine................................................................................................ 99 5.1 Starting/turning off vehicle engine.....................................................................101 5.1.1 CHECKLIST: Starting vehicle engine................................................................101 5.1.2 CHECKLIST: In winter..............................................................................104 5.1.3 Checks before starting up vehicle engine..........................................................105 Checking the hydraulic system stop cocks...........................................................105 Switching on the battery master switch..............................................................105 Pre-checking the oil level in the automatic transmission............................................106 Checking the coolant level.........................................................................107 Checking hydraulic oil level........................................................................108 Checking the engine oil level......................................................................108 Topping up engine oil...............................................................................109 5.1.4 Refuelling........................................................................................110 5.1.5 Starting vehicle engine...........................................................................111 Activating the ignition............................................................................111 Starting the vehicle engine........................................................................113 5.1.6 Inspections after the engine has been started.....................................................115 Checking instruments...............................................................................115 Checking oil level in the automatic gearbox.........................................................116 5.1.7 Turning off the vehicle engine....................................................................121 5.1.8 Emergency stop via the air intake inhibitor (additional equipment)................................122 Switching on the air intake inhibitor...............................................................122 Releasing the air intake inhibitor manually.........................................................123 6 Driving the truck crane.......................................................................................125 6.1 Checking the truck crane before driving.................................................................127 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving.......................................127 6.1.2 On-road driving mode table........................................................................131 Axle loads in driving mode..........................................................................132 6.1.3 Checking the condition of the truck crane.........................................................133 Checking the reservoir of the windscreen washing system...........................................133 Warning plates for vehicle width....................................................................133 Checking the tyres.................................................................................134 Checking the electrical system......................................................................134 Adjusting the mirrors..............................................................................135 Check the compressed air and brake systems..........................................................135 Checking suspension.................................................................................136 Check the on-the- road level........................................................................136 Checking the transverse differential locks..........................................................137 Check the drive of the second axle line/longitudinal differential locks.............................137 Checking the steering locks........................................................................137 Checking the Boom not set down warning lamp.........................................................138 6.1.4 Adjusting the seat and the steering column........................................................139 Adjusting the driver’s seat.......................................................................139 Adjusting the steering column......................................................................139 6.1.5 Trip recorder.....................................................................................140 Inserting the 24hour disc in the trip recorder.....................................................140 6.2 General operation.......................................................................................143 6.2.1 Operating the automatic transmission..............................................................143 Switching on........................................................................................143 Automatic transmission driving modes...............................................................144 Selecting the driving direction....................................................................145 Starting............................................................................................146 Driving and changing gears..........................................................................146 Switching transmission to neutral position..........................................................147 Changing the direction of travel....................................................................148 Stopping the truck crane............................................................................149 Cold start program.................................................................................149 On the roller type dynamometer......................................................................149 6.2.2 Monitoring the control instruments while driving..................................................150 6.2.3 Driving on downhill slopes........................................................................155 Retarder............................................................................................155 Preselecting gears..................................................................................156 Eddy current retarder (additional equipment)........................................................157 6.2.4 Driving on uphill slopes..........................................................................158 6.2.5 Cruise control....................................................................................159 Activating the cruise control.......................................................................159 Driving with cruise control........................................................................159 Deactivating the cruise control.....................................................................160 6.2.6 Temposet..........................................................................................161 Switching Temposet on...............................................................................161 Switching Temposet off..............................................................................161 6.2.7 Turning off the truck crane.......................................................................162 Locking the parking brake..........................................................................162 Automatic gearbox in neutral position............................................................162 Turning off the vehicle engine.....................................................................162 Securing the truck crane from rolling...............................................................162 Switch off the battery master switch if the truck crane is idle for a longer period of time........163 Securing the truck crane against unauthorised use..................................................163 6.3 Off-the-road driving....................................................................................165 6.3.1 Drive of the 1st axle line / longitudinal differential locks......................................166 Switching on drive / longitudinal differential locks................................................166 Switching off drive/longitudinal differential locks.................................................167 6.3.2 Transverse differential locks in all driven axle lines............................................168 Activating transverse differential locks............................................................168 Deactivating transverse differential locks.........................................................169 6.3.3 Level adjustment system...........................................................................170 Activating the level adjustment system.............................................................170 Raising or lowering the entire truck crane.........................................................171 Tilting the truck crane lengthwise or crosswise.....................................................172 Moving the truck crane into position On-the-road level.............................................173 Deactivating the level adjustment system............................................................173 6.3.4 Freeing an immobilised truck crane................................................................174 Freeing the truck crane by its own power..........................................................174 Towing free to the front...........................................................................175 Towing in reverse..................................................................................175 6.4 Separate steering.......................................................................................177 6.4.1 Switching on separate steering....................................................................178 6.4.2 Steering axle lines with separate steering........................................................179 All-wheel steering..................................................................................179 Crab travel mode....................................................................................179 6.4.3 Switching off separate steering and locking steering..............................................180 Locking the steering................................................................................180 6.5 Heating and ventilation.................................................................................183 6.5.1 Driver’s cab heating system.......................................................................183 Ventilating the driver’s cab........................................................................185 6.5.2 Additional water heating system (additional equipment)............................................186 Preheating the vehicle engine......................................................................186 Preheating the driver’s cab........................................................................186 Switching on the additional heating system.........................................................186 Deactivating the additional heating system.........................................................187 6.5.3 Additional heating system with timer (additional equipment).......................................188 Preheating the vehicle engine......................................................................188 Preheating the driver’s cab........................................................................188 Switching the auxiliary heater on/off...............................................................188 Displaying and setting the current time.............................................................189 Switching on and saving automatic heating start.....................................................189 Switching off automatic heating start...............................................................190 6.5.4 Roof blower (additional equipment)................................................................191 6.6 Air-conditioning system (additional equipment)..........................................................193 6.6.1 Switching on......................................................................................193 6.6.2 Switching off.....................................................................................193 6.6.3 Air conditioning..................................................................................194 How to ensure pleasant air- conditioning............................................................194 Dehumidifying the air in the driver’s cab..........................................................195 6.7 Towing a trailer (additional equipment).................................................................197 Effects on the axleloads...............................................................................197 Coupling the trailer...................................................................................198 Connecting supply cables................................................................................199 Removing the supply lines...............................................................................200 Uncoupling the trailer..................................................................................200 Test position of the parking brake when towing a trailer................................................202 7 Rigging for on-road driving...................................................................................203 7.1 Rigging work for driving with a trailer.................................................................207 7.1.1 Switch on slewing gear freewheel..................................................................208 7.1.2 Switching on boom floating position...............................................................210 Setting the main boom down on the trailer...........................................................210 7.1.3 Switching on boom pretensioning...................................................................212 7.2 Rigging the outrigger beams (additional equipment)......................................................215 Equipment...............................................................................................215 7.2.1 CHECKLIST: Removal of support beams...............................................................216 7.2.2 CHECKLIST: Installation of outrigger beams........................................................218 7.2.3 Preparing the truck crane for removal/installation................................................220 Prerequisites for installation/removal..............................................................220 Preparing the truck crane..........................................................................220 7.2.4 Removing/inserting outrigger pads.................................................................221 Removing outrigger pads............................................................................221 Attaching the outrigger pads.......................................................................222 7.2.5 Disconnecting/establishing hydraulic connection...................................................223 Disconnecting the hydraulic connection............................................................223 Establishing the hydraulic connection...............................................................224 7.2.6 Establishing/disconnecting the electrical connection for the outrigger pressure indicator.........225 7.2.7 Screwing in/unscrewing and setting spacers........................................................226 Screwing in spacers................................................................................226 Unscrewing and setting spacers......................................................................226 7.2.8 Transport position/operating position of the holding angle........................................227 7.2.9 Locking/releasing the sliding cylinder locking pin................................................228 Releasing the locking pin...........................................................................228 Locking the sliding cylinder........................................................................229 7.2.10 Extending/reinserting outrigger beams............................................................229 Extending the outrigger beams.......................................................................229 Reinserting the outrigger beams....................................................................232 7.2.11 Transporting the outrigger beams/outrigger pads..................................................234 7.3 Rigging the main boom...................................................................................235 Additional equipment required...........................................................................235 7.3.1 CHECKLIST: Removing the main boom.................................................................237 Prerequisites.......................................................................................237 Main boom removing..................................................................................237 7.3.2 CHECKLIST: Mounting the main boom.................................................................240 Prerequisites.......................................................................................240 Installing the mainboom............................................................................240 7.3.3 Supporting the truck crane while installing/removing the mainboom................................244 7.3.4 Rigging work with the auxiliary crane.............................................................245 Lifting the main boom from the turntable............................................................245 Lifting the main boom onto the turntable............................................................246 7.3.5 Establishing/disconnecting the hydraulic connection to the lattice extension (additional eq.......247 Breaking the hydraulic connection...................................................................247 Establishing the hydraulic connection...............................................................248 7.3.6 Pulling device on the bottom axle of the boom (additional equipment)..............................249 Bottom axle pin- type keepers.......................................................................249 Hydraulic connection................................................................................250 Retracting/extending pins...........................................................................251 7.3.7 Locking pin at derricking cylinder head eyelet....................................................252 Operating the lifting equipment....................................................................252 Retracting/ extending pins.........................................................................254 7.3.8 Hydraulic connections on the main boom............................................................255 Removing/attaching the guide plates.................................................................256 Establishing hydraulic connection...................................................................256 Breaking the hydraulic connection...................................................................257 7.3.9 Electrical connections on the main boom...........................................................258 7.3.10 Checks following main jib mounting...............................................................259 Hydraulic system check.............................................................................259 Checking the electrical system.....................................................................260 7.3.11 Before road driving..............................................................................262 Securing the derricking cylinder for on-road driving................................................262 Transporting the main boom..........................................................................262 7.3.12 Derricking cylinder pressure relief..............................................................263 Activating pressure relief..........................................................................263 Deactivating pressure relief.......................................................................264 7.4 Installing/removing the auxiliary hoist (additional equipment)..........................................265 7.4.1 Slinging points and transport.....................................................................265 Slinging points.....................................................................................265 Transport...........................................................................................266 7.4.2 Mounting the auxiliary hoist......................................................................267 Removing pin- type keeper and pins..................................................................267 Attach the auxiliary hoist to the main hoist........................................................267 Locking the auxiliary hoist.........................................................................268 Establishing hydraulic and electrical connections...................................................268 7.4.3 Removing the auxiliary hoist......................................................................269 7.4.4 Permitted applications for the auxiliary hoist....................................................270 Replacement for the main hoist......................................................................270 Alternating operation with the main and auxiliary hoists............................................271 8 Malfunctions on the carrier...................................................................................273 8.1 Emergency stop device on carrier........................................................................275 Turning off the vehicle engine.........................................................................275 8.2 Breakdown in road traffic...............................................................................277 8.3 Towing the truck crane..................................................................................279 8.3.1 Towing in the case of engine or transmission damage...............................................279 Towing the truck crane out of the danger area.......................................................280 Longer distances....................................................................................280 Compressed-air supply in the event of engine failure................................................282 Power supply........................................................................................282 Gearbox.............................................................................................283 Vehicle engine......................................................................................283 Parking brake.......................................................................................283 Mechanically releasing the parking brake..........................................................284 Towing procedure....................................................................................284 Removing the mechanical locking from all spring- loaded brake cylinders...........................285 Tow starting........................................................................................285 8.4 Wheels..................................................................................................287 8.4.1 Wheel change......................................................................................287 Removing a damaged tyre............................................................................287 Removing the wheel from the spare wheel holder.....................................................288 Mounting a damaged wheel on the spare wheel holder.................................................289 Mounting the spare wheel...........................................................................290 8.4.2 Filling the tyres yourself........................................................................291 Connecting the filling hose.........................................................................291 Filling the tyres...................................................................................292 Removing the tyre inflator hose.....................................................................292 8.5 Electrical system.......................................................................................293 8.5.1 Inserts...........................................................................................294 Front plug-in module................................................................................294 8.5.2 Fuses.............................................................................................296 Group F1 to F6....................................................................................296 Groups F7 to F9...................................................................................300 8.6 Troubleshooting and malfunction correction..............................................................301 8.6.1 Vehicle engine malfunctions.......................................................................301 8.6.2 Automatic gearbox malfunctions....................................................................303 8.6.3 Differential lock malfunctions....................................................................304 8.6.4 Service brake malfunctions........................................................................305 8.6.5 Steering system malfunctions......................................................................306 8.6.6 Outrigger malfunctions............................................................................306 8.6.7 Suspension locking system malfunctions............................................................307 8.6.8 Level adjustment system malfunctions..............................................................307 8.7 Procedure in the event of malfunctions..................................................................309 8.7.1 Switching the fan thermostat to emergency operation...............................................309 8.7.2 Troubleshooting for malfunctions in the automatic transmission....................................310 Troubleshooting.....................................................................................310 Effect of error.....................................................................................310 Reading error codes...............................................................................311 Error messages while checking oil level.............................................................313 8.7.3 Emergency operation of the solenoid valves for the outriggers.....................................315 9 Technical specifications carrier..............................................................................319 9.1 Technical description of the carrier....................................................................321 9.1.1 Crane carrier.....................................................................................321 9.1.2 Driver’s cab......................................................................................321 9.1.3 Drive units.......................................................................................322 9.1.4 Engine and gearbox cooling system................................................................322 9.1.5 Hydraulic system..................................................................................322 9.1.6 Steering..........................................................................................323 9.1.7 Suspension system................................................................................323 9.1.8 Outrigger.........................................................................................324 9.1.9 Compressed air system.............................................................................324 9.1.10 Service brake....................................................................................325 9.1.11 Parking brake....................................................................................325 9.1.12 Retarder.........................................................................................325 9.1.13 Secondary consumers.............................................................................326 9.1.14 Towing the crane.................................................................................326 9.1.15 Towing a trailer.................................................................................326 9.1.16 Electrical system................................................................................326 9.1.17 Slewing duct.....................................................................................326 9.2 Technical specifications................................................................................327 9.2.1 Measurements and weights of the truck crane.......................................................328 Dimensions for driving on public roads.............................................................329 9.2.2 Dimensions and weights of removable parts.........................................................330 Spare wheel (additional equipment)..................................................................330 Main boom...........................................................................................330 Outriggers..........................................................................................330 9.2.3 Carrier technical data............................................................................331 Vehicle engine......................................................................................331 On-load shift gearbox..............................................................................331 Transfer case.......................................................................................331 Axle lines..........................................................................................331 Steering............................................................................................331 Tyres...............................................................................................332 Vehicle's electrical system.........................................................................332 Tools...............................................................................................332 Outriggers..........................................................................................333 Driving speeds......................................................................................334 Climbing ability....................................................................................334 Turning circle radiuses............................................................................335 10 Index........................................................................................................337 A...........................................................................................................341 B...........................................................................................................342 C...........................................................................................................342 D...........................................................................................................344 E...........................................................................................................345 F...........................................................................................................346 H...........................................................................................................346 I...........................................................................................................347 K...........................................................................................................347 L...........................................................................................................347 M...........................................................................................................347 O...........................................................................................................348 P...........................................................................................................349 R...........................................................................................................349 S...........................................................................................................350 T...........................................................................................................351 U...........................................................................................................353 V...........................................................................................................353 W...........................................................................................................353 Operating instructions Part 2 Crane operation.......................................................................357 11 Description of the truck crane – crane section...............................................................363 11.1 Overview of the operating and display instruments......................................................365 11.1.1 Overview of crane section........................................................................365 11.1.2 Crane cab overview...............................................................................368 11.1.3 Instrument panel.................................................................................370 Front instrument panel..............................................................................370 Fittings behind the crane driver seat...............................................................383 11.1.4 Left control console.............................................................................384 11.1.5 Right control console............................................................................385 11.1.6 Control lever configuration......................................................................386 Version 1 (standard)................................................................................386 Version 2 (additional equipment)....................................................................387 11.1.7 Control box for operating the outriggers.........................................................388 11.1.8 Counterweight hoisting gear switch unit..........................................................389 11.1.9 Switch box for electronic level..................................................................390 11.2 Functional description of the display and operating instruments.......................................391 11.2.1 Crane work.......................................................................................391 Crane engine........................................................................................391 Outrigger operation................................................................................392 Counterweight lifting gear and lock................................................................394 Crane control.......................................................................................396 Main hoist..........................................................................................398 Auxiliary hoist (additional equipment).............................................................399 Slewing gear........................................................................................400 Derricking gear.....................................................................................401 Telescoping gear....................................................................................402 Safe load indicator................................................................................407 Hydraulics..........................................................................................414 Electronics.........................................................................................414 Other operating instruments.........................................................................415 Electronic level in crane cab.......................................................................417 Toggle switch to change measuring range............................................................417 Crane cab heating system...........................................................................417 Auxiliary heater with time switch (additional equipment)............................................418 Air-conditioning system (additional equipment)......................................................420 Houselock (additional equipment)....................................................................421 Anemometer..........................................................................................421 Outrigger pressure display (additional equipment)...................................................422 11.2.2 Other operating instruments on the crane cab.....................................................423 Doors, keys, windows................................................................................423 Fire extinguisher (additional equipment)............................................................424 Crane engine diagnostics plug......................................................................425 11.3 Functional description of the safety devices...........................................................427 11.3.1 Safe load indicator (SLI)........................................................................427 11.3.2 Lowering limit switch............................................................................428 11.3.3 Lifting limit switch............................................................................429 Overriding the lifting limit switch shutdown.......................................................429 11.3.4 Dead man's switch and seat contact switch........................................................430 12 Crane engine.................................................................................................431 12.1 Starting/turning off the crane engine..................................................................433 12.1.1 CHECKLIST: Starting the crane engine.............................................................433 12.1.2 CHECKLIST: In winter.............................................................................435 12.1.3 Inspections before starting the crane engine.....................................................436 Checking the stop cock on the hydraulic system.....................................................436 Switching on the battery master switch.............................................................436 Checking coolant level..............................................................................437 Checking the hydraulic oil level....................................................................438 Checking the oil level in the crane engine........................................................438 Topping up engineoil..............................................................................439 Refuelling..........................................................................................440 12.1.4 Starting the crane engine........................................................................441 Switching on the ignition..........................................................................441 Starting the crane engine..........................................................................442 12.1.5 Inspections after starting the crane engine......................................................444 Checking instruments...............................................................................444 12.2 Switching off the crane engine.........................................................................447 12.2.1 Emergency stop via the air intake inhibitor (additional equipment)...............................448 Switching on the air intake inhibitor...............................................................448 Manually releasing the air intake lock..............................................................449 13 Crane operation..............................................................................................451 13.1 Checking the truck crane before working with thecrane...............................................453 13.1.1 CHECKLIST: When truck crane is rigged............................................................453 13.1.2 Adjusting the crane operator's seat..............................................................457 13.1.3 Checking the condition of the truck crane........................................................458 Checking the reservoir of the windscreen washing system.............................................458 Visual inspection of the entire crane...............................................................458 Checking the position of the hoist ropes............................................................459 Electrical system...................................................................................459 13.1.4 Checking the safety devices......................................................................460 Safe load indicator.................................................................................460 Lifting limit switch................................................................................460 Dead man's switch system............................................................................461 Emergency stop switch for the crane control.........................................................461 13.1.5 Preheating the hydraulic oil.....................................................................462 With an oil temperature of between –15 C and 0 C (5 F and 32 F):................................462 With an oil temperature below –15 C (5 F):........................................................462 13.1.6 Superstructure lock..............................................................................463 Removing the lock..................................................................................464 Engaging the lock..................................................................................464 13.1.7 Houselock (additional equipment).................................................................465 Switching on the houselock..........................................................................465 Switching off the houselock.........................................................................466 13.1.8 Adjusting the mirrors............................................................................467 13.2 Operating the safe load indicator (SLI)................................................................469 13.2.1 Switching on the SLI.............................................................................469 Switching on........................................................................................469 Lamp test on the SLI................................................................................471 Dimmers for the SLI status displays................................................................471 13.2.2 Setting rigging mode.............................................................................472 Setting using the SLI code..........................................................................472 Setting using individual components................................................................472 General instructions...............................................................................473 Sequence during setting.............................................................................473 Switching on entry mode............................................................................474 Entering values.....................................................................................475 Confirming entry....................................................................................477 Transferring values.................................................................................477 Switching over hoist position lights...............................................................478 13.2.3 Checks before working with the crane.............................................................479 13.2.4 During crane work................................................................................481 Continuous displays................................................................................481 Optional status displays...........................................................................482 SLI early warning...................................................................................483 SLI shutdown........................................................................................483 Error messages......................................................................................484 Error messages with additional optical displays.....................................................485 SLI override........................................................................................486 13.3 Crane work with the main boom..........................................................................487 13.3.1 External influences during crane operation.......................................................487 Horizontal alignment...............................................................................487 Safe distances......................................................................................487 Effect of wind on crane operations..................................................................488 Anemometer..........................................................................................488 Permissible wind load...............................................................................489 Earthing the load...................................................................................490 13.3.2 Slewing ranges permitted for working with the crane..............................................491 360 slewing range..................................................................................491 Working position 0 to the rear.....................................................................491 13.3.3 Hoists...........................................................................................492 Main hoist..........................................................................................492 Auxiliary hoist (additional equipment)..............................................................495 13.3.4 Derricking gear..................................................................................497 13.3.5 Slewing gear.....................................................................................499 Slewing gear permanent brake........................................................................499 Slewing.............................................................................................499 Slewing speed.......................................................................................500 Tracking the slewing gear..........................................................................500 Maximum permitted slewing speed....................................................................501 13.3.6 Telescoping gear.................................................................................503 Structure of the chapter............................................................................503 Description of functioning..........................................................................504 Main boom fixed length, intermediate length, telescoping length.....................................505 Telescope status....................................................................................506 Notes on telescope sequence.........................................................................509 Check before telescoping for the first time.........................................................509 Function of the control lever.......................................................................510 Example of procedures when telescoping..............................................................512 Check initial position.............................................................................513 Unlocking telescoping cylinder......................................................................516 Extending/ retracting telescoping cylinder and locking.............................................518 Unlock telescope section............................................................................521 Telescoping telescope section to fixed length and lock..............................................523 Telescoping telescope section to intermediate length................................................527 Locking telescope section...........................................................................528 Telescoping with fully automatic control............................................................529 Example of telescoping with teleautomatic...........................................................531 Lowering the main boom for maintenance..............................................................533 Telescoping the main boom in the horizontal position...............................................533 13.3.7 Fast speed.......................................................................................534 13.3.8 Menus on the crane control display...............................................................535 Menu Display states.................................................................................535 Menu Display telescoping status and teleautomatic..................................................539 Menu Power unit speeds/Critical load control........................................................539 Access emergency operation menu.....................................................................543 Display of an error message.........................................................................544 13.3.9 Setting a constant engine speed..................................................................546 13.3.10 Critical load control...........................................................................547 13.3.11 Incline crane cab...............................................................................548 13.3.12 Cooling the hydraulic oil.......................................................................549 Standard oil cooler.................................................................................549 Additional oil cooler...............................................................................549 13.3.13 Movements which can be carried out simultaneously...............................................550 13.4 Driving with a rigged crane............................................................................551 13.4.1 Driving route....................................................................................551 13.4.2 Rigging mode and axle loads......................................................................552 Boom positions......................................................................................552 13.4.3 Driving the rigged truck crane...................................................................554 Locking the superstructure and engaging the slewing gear permanent brake..........................554 Retracting the outriggers..........................................................................554 Switching over the suspension locking system........................................................554 Switching on separate steering......................................................................555 Driving.............................................................................................556 Extending the outriggers............................................................................556 13.5 Work break.............................................................................................557 13.5.1 Short work break.................................................................................557 13.5.2 Work breaks lasting more than 8 hours............................................................557 13.6 Crane cab heating and ventilation......................................................................559 13.6.1 Heating the crane cab............................................................................559 Additional water heating system (additional equipment).............................................560 Switching on the additional heating system.........................................................560 Switching off the additional heating system........................................................561 13.6.2 Auxiliary heater with timer (additional equipment)...............................................561 Preheating crane engine............................................................................561 Preheating cranecab...............................................................................562 Switching the auxiliary heater on/off...............................................................562 Displaying and setting the current time.............................................................562 Switching on and saving the automatic heating start.................................................563 Switching off the automatic heating start...........................................................564 13.6.3 Ventilating the crane cab........................................................................564 13.7 Air-conditioning system (additional equipment).........................................................565 13.7.1 Switching on.....................................................................................565 13.7.2 Switching off....................................................................................566 13.7.3 Air conditioning.................................................................................566 How to ensure pleasant air- conditioning............................................................566 Dehumidifying crane cab air.........................................................................567 14 Rigging work.................................................................................................569 14.1 Check lists for rigging work for crane operation with main boom........................................573 14.1.1 CHECKLIST: Rigging...............................................................................573 14.1.2 CHECKLIST: Unrigging.............................................................................577 14.2 Choosing a suitable site...............................................................................579 14.2.1 Load bearing capacity of the ground and the outrigger............................................579 Enlarging the surface area of the outrigger........................................................581 14.2.2 Safe distance from banks and pits................................................................582 14.2.3 Earthing the truck crane.........................................................................583 Earthing the truck crane............................................................................583 14.2.4 Safe distance from electrical lines..............................................................584 14.3 Rigging work after driving with trailer................................................................587 14.3.1 Switching off slewing gear freewheel (additional equipment)......................................588 Before slewing......................................................................................589 14.3.2 Switching off the boom floating position (additional equipment)..................................590 14.3.3 Switching off boom pre-tensioning (additional equipment).........................................591 14.4 Outrigger..............................................................................................593 14.4.1 CHECKLIST: Extending the outriggers..............................................................593 14.4.2 CHECKLIST: Retracting outrigger..................................................................595 14.4.3 Outrigger span...................................................................................597 Outrigger span 8.50x8.30m (27.9 x 27.2 ft).......................................................597 Outrigger span 8.50x5.70m (27.9 x 18.7 ft).......................................................598 Outrigger span 8.50x2.72m (27.9x8.9 ft)........................................................598 14.4.4 Preparing the truck crane........................................................................599 Aligning the truck crane horizontally..............................................................599 Locking the suspension.............................................................................599 14.4.5 Securing / releasing outrigger beams.............................................................600 Securing the outrigger beams........................................................................600 Releasing the outrigger beams.......................................................................601 14.4.6 Extending/retracting the outrigger beams.........................................................602 Extending the outrigger beams.......................................................................602 Retracting the outrigger beams.....................................................................604 Setting outrigger spans.............................................................................605 14.4.7 Moving the outrigger pads into working/driving position..........................................608 Moving the outrigger pads into working position...................................................608 Moving the outrigger pads into driving position..................................................609 14.4.8 Extending/retracting the outrigger cylinders.....................................................610 Extending the support cylinders.....................................................................610 Retracting the outrigger cylinders.................................................................611 14.4.9 Aligning the truck crane horizontally............................................................613 Reading the status display..........................................................................613 Switching over the measuring range..................................................................614 Aligning the truck crane horizontally...............................................................614 14.4.10 Outrigger pressure display (additional equipment)..............................................615 Reading the status displays.........................................................................615 14.5 Counterweight..........................................................................................617 14.5.1 Counterweight sections and identification........................................................617 Counterweight sections..............................................................................617 Identification......................................................................................617 14.5.2 Counterweight versions...........................................................................618 14.5.3 Slinging points on the counterweight sections....................................................621 14.5.4 CHECKLIST: Rigging the counterweight.............................................................622 Rig counterweight...................................................................................622 14.5.5 CHECKLIST: Unrigging the counterweight...........................................................625 Unrig counterweight.................................................................................625 14.5.6 Placing the counterweight........................................................................627 5.4 t base plate on counterweight platform..........................................................627 Stacking counterweight sections.....................................................................628 14.5.7 Connecting/disconnecting the hydraulic connection................................................629 Establishing hydraulic connection.................................................................629 Disconnecting the hydraulic connection..............................................................630 14.5.8 Assembling the counterweight version.............................................................631 14.5.9 3.5 t counterweight section......................................................................636 Rigging with assemble rods (additional equipment)...................................................636 Locking the 3.5 t counterweight section.............................................................637 14.5.10 Extending/retracting the lifting cylinders of the 5.4 t base plate or lifting/lowering c.......638 Extend the lifting cylinders........................................................................639 Retract hoist cylinder.............................................................................640 14.5.11 Locking the counterweight on the turntable/releasing the locking pin...........................640 Hasp positions......................................................................................641 Safety cock.........................................................................................641 Locking the counterweight..........................................................................642 Unlocking the counterweight.........................................................................642 14.5.12 Rigging 3 t counterweight blocks (additional equipment)........................................643 14.5.13 Slewing with the counterweight rigged...........................................................644 14.6 Rigging work on the main boom..........................................................................645 14.6.1 Hook block on the bumper.........................................................................645 Picking up the hook block...........................................................................645 Attaching the hook block............................................................................646 14.6.2 Hook block on a separate vehicle.................................................................647 Picking up the hook block...........................................................................647 Setting down the hook block and securing the hoist rope for on-road driving........................648 14.6.3 Reeving and unreeving the hoist rope............................................................649 Rope end clamp......................................................................................649 Reeving the hoist rope..............................................................................651 Lifting limit switch on the main boom...............................................................653 14.6.4 Possible reeving methods on the main boom........................................................657 14.6.5 Anemometer.......................................................................................661 Installing the anemometer...........................................................................661 Remove the anemometer..............................................................................662 14.6.6 Rigging heavy duty equipment.....................................................................663 Heavy duty equipment parts..........................................................................663 Equipment required.................................................................................663 Rigging heavy duty equipment........................................................................664 Unrigging heavy duty equipment......................................................................667 Reevings with heavy duty equipment..................................................................669 15 Malfunctions on the superstructure...........................................................................671 15.1 Superstructure emergency stop device...................................................................673 Switching off the crane engine.........................................................................673 Crane control emergency stop switch.....................................................................674 15.2 Troubleshooting for malfunctions that occur during crane operation....................................675 Load cannot be lowered..................................................................................675 15.3 Electrical system......................................................................................677 15.3.1 Plug-in modules and consoles.....................................................................678 15.3.2 Fuses............................................................................................680 Groups F1 to F9...................................................................................680 Groups F10 to F13...................................................................................684 15.3.3 SLI fuses........................................................................................685 Replacing fuses.....................................................................................685 15.4 Troubleshooting and malfunction correction.............................................................687 15.4.1 Crane engine malfunctions........................................................................687 15.4.2 Main hoist malfunctions..........................................................................688 15.4.3 Auxiliary hoist malfunctions.....................................................................690 15.4.4 Derricking gear malfunctions.....................................................................692 15.4.5 Telescoping gear malfunctions....................................................................694 15.4.6 Slewing gear malfunctions........................................................................696 15.4.7 Counterweight lifting gear/lock malfunctions.....................................................697 15.4.8 Hydraulic system/hydraulic oil cooler malfunctions...............................................698 15.4.9 Crane control malfunctions.......................................................................698 15.4.10 Malfunctions on the SLI.........................................................................699 Other malfunctions on the SLI......................................................................699 SLI error message table............................................................................700 Switch off sensor/ indicator during malfunction.....................................................707 Check that the remaining sensor/ indicator is working..............................................708 Accepting the telescope status from the crane control...............................................709 Checking SLI lines and connections.................................................................710 15.4.11 Retraction emergency operation..................................................................712 Check before all emergency operation................................................................712 Procedure for retracting...........................................................................713 Mechanical emergency operation......................................................................714 Hydraulic emergency operation.......................................................................716 15.5 Error messages crane control...........................................................................729 15.5.1 Error messages about control units...............................................................729 15.5.2 Error messages about power units.................................................................730 Determining defective part..........................................................................731 Determining error area..............................................................................732 Error causes and effects............................................................................733 15.5.3 Telescoping error messages.......................................................................735 15.5.4 Changing the connections in the control units....................................................736 Connections and control units.......................................................................736 Unrigging mobile crane with defective control unit..................................................736 Inserting and removing connections..................................................................739 15.5.5 Control lever emergency program..................................................................740 Indications on the display..........................................................................740 Carrying out emergency program.....................................................................741 15.5.6 Emergency operation submenu......................................................................742 Retracting with an error on the length indicator....................................................743 Retracting with an error on the proximity switch....................................................746 Table for approaching the locking points............................................................747 15.5.7 Entering telescope status after emergency operation menu.........................................748 15.6 Hydraulic emergency stop according to ZH1/461 (additional equipment)...................................751 15.6.1 Important instructions for hydraulic emergency operation.........................................751 15.6.2 Functioning and accessories......................................................................753 15.6.3 Connecting the transformer.......................................................................754 15.6.4 Switching emergency operation on/off.............................................................755 15.6.5 Establishing required hydraulic circuits.........................................................756 Making connections on the plug- in field............................................................756 Additional switches for hoisting gear and slewing gear.............................................757 15.6.6 Executing emergency operation....................................................................758 Driving hoisting gear emergency operation...........................................................758 Emergency operation driving derricking gear.........................................................759 Emergency operation driving the slewing gear........................................................759 15.6.7 After the emergency operation....................................................................760 16 Technical information for superstructure.....................................................................761 16.1 Technical description of the superstructure............................................................763 16.1.1 Turntable........................................................................................763 16.1.2 Crane operator’s cab.............................................................................763 16.1.3 Crane engine and hydraulic system................................................................764 16.1.4 Control system...................................................................................764 16.1.5 Main boom........................................................................................765 16.1.6 Telescoping gear.................................................................................765 16.1.7 Hoists...........................................................................................766 16.1.8 Slewing gear units...............................................................................766 16.1.9 Houselock (additional equipment).................................................................766 16.1.10 Derricking cylinder.............................................................................767 16.1.11 Electrical system..............................................................................767 16.1.12 Counterweight...................................................................................767 16.1.13 Safety equipment................................................................................768 16.2 Technical data.........................................................................................769 16.2.1 Maximum lifting capacity.........................................................................769 DIN/ISO/EN..........................................................................................769 ANSI B 30.5 (85%)...................................................................................769 16.2.2 Guaranteed value specifications..................................................................769 16.2.3 Measurements and weights of the truck crane......................................................770 Dimensions for driving on public roads.............................................................771 16.2.4 Dimensions and weights of removable parts........................................................772 Counterweight parts................................................................................772 Hook blocks and hook tackle.........................................................................773 Auxiliary hoist.....................................................................................773 Main boom...........................................................................................774 Heavy dutyequipment................................................................................774 Counterweight versions..............................................................................774 16.2.5 Technical data for superstructure................................................................777 Crane engine........................................................................................777 Crane’s electrical system...........................................................................777 Main hoist..........................................................................................777 Auxiliary hoist (additional equipment)..............................................................778 Slewing gears.......................................................................................778 Derricking gear.....................................................................................778 Main boom...........................................................................................778 Operating speeds and times without a load..........................................................779 17 Index........................................................................................................781 A...........................................................................................................785 B...........................................................................................................786 C...........................................................................................................786 D...........................................................................................................788 E...........................................................................................................789 F...........................................................................................................790 H...........................................................................................................790 I...........................................................................................................791 K...........................................................................................................791 L...........................................................................................................791 M...........................................................................................................791 O...........................................................................................................792 P...........................................................................................................793 R...........................................................................................................793 S...........................................................................................................794 T...........................................................................................................795 U...........................................................................................................797 V...........................................................................................................797 W...........................................................................................................797
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