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Grove Crane GMK 5220 Driving Operating Instructions Manual 3112376 – PDF DOWNLOAD
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Description
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112376 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112376 – PDF DOWNLOAD
Language : English
Pages : 918
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112376 – PDF DOWNLOAD
Documentation supplied:
The precise number of the documents supplied depends on how the truck
crane is rigged. The following documents are included in delivery:
– Operating instructions
Contain information on driving and crane operation.
– Lattice extension operating instructions
Are only supplied when the truck crane is rigged with a lattice extension
or other parts for extending the main boom (e.g. single-sheave boom top
and heavy load lattice extension).
– Operating instructions for additional equipment
These are only supplied when the truck crane is rigged with additional
equipment, which is not described in the operating instructions for driving
and crane operation.
– Documents from other manufacturers
Original documentation for parts which are not manufactured by GROVE
in Germany, such as the engine and central lubrication system, as well as
the tachograph, auxiliary heaters, radio and, when appropriate, other additional
equipment.
– Maintenance manual
Contains information on maintenance work alone, and contains no repair
work instructions.
– Safety manual
Provides information on the safe operation of the truck crane.
– Circuit diagrams
Circuit diagrams for the electrical system, hydraulic system and pneumatic
system are supplied.
– Lifting capacity table
Information on the lifting capacity when the truck crane is in different rigging
modes.
TABLE OF CONTENTS:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112376 – PDF DOWNLOAD
Part 1......................................................................................................... 1 Additional page............................................................................................ 3 Stop at 0°or 180°...................................................................................... 3 Correction sheet........................................................................................... 5 Fuses.................................................................................................. 5 Correction sheet........................................................................................... 7 1 Driving with a trailer (dolly)....................................................................... 7 Switching on boom floating position................................................................ 8 Switching on the slewing gear freewheel............................................................ 10 Switching on boom pre-tensioning................................................................... 12 2 Pressure relief for removing the main boom........................................................... 14 Correction sheet........................................................................................... 15 Fuses.................................................................................................. 15 On the turntable................................................................................... 15 In the driver's cab................................................................................ 16 Additional page Interruption during pressure build-up......................................................399 Additional page Rigging outrigger pads.....................................................................400 Additional page Controls for crane cabin heating........................................................... 19 Correction sheet – Accepting the telescope status.......................................................... 21 1 Overview................................................................................................. 27 1.1 Identification..................................................................................... 27 1.2 EC Declaration of Conformity....................................................................... 31 1.3 Documentation supplied............................................................................. 32 1.4 Information about the operating instructions....................................................... 33 1.4.1 What do the symbols used mean?............................................................... 33 1.4.2 How are the operating instructions structured?............................................... 35 Division....................................................................................... 35 Structure of the chapters...................................................................... 35 Structure of the pages......................................................................... 36 1.4.3 How do I find the information I need?........................................................ 37 Cross-references example....................................................................... 38 1.4.4 What information is available for operations planning?....................................... 40 1.5 Conversion table for US measurements............................................................... 41 2 Basic safety instructions................................................................................ 45 2.1 Intended use....................................................................................... 45 2.1.1 Improper use................................................................................. 46 2.2 Organisational measures............................................................................ 47 2.3 Personnel qualification............................................................................ 49 2.4 Safety instructions for driving the truck crane.................................................... 50 2.5 Safety instructions for crane operation............................................................ 51 3 Operating elements when driving.......................................................................... 55 3.1 Overview of the operating elements................................................................. 55 3.1.1 On the outside of the truck crane............................................................ 56 3.1.2 In the driver's cab.......................................................................... 58 Top view of driver's cab...................................................................... 58 Below in the driver's cab..................................................................... 60 Above in the driver's cab..................................................................... 61 Behind the cover.............................................................................. 62 3.1.3 Front instrument panel....................................................................... 63 Left........................................................................................... 63 Tachograph version 1.......................................................................... 64 Middle......................................................................................... 65 Right.......................................................................................... 67 3.1.4 ECOS control unit............................................................................ 68 3.1.5 ECOS display – main menu..................................................................... 70 3.1.6 ECOS display – submenus...................................................................... 72 Level adjustment system submenu............................................................... 72 Settings submenu............................................................................... 74 Submenu Monitoring............................................................................. 75 Operating hours submenu....................................................................... 76 Warning submenu................................................................................ 76 Error submenu.................................................................................. 77 3.1.7 Side instrument panel........................................................................ 78 Standard heating............................................................................... 79 Auxiliary water heater....................................................................... 80 Auxiliary air heater........................................................................ 81 3.1.8 Transmission................................................................................. 82 3.1.9 Steering column.............................................................................. 83 3.1.10 Sockets for hand-held control............................................................... 84 3.1.11 Outrigger control units..................................................................... 85 3.2 Short description of the operating elements........................................................ 87 3.2.1 Definition of positional references.......................................................... 87 Basic rule..................................................................................... 87 Switches and buttons.......................................................................... 88 3.2.2 General information on the operating elements................................................ 88 3.2.3 General rules for buttons and symbols on the display......................................... 89 3.2.4 Engine....................................................................................... 90 Steering column................................................................................ 90 Multipurpose switch............................................................................ 90 Instrument panels.............................................................................. 91 3.2.5 Electrical system/electronics................................................................ 92 Electrical system.............................................................................. 92 3.2.6 ECOS crane control........................................................................... 93 Control unit................................................................................... 93 Instrument panel............................................................................... 96 3.2.7 Transmission................................................................................. 97 ECOS display................................................................................... 97 Side instrument panel.......................................................................... 98 3.2.8 Transfer case................................................................................101 3.2.9 Final drive..................................................................................102 3.2.10 Brakes......................................................................................104 Service brake..................................................................................104 Parking brake..................................................................................105 Additional brakes..............................................................................106 3.2.11 Normal steering mode/separate steering......................................................107 Instrument panels..............................................................................107 ECOS display...................................................................................108 Driver's door..................................................................................109 3.2.12 Suspension..................................................................................110 3.2.13 Lighting/windscreen wipers/horn.............................................................111 Steering column................................................................................111 Instrument panels..............................................................................111 Overhead in the driver's cab...................................................................113 3.2.14 Level adjustment system.....................................................................114 3.2.15 Tachograph/Speedometer......................................................................116 Tachograph.....................................................................................116 Speedometer...................................................................................116 3.2.16 Roof ventilator.............................................................................117 3.2.17 Diagnostics.................................................................................118 Connections/buttons............................................................................118 Display/submenu................................................................................118 3.2.18 Windows, doors, keys........................................................................119 Windows........................................................................................119 Doors..........................................................................................120 Keys...........................................................................................121 3.2.19 Front flap..................................................................................121 4 Starting/turning off the engine for driving..............................................................125 4.1 Starting the engine from the driver's cab..........................................................125 4.1.1 CHECKLIST: Starting the engine...............................................................125 4.1.2 CHECKLIST: In low temperatures...............................................................128 4.1.3 Access ladders and ladders...................................................................128 Access ladders.................................................................................128 Ladders........................................................................................129 4.1.4 Refuelling...................................................................................131 4.1.5 Checks before starting the engine............................................................132 On the hydraulic tank..........................................................................132 Battery master switch..........................................................................133 Checking the hand-held control.................................................................133 4.1.6 Ignition, switching on.......................................................................133 4.1.7 Lamp test/equalisation of the switching states...............................................134 Lamp test......................................................................................134 Equalisation of the switching states...........................................................135 4.1.8 Adjusting the brightness of the display......................................................137 4.1.9 Starting the engine..........................................................................138 Without flame start system.....................................................................139 With flame start system.......................................................................140 4.1.10 Checks after starting the engine............................................................141 Checks in the main menu........................................................................141 Checks on the instrument panels................................................................142 4.1.11 Monitoring submenu..........................................................................143 4.1.12 Setting the idling speed....................................................................144 4.2 Turning off the engine.............................................................................145 4.2.1 Usually with the ignition lock/with the hand-held control....................................145 Hand-held control not connected................................................................145 Hand-held control connected....................................................................145 After parking.................................................................................145 4.2.2 With emergency stop switches in emergencies..................................................146 Resetting the emergency stop switch............................................................146 4.3 Air intake inhibitor...............................................................................147 Removing the air intake inhibitor..................................................................147 5 Driving..................................................................................................151 5.1 Before driving.....................................................................................151 5.1.1 CHECKLIST: Checks before on-road driving.....................................................151 5.1.2 Checking the condition of the truck crane....................................................157 Windscreen washing system......................................................................157 Warning signs for vehicle width................................................................157 Electrical system..............................................................................158 Mirror setting.................................................................................158 Checking the vehicle height....................................................................159 Checking the compressed air and brake systems.................................................160 5.1.3 Adjusting the seats and steering column......................................................162 Adjusting the driver's seat..................................................................162 Adjusting the passenger seat.................................................................163 Adjusting the steering column.................................................................164 5.1.4 Switching the suspension on/off..............................................................165 Opening the submenu...........................................................................165 Switching on the suspension...................................................................166 Switching off the suspension..................................................................166 5.1.5 Setting the tachograph – version 1...........................................................167 Prerequisites..................................................................................167 Display of error messages.....................................................................167 Adjusting the tachograph......................................................................168 5.1.6 Displaying the operating hours...............................................................172 5.2 Operating the transmission.........................................................................173 5.2.1 Switching on.................................................................................173 5.2.2 Switching the transmission to neutral position...............................................174 While driving..................................................................................174 5.2.3 Changing the driving mode....................................................................175 5.2.4 Selecting the driving direction..............................................................176 5.2.5 Selecting highest gear/starting gear.........................................................177 5.2.6 Starting.....................................................................................177 5.2.7 Driving and changing gears...................................................................178 5.2.8 Changing the driving direction...............................................................179 5.2.9 Stopping.....................................................................................180 Stopping for a long period of time............................................................180 5.2.10 On the roller type dynamometer..............................................................180 5.2.11 Oil level gauge.............................................................................181 5.3 Driving and turning off the truck crane............................................................183 5.3.1 Checks while driving.........................................................................183 Directly after you start to move...............................................................183 While driving..................................................................................184 5.3.2 Tempomat.....................................................................................187 Activating the Tempomat.......................................................................187 Driving with the Tempomat.....................................................................187 Switching off the Tempomat....................................................................188 5.3.3 Temposet.....................................................................................189 Switching on the Temposet.....................................................................189 Driving with the Temposet.....................................................................189 Switching the Temposet off....................................................................189 5.3.4 Driving downhill.............................................................................190 Starting.......................................................................................190 Checks when driving downhill..................................................................190 Shifting down from the highest gear............................................................191 Sustained action brake.........................................................................192 Retarder.......................................................................................193 5.3.5 Driving uphill...............................................................................194 Starting.......................................................................................194 Driving........................................................................................194 5.3.6 Warning submenu..............................................................................195 Opening the submenu...........................................................................195 Meaning of the symbols.........................................................................196 Exiting the submenu...........................................................................199 5.3.7 Error submenu................................................................................199 5.3.8 Parking the truck crane......................................................................200 Securing the truck crane against rolling away..................................................201 When standing still for more than 8 hours......................................................202 5.3.9 Folding berth................................................................................203 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 – off-road gear on/off.........................................................206 Prerequisites..................................................................................206 Switching on...................................................................................206 Switching off..................................................................................207 Neutral position...............................................................................207 5.4.2 Operation of the longitudinal differential locks.............................................208 Switching on...................................................................................208 Switching off..................................................................................209 5.4.3 Operation of the transverse differential locks...............................................210 Switching on...................................................................................210 Switching off..................................................................................211 5.4.4 Operation of the level adjustment system.....................................................212 Opening the submenu...........................................................................212 Setting the on- road level....................................................................213 Pre-selecting suspension struts..............................................................213 Changing the vehicle level.....................................................................214 Viewing the current inclination................................................................214 Exiting the submenu...........................................................................215 5.4.5 Freeing the immobilised truck crane..........................................................216 Rocking the truck crane free..................................................................216 Towing free to the front......................................................................217 Towing free backwards.........................................................................217 5.5 Separate steering..................................................................................219 5.5.1 Switching on separate steering...............................................................220 5.5.2 Steering with separate steering..............................................................220 Manually.......................................................................................220 Automatically..................................................................................221 5.5.3 Switching off separate steering..............................................................222 5.6 Heating and ventilating the driver's cab...........................................................223 5.6.1 Standard heating.............................................................................223 Switching the heating on and off...............................................................223 Setting the temperature.......................................................................223 Setting recirculated/fresh air.................................................................224 Setting the air distribution.................................................................224 Ventilating the driver's cab...................................................................225 5.6.2 Auxiliary water heating system...............................................................226 Preheating the engine.........................................................................226 Preheating the driver's cab...................................................................226 Switching on the auxiliary heater..............................................................227 Switching off the auxiliary heater.............................................................228 Setting the time and weekday...................................................................228 Saving the automatic heating start............................................................229 Setting the heating period....................................................................230 Switching the automatic heating start on and off...............................................230 Setting the remaining time....................................................................231 5.6.3 Auxiliary air heater with timer..............................................................232 Switching on the auxiliary heater..............................................................232 Setting the temperature........................................................................233 Switching off the auxiliary heater............................................................233 Further functions..............................................................................233 5.6.4 Air-conditioning system......................................................................234 Switching on...................................................................................234 Setting the air distribution.................................................................234 Switching off..................................................................................235 Information on how to get the maximum benefit from the air conditioning .....................235 Dry air in the driver's cab...................................................................236 5.7 Towing a trailer...................................................................................237 Effects on the axle loads..........................................................................237 Coupling the trailer..............................................................................238 Connecting the supply lines.......................................................................239 Removing supply lines............................................................................240 Uncoupling the trailer............................................................................240 Checking the braking force........................................................................242 6 Driving modes and rigging for on-road driving............................................................245 6.1 Driving modes......................................................................................245 Information on the axle loads......................................................................245 6.1.1 Information on how to use the tables.........................................................246 6.1.2 Tables for maximum axle load 12t (26500lbs)...............................................247 For 14.00 R25 tyres............................................................................247 For 16.00 R25/ 20.5R25 tyres..................................................................248 6.2 Rigging work for driving with a trailer............................................................249 6.2.1 Switching on the slewing gear freewheel......................................................249 Prerequisites..................................................................................249 6.2.2 Switching on boom floating position..........................................................251 6.2.3 Switching on boom pre-tensioning.............................................................252 6.2.4 Switching the superstructure driving lights on/off...........................................254 Switching off..................................................................................254 Switching on...................................................................................254 6.3 Rigging the main boom..............................................................................255 Additional equipment required......................................................................255 6.3.1 CHECKLIST: Removing the main boom............................................................256 Prerequisites..................................................................................256 Checklist......................................................................................256 6.3.2 CHECKLIST: Mounting the main boom............................................................259 Prerequisites..................................................................................259 Checklist......................................................................................259 6.3.3 Slinging the main boom.......................................................................262 Marking........................................................................................262 Installing the sling gear......................................................................262 Removing the sling gear........................................................................263 6.3.4 Removing/attaching the clamp.................................................................264 6.3.5 Switching the pressure relief on/off.........................................................265 6.3.6 Retracting/fitting the derricking cylinder head pin..........................................266 Derricking cylinder...........................................................................266 Operation of the lifting device................................................................266 Retracting the derricking cylinder head axle...................................................267 Fitting the derricking cylinder head axle......................................................268 6.3.7 Retracting/extending the boom pivot pin......................................................269 Before retracting..............................................................................269 After extension................................................................................269 Retracting/extending the pivot pin.............................................................270 6.3.8 Separate the hydraulic/electrical connection.................................................271 Lifting in front of the turntable..............................................................271 Breaking.......................................................................................272 6.3.9 Establishing the hydraulic/electrical connection.............................................273 Lifting onto the turntable.....................................................................273 Establishing...................................................................................274 6.3.10 Aligning the connecting points..............................................................275 6.3.11 Securing/releasing derricking cylinder......................................................275 6.3.12 Transporting the main boom..................................................................276 6.3.13 Checks after main boom installation.........................................................277 6.4 Rigging the outrigger beam.........................................................................279 6.4.1 CHECKLIST: Removing the outrigger beams......................................................280 6.4.2 CHECKLIST: Mounting the outrigger beams......................................................282 6.4.3 Preparing the truck crane....................................................................285 Prerequisites..................................................................................285 For removal....................................................................................285 6.4.4 Removing/attaching outrigger pads............................................................286 Removing the outrigger pad.....................................................................286 Applying the outrigger pads....................................................................287 6.4.5 Disconnecting/establishing the hydraulic connection..........................................288 6.4.6 Establishing/disconnecting the electrical connection.........................................289 6.4.7 Unscrewing/screwing in the spacers...........................................................290 Unscrewing.....................................................................................290 Screwing in....................................................................................291 6.4.8 Disconnecting/establishing the connections to the outrigger box..............................292 6.4.9 Pulling out/Inserting the outrigger beam.....................................................292 Pulling out the outrigger beam.................................................................292 Inserting the outrigger beam...................................................................294 6.4.10 Transporting the outrigger beams............................................................296 6.5 Rig the auxiliary hoist............................................................................297 6.5.1 Slinging the auxiliary hoist.................................................................297 6.5.2 CHECKLIST: Installing the auxiliary hoist....................................................298 6.5.3 CHECKLIST: Removing the auxiliary hoist......................................................299 6.5.4 Creating/loosening the connection to the turntable...........................................300 6.5.5 Establishing/disconnecting the hydraulic connection..........................................301 6.5.6 Making/breaking the electrical connection....................................................302 6.5.7 Securing the hoist rope......................................................................303 6.5.8 Transporting the auxiliary hoist.............................................................304 6.5.9 Check that the auxiliary hoist is functioning properly.......................................305 Slewing direction..............................................................................305 Slewing indicator..............................................................................305 7 Malfunctions in driving mode.............................................................................309 7.1 Emergency stop devices.............................................................................309 7.2 What to do when a malfunction occurs in road traffic...............................................311 7.3 Towing the truck crane.............................................................................313 7.3.1 Towing in the event of engine or transmission damage.........................................313 Compressed-air supply..........................................................................314 Electric power supply..........................................................................314 Axle drives....................................................................................314 Transmission...................................................................................314 Transfer case..................................................................................315 Parking brake..................................................................................315 Towing the truck crane out of the danger area..................................................316 7.3.2 Starting to tow..............................................................................316 7.4 Wheels and tyres...................................................................................317 7.4.1 Wheel change.................................................................................317 Removing a damaged wheel.......................................................................318 On the spare wheel holder......................................................................318 Wheel, installing..............................................................................319 7.4.2 Filling the tyres yourself...................................................................321 Connecting the filling hose....................................................................321 Filling the tyres..............................................................................322 Remove the filling hose........................................................................322 7.5 Fuses on the carrier...............................................................................323 Information on replacing fuses...................................................................323 7.5.1 Fuses in the driver's cab....................................................................324 7.5.2 Fuses in the battery box.....................................................................328 7.5.3 Fuses on I/O boards..........................................................................329 7.6 Finding and eliminating malfunctions...............................................................331 7.6.1 Malfunctions on the engine for driving.......................................................331 7.6.2 Differential lock malfunctions...............................................................333 7.6.3 Malfunctions on the transmission.............................................................334 7.6.4 Malfunctions of the transfer case............................................................335 7.6.5 Service brake malfunctions...................................................................335 7.6.6 Steering malfunctions........................................................................336 7.6.7 Malfunctions to the suspension...............................................................337 7.6.8 Level adjustment system malfunctions.........................................................337 7.6.9 Malfunctions in the hydraulic system/hydraulic oil cooler....................................338 7.6.10 Malfunctions on the ECOS carrier............................................................339 ECOS program version...........................................................................339 General malfunctions..........................................................................339 Error messages.................................................................................340 Exiting the submenu...........................................................................341 Error display on the control units.............................................................342 7.7 Procedure in the event of malfunctions.............................................................343 7.7.1 Switching on emergency operation in coolant circuit..........................................343 7.7.2 Malfunctions on the engine...................................................................344 7.7.3 Malfunctions to the transmission.............................................................345 General malfunctions...........................................................................345 Display E......................................................................................345 Transmission malfunction.......................................................................346 Reading error codes...........................................................................347 8 Technical information on the carrier.....................................................................351 8.1 Technical data.....................................................................................351 8.1.1 Dimensions and weights of the truck crane, axle loads........................................352 Dimensions.....................................................................................353 Weight and axle loads..........................................................................353 8.1.2 Dimensions and weights of removable parts....................................................354 Spare wheel....................................................................................354 Outriggers.....................................................................................354 Main boom......................................................................................355 Auxiliary hoist................................................................................355 8.1.3 Carrier......................................................................................355 Engine.........................................................................................355 Transmission...................................................................................355 Transfer case..................................................................................355 Axle lines.....................................................................................356 Steering.......................................................................................356 Tyres..........................................................................................356 Vehicle's electrical system....................................................................357 Tools..........................................................................................357 Towing coupling...............................................................................357 Outriggers.....................................................................................357 Driving speeds.................................................................................358 Climbing ability...............................................................................358 Turning circle radiuses........................................................................358 9 Index....................................................................................................361 A......................................................................................................363 B......................................................................................................363 C......................................................................................................364 D......................................................................................................366 E......................................................................................................367 F......................................................................................................369 H......................................................................................................369 I......................................................................................................370 K......................................................................................................371 L......................................................................................................371 M......................................................................................................371 O......................................................................................................372 P......................................................................................................373 R......................................................................................................373 S......................................................................................................375 T......................................................................................................376 V......................................................................................................378 W......................................................................................................378 Part 2.........................................................................................................383 Additional page............................................................................................385 Stop at 0°or 180°......................................................................................385 Correction sheet...........................................................................................387 Fuses..................................................................................................387 Correction sheet...........................................................................................389 1 Driving with a trailer (dolly).......................................................................389 Switching on boom floating position................................................................390 Switching on the slewing gear freewheel............................................................392 Switching on boom pre-tensioning...................................................................394 2 Pressure relief for removing the main boom...........................................................396 Correction sheet...........................................................................................397 Fuses..................................................................................................397 On the turntable...................................................................................397 In the driver's cab................................................................................398 Additional page Interruption during pressure build-up......................................................399 Additional page Rigging outrigger pads.....................................................................400 Additional page Controls for crane cabin heating...........................................................401 Correction sheet – Accepting the telescope status..........................................................403 10 Operating elements for crane operation..................................................................409 10.1 Overview of the operating elements................................................................409 10.1.1 On the outside of the truck crane...........................................................410 10.1.2 Crane cab...................................................................................412 10.1.3 Front panel.................................................................................414 10.1.4 Side panel..................................................................................415 Bottom.........................................................................................415 Top............................................................................................416 Standard heating system........................................................................419 Auxiliary water heating system.................................................................420 Auxiliary air heater.........................................................................421 10.1.5 Control panels..............................................................................422 Left-hand controlpanel........................................................................422 Right-hand controlpanel.......................................................................423 10.1.6 Control lever assignment....................................................................424 Version 1......................................................................................424 Version 2......................................................................................425 10.1.7 ECOS control unit...........................................................................426 10.1.8 ECOS display – main menu....................................................................428 10.1.9 ECOS display – submenus.....................................................................430 Counterweight submenu..........................................................................430 Submenu slewing gear/Houselock.................................................................431 Outriggers submenu.............................................................................432 Telescoping submenu............................................................................434 Power unit speeds submenu......................................................................436 Monitoring submenu.............................................................................437 Settings submenu...............................................................................438 Operating hours submenu........................................................................440 Warning submenu................................................................................440 Error submenu..................................................................................441 Working range limitation submenu..............................................................442 10.1.10 SLI control unit...........................................................................444 10.1.11 SLI display – main menu....................................................................446 10.1.12 SLI display – submenus.....................................................................447 Enter rigging mode submenu...................................................................447 Monitoring submenu............................................................................448 Rigging mode monitoring submenu................................................................450 Lifting capacity tablesubmenu.................................................................451 Working range submenu..........................................................................452 Error submenu..................................................................................453 Settings submenu...............................................................................455 10.1.13 Hand-held control..........................................................................456 Outriggers control panel.......................................................................457 10.1.14 On the outrigger control units.............................................................458 Outriggers.....................................................................................459 Outrigger pressure display.....................................................................459 Inclination display............................................................................459 10.2 Short description of the operating elements.......................................................461 10.2.1 Definition of positional references.........................................................461 Basic rule.....................................................................................461 Switch.........................................................................................462 10.2.2 General rules for buttons and symbols on the display........................................462 10.2.3 Engine for crane operation..................................................................463 Side panel.....................................................................................463 ECOS display...................................................................................464 10.2.4 Engine for driving..........................................................................465 Side panel.....................................................................................465 Outriggers submenu.............................................................................465 10.2.5 Seat contact switch and dead man's switch...................................................466 10.2.6 ECOS crane control..........................................................................467 Control unit...................................................................................467 10.2.7 Outriggers..................................................................................471 Hand-held control..............................................................................471 In the Outriggers submenu......................................................................472 In the Settings submenu........................................................................473 On the outrigger control units.................................................................474 10.2.8 Inclination displays........................................................................476 10.2.9 Outrigger pressure displays.................................................................477 Outriggers submenu............................................................................477 Outrigger control units........................................................................477 10.2.10 Anemometer displays........................................................................477 10.2.11 Counterweight submenu......................................................................478 Counterweight submenu..........................................................................478 10.2.12 Main hoist.................................................................................481 10.2.13 Auxiliary hoist............................................................................483 10.2.14 Slewing gear...............................................................................484 Control panels.................................................................................484 Submenu........................................................................................485 10.2.15 Derricking gear............................................................................487 10.2.16 Telescoping mechanism......................................................................488 Control panels.................................................................................488 Submenu........................................................................................489 In the Settings submenu........................................................................493 10.2.17 Hydraulic system...........................................................................495 10.2.18 Houselock..................................................................................496 10.2.19 Safe load indicator (SLI)..................................................................497 Control unit...................................................................................497 Main menu......................................................................................499 Enter rigging mode submenu.....................................................................500 Monitoring submenu.............................................................................503 Lifting capacity table submenu................................................................506 Working range submenu..........................................................................507 Other..........................................................................................508 10.2.20 Electrical system..........................................................................509 10.2.21 Lighting, windscreen wiper/washing system..................................................509 Lighting.......................................................................................509 Windscreen wiper/washing system...............................................................511 10.2.22 Hand-held control..........................................................................512 Sockets on truck crane.........................................................................512 Engine control panel...........................................................................513 Horn...........................................................................................513 Outriggers control panel.......................................................................514 10.2.23 Diagnostics................................................................................516 10.2.24 Windows, doors, keys.......................................................................517 Windows........................................................................................517 Crane cab door.................................................................................517 Keys...........................................................................................518 11 Starting/turning off the engine – for crane operation..................................................521 11.1 Starting the engine – from the crane cab..........................................................521 11.1.1 CHECKLIST: Starting the engine..............................................................521 11.1.2 CHECKLIST: for low temperatures.............................................................524 11.1.3 Refuelling..................................................................................525 For standard equipment.........................................................................525 For additional equipment.......................................................................526 11.1.4 Checks before starting the engine...........................................................527 On the hydraulic tank..........................................................................527 Battery master switch..........................................................................527 Checking the hand-held control.................................................................528 11.1.5 Switching on the ignition...................................................................528 11.1.6 Lamp test...................................................................................529 Lamp test......................................................................................529 11.1.7 Adjusting the brightness of the display.....................................................531 11.1.8 Starting the engine.........................................................................532 Without flame start system.....................................................................532 With flame start system........................................................................533 11.1.9 Checks after starting the engine............................................................534 11.1.10 Monitoring submenu.........................................................................535 11.1.11 Setting the idling speed...................................................................536 11.2 Starting the engine – with the hand-held control..................................................537 Prerequisites......................................................................................537 Starting the engine................................................................................537 11.3 Turning off the engine............................................................................539 11.3.1 During normal operation, with the ignition lock/with the hand- held control.................539 Hand-held control not connected................................................................539 Hand-held control connected....................................................................539 After parking..................................................................................539 11.3.2 In emergencies, with the emergency-stop switches............................................540 Resetting the emergency stop switch............................................................540 11.4 Air intake inhibitor..............................................................................541 Releasing the air intake inhibitor.................................................................541 12 Crane operation.........................................................................................545 12.1 Before crane operation............................................................................545 12.1.1 CHECKLIST: Inspections before operating the crane...........................................545 12.1.2 Checking the condition of the truck crane...................................................549 Windscreen washing system......................................................................549 Auxiliary heater...............................................................................549 Visual inspection..............................................................................550 Checking the position of the hoist ropes.......................................................550 Checking the electrical system.................................................................551 12.1.3 Adjusting the crane cab seat and front panel................................................551 Adjusting the crane cab seat...................................................................551 Adjusting the front panel......................................................................552 12.1.4 Checking the safety devices.................................................................552 Safe load indicator............................................................................552 Lifting limit switch...........................................................................553 Emergency stop switch..........................................................................553 Seat contact switch and dead man's switch......................................................554 12.1.5 Earthing the load...........................................................................555 12.1.6 Preheating the hydraulic oil................................................................557 12.1.7 Switching the houselock on/off..............................................................558 Switching on the houselock.....................................................................558 Switching off the houselock....................................................................560 12.2 Operation of the safe load indicator..............................................................561 12.2.1 Switching on the SLI........................................................................562 Switching on...................................................................................562 Brightness of the displays.....................................................................564 12.2.2 Entering the rigging mode...................................................................565 Entering individual components.................................................................566 Entering the SLI code..........................................................................569 Entering the reeving...........................................................................570 Accept rigging mode............................................................................570 12.2.3 Checks prior to crane operation.............................................................572 Open the submenu...............................................................................572 Checks.........................................................................................573 12.2.4 Displays during crane operation.............................................................575 12.2.5 SLI early warning...........................................................................578 12.2.6 SLI shutdown................................................................................578 Shutdown due to overload.......................................................................578 12.2.7 Display in the event of errors..............................................................580 12.2.8 SLI override................................................................................581 12.2.9 Displaying the lifting capacity tables......................................................582 12.2.10 Entering the time/date.....................................................................584 12.3 Crane operation with main boom....................................................................585 12.3.1 Checks during crane operation...............................................................585 Horizontal alignment...........................................................................585 Safe distances.................................................................................585 Checking the wind speed........................................................................586 12.3.2 Permissible slewing ranges and working positions for crane operation.......................587 360 slewing range.............................................................................587 0 to the rear working position................................................................587 180 to the front rigging position.............................................................587 12.3.3 Main hoist..................................................................................589 Switching on the main hoist....................................................................590 Lifting and lowering...........................................................................590 Switching off the main hoist...................................................................591 12.3.4 Auxiliary hoist.............................................................................592 Switching on the auxiliary hoist...............................................................592 Lifting and lowering...........................................................................593 Switching off the auxiliary hoist..............................................................594 12.3.5 Lifting limit switch and lowering limit switch..............................................595 Lifting limit switch...........................................................................595 Lowering limit switch..........................................................................597 12.3.6 Derricking gear.............................................................................598 Switching on the derricking gear...............................................................598 Raising and lowering the boom..................................................................598 Switching off the derricking gear..............................................................599 Lowering the main boom to a horizontal position................................................600 12.3.7 Telescoping mechanism.......................................................................601 Overview.......................................................................................602 Telescoping process...........................................................................602 Assignment to display..........................................................................604 Fixed length, intermediate length, telescoping length..........................................606 Telescoping....................................................................................607 Telescoping sequence..........................................................................607 Checks prior to starting operations............................................................608 Switching on the telescoping mechanism.........................................................609 Function of the control lever..................................................................609 Switching off the telescoping mechanism........................................................611 Manual telescoping.............................................................................612 Checking the initial position..................................................................612 Unlocking the telescoping cylinder............................................................615 Extending/Retracting the telescoping cylinder..................................................617 Locking the telescoping cylinder...............................................................618 Unlocking a telescopic section.................................................................619 Telescope telescopic section...................................................................621 Locking the telescopic section.................................................................622 Locking the telescopic section for on-road driving.............................................623 Telescopic extension with teleautomation.......................................................624 Telescoping the main boom in horizontal position...............................................629 12.3.8 High speed..................................................................................630 Derricking gear/ Telescoping mechanism.........................................................630 Hoisting gears.................................................................................631 12.3.9 Slewing gear................................................................................632 Slewing gear brake.............................................................................632 Switching on the slewing gear..................................................................633 Releasing the slewing gear brake...............................................................633 Engaging the slewing gear brake................................................................633 Slewing........................................................................................634 Slewing to 0 or 180 ..........................................................................636 Braking the slewing movement...................................................................637 Slewing gear freewheel.........................................................................637 Switching off the slewing gear.................................................................638 12.3.10 Possible movement combinations.............................................................639 12.3.11 Hydraulic oil cooling......................................................................640 12.4 Settings and displays for crane operation.........................................................641 12.4.1 Limiting the power unit speeds..............................................................641 12.4.2 Setting the characteristic curve for the control levers.....................................643 12.4.3 Inclining the crane cab.....................................................................644 12.4.4 Setting the idling speed....................................................................644 12.4.5 Critical load control.......................................................................645 Function.......................................................................................645 Switching on and off...........................................................................645 12.4.6 Adjusting the stroke interval of the windscreen wiper.......................................646 12.4.7 Operation of the directional spotlights.....................................................647 Switching on/off...............................................................................647 Directing......................................................................................647 12.4.8 Displaying the operating hours..............................................................648 12.4.9 Warning submenu.............................................................................649 Opening the submenu............................................................................649 Meaning of the symbols.........................................................................649 Exiting the submenu............................................................................652 12.4.10 Error submenu..............................................................................652 12.5 Working range limiter.............................................................................653 12.5.1 Opening the Working range limiter submenu...................................................654 12.5.2 Viewing current settings....................................................................654 12.5.3 Entering limit values.......................................................................656 Overall height/ Working radius.................................................................656 Slewing angle..................................................................................657 Entering objects...............................................................................659 12.5.4 Entering limit values/objects manually......................................................662 Limit values...................................................................................662 Objects........................................................................................663 12.5.5 Switching monitoring functions on/off.......................................................664 12.5.6 Shutdown by working range limiter...........................................................665 12.6 Work break........................................................................................667 12.6.1 Short work breaks...........................................................................667 12.6.2 Work breaks of more than 8 hours............................................................668 Securing the truck crane against unauthorised use..............................................668 12.7 Heating and ventilating the crane cab.............................................................669 12.7.1 Standard heating system.....................................................................669 Switch heating system on/off...................................................................669 Setting the temperature........................................................................670 Setting recirculated/fresh air................................................................670 Setting the air distribution...................................................................670 12.7.2 Auxiliary water heating system..............................................................672 Preheating the engine.........................................................................672 Preheating the crane cab.......................................................................673 Switching on the heating system................................................................673 Switching off the heater.......................................................................674 Setting the time and weekday...................................................................675 Saving the automatic heating start.............................................................676 Setting the heating period.....................................................................677 Switching the automatic heating start on and off...............................................677 Setting the remaining time.....................................................................678 12.7.3 Auxiliary air heater........................................................................679 Switching on the heater........................................................................679 Setting the temperature........................................................................680 Switching off the heater.......................................................................680 Additional functions...........................................................................680 12.7.4 Air-conditioning system.....................................................................681 To switch on...................................................................................681 Setting the air distribution...................................................................681 Switching off..................................................................................682 For pleasant air conditioning in the crane cab.................................................682 Drying the air.................................................................................683 13 Rigging work............................................................................................687 13.1 Rigging work checklists for crane operation with the main boom....................................687 13.1.1 CHECKLIST: Rigging..........................................................................687 13.1.2 CHECKLIST: Unrigging........................................................................691 13.2 Choosing a suitable site..........................................................................695 13.2.1 Determining the required ground bearing area................................................695 13.2.2 Safe distance from slopes and pits..........................................................698 13.2.3 Earthing the truck crane....................................................................699 13.2.4 Safe distance from electrical lines.........................................................700 13.3 Rigging work after driving with a trailer.........................................................703 13.3.1 Switching off the slewing gear freewheel....................................................704 Prerequisites..................................................................................704 Before slewing.................................................................................704 13.3.2 Switching off the boom floating position....................................................705 13.3.3 Switching off boom pre-tensioning...........................................................706 13.4 Connecting/Disconnecting the hand-held control....................................................707 13.5 Starting the engine for driving for rigging work..................................................709 13.5.1 Starting/Turning off the engine with the hand-held control..................................709 Prerequisites..................................................................................709 Starting theengine............................................................................710 Turning off theengine.........................................................................710 13.5.2 Starting/Turning off the engine from the crane cab..........................................711 Prerequisites..................................................................................711 Starting theengine............................................................................711 After starting theengine......................................................................712 Turning off theengine.........................................................................712 13.6 Outriggers........................................................................................713 13.6.1 CHECKLIST: Extending the outriggers.........................................................713 13.6.2 CHECKLIST: Retract outriggers...............................................................715 13.6.3 Permissible outrigger spans.................................................................716 13.6.4 Preparing the truck crane...................................................................717 In the driver's cab............................................................................717 Outrigger control units........................................................................717 13.6.5 Setting the outrigger spans.................................................................718 For on-road driving...........................................................................720 13.6.6 Extending/Retracting the outrigger beams....................................................721 From the control units.........................................................................721 With the hand- held control....................................................................723 From the crane cab.............................................................................725 13.6.7 Moving the outrigger pads into working/driving position.....................................727 13.6.8 Enlarging the ground bearing area...........................................................728 13.6.9 Extending/Retracting outrigger cylinders....................................................729 From the control units.........................................................................730 With the hand- held control....................................................................731 From the crane cab.............................................................................732 13.6.10 Levelling the truck crane on outriggers....................................................734 Inclination displays..........................................................................734 Prerequisites..................................................................................735 Manual alignment...............................................................................736 Automatic alignment...........................................................................737 13.6.11 Outrigger pressure display.................................................................739 13.7 Rigging/Unrigging the counterweight...............................................................741 13.7.1 Counterweight parts.........................................................................741 13.7.2 Identification..............................................................................743 13.7.3 Slinging points.............................................................................745 13.7.4 CHECKLIST: Rigging counterweight............................................................746 13.7.5 CHECKLIST: Unrigging counterweight..........................................................747 13.7.6 Assemble counterweight versions.............................................................748 With Version A.................................................................................750 With Version B.................................................................................752 13.7.7 Counterweight hoist unit....................................................................754 Counterweight submenu..........................................................................754 Extending/ retracting the lifting cylinders..................................................755 Automatic mode, rigging........................................................................756 Automatic mode, unrigging......................................................................758 Cancel automatic mode..........................................................................760 13.7.8 Screwing the counterweight section to the turntable.........................................761 13.7.9 Slewing with rigged counterweight...........................................................762 13.7.10 Assembling counterweight parts for driving the truck crane.................................764 13.8 Rigging work on the main boom.....................................................................765 13.8.1 Hook block on the bumper....................................................................765 Picking up the hook block......................................................................765 Attaching the hook block.......................................................................766 13.8.2 Hook block on a separate vehicle............................................................767 Picking up the hook block......................................................................768 Setting down the hook block....................................................................768 13.8.3 Reeving and unreeving the hoist rope........................................................770 Fastening the rope end clamp...................................................................770 Reeving the hoist rope.........................................................................772 Unreeving the hoist rope.......................................................................776 13.8.4 Possible reevings with 8 head sheaves.......................................................777 13.8.5 Possible reevings with 9 head sheaves.......................................................781 13.8.6 Installing/Removing the lifting limit switch................................................785 Installing the lifting limit switch............................................................785 Removing the lifting limit switch.............................................................789 13.8.7 Locking/Unlocking the lifting limit switch..................................................791 Locking........................................................................................791 Removing the lock..............................................................................792 13.8.8 Anemometer and air traffic control light....................................................793 Installing.....................................................................................793 Removing.......................................................................................794 13.9 Other rigging work................................................................................795 13.9.1 Folding mirrors in and out and adjusting them...............................................795 13.9.2 Installing/removing the heavy duty equipment................................................797 Additional equipment required..................................................................797 Equipment required............................................................................797 Installing.....................................................................................798 Maximum reeving................................................................................799 Removing.......................................................................................800 14 Driving the rigged truck crane..........................................................................803 14.1 Route.............................................................................................803 14.2 Permissible rigging modes and axle loads..........................................................804 Axle load table....................................................................................804 14.3 Before driving....................................................................................806 14.3.1 Secure superstructure so it cannot slew.....................................................806 14.3.2 Checking the tyre pressure and the wind speed...............................................806 14.3.3 Putting the truck crane on the wheels.......................................................807 14.3.4 Transmission/Connections....................................................................809 Transmission...................................................................................809 Connections....................................................................................809 14.4 While driving.....................................................................................809 14.5 After driving.....................................................................................810 15 Malfunctions during crane operation.....................................................................813 15.1 Emergency stop devices............................................................................813 15.2 What to do when a malfunction occurs during crane operation.......................................815 Load can be lowered................................................................................815 Load cannot be lowered.............................................................................815 15.3 Fuses on the superstructure.......................................................................817 Notes on changing fuses............................................................................817 15.3.1 Fuses on the turntable......................................................................818 Fuse groups F1/F2..............................................................................818 Fuses on the circuit board.....................................................................820 Fuses on I/O circuit boards....................................................................820 15.3.2 Fuses in the crane cab......................................................................821 15.3.3 Fuses in the battery box....................................................................823 15.3.4 SLI fuses...................................................................................824 15.4 Finding and eliminating malfunctions..............................................................827 15.4.1 Malfunctions on the engine for crane operation..............................................827 15.4.2 Malfunctions when operating with the hand-held control......................................829 15.4.3 Malfunctions on the main hoist/auxiliary hoist..............................................830 15.4.4 Malfunctions on the derricking gear.........................................................831 15.4.5 Malfunctions on the slewing gear............................................................832 15.4.6 Malfunctions on the counterweight hoist unit................................................833 15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler...................................834 15.4.8 Malfunctions during the inclination of the crane cab........................................834 15.4.9 Malfunctions in the telescoping mechanism...................................................835 Telescoping mechanism error messages...........................................................837 15.4.10 Malfunctions on the outriggers.............................................................838 15.4.11 Troubleshooting on the SLI.................................................................839 General malfunctions...........................................................................839 Error messages in the Monitoring submenu.......................................................840 Displays in the Errors submenu................................................................842 Table of error codes...........................................................................844 Switch off sensor/ tachogenerator..............................................................847 15.4.12 Malfunctions ECOS – superstructure.........................................................848 ECOS program version...........................................................................848 General malfunctions...........................................................................848 Error messages.................................................................................849 Exiting the submenu............................................................................850 15.5 Emergency operations and programs.................................................................851 15.5.1 Mechanical emergency operation for retracting...............................................852 Check prior to the emergency operation.........................................................852 Procedure......................................................................................852 Mechanical emergency operation.................................................................853 15.5.2 Telescoping emergency program...............................................................855 Starting the emergency program.................................................................855 Determining the type of error..................................................................856 If there is an error on the length indicator...................................................857 If there is an error on a proximity switch.....................................................861 Terminating the emergency program..............................................................862 Tables for approaching the locking points......................................................863 15.5.3 Entering the current telescoping............................................................865 15.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....867 Preparations...................................................................................867 Operating a power unit.........................................................................868 Stopping movements.............................................................................870 Stopping movements in emergencies..............................................................870 Turning off the engine........................................................................870 15.6 Hydraulic emergency operation.....................................................................871 15.6.1 Important instructions for hydraulic emergency operation....................................871 15.6.2 Operating principle and accessories.........................................................873 For emergency operation.......................................................................873 For the emergency supply.......................................................................874 15.6.3 Connecting/Disconnecting hoses..............................................................875 Establishing connections.......................................................................875 Disconnecting..................................................................................876 15.6.4 Activating/Deactivating emergency mode......................................................877 15.6.5 Establishing the required hydraulic circuits................................................878 Switching over valves..........................................................................878 For lifting/lowering...........................................................................880 For slewing....................................................................................881 15.6.6 Carrying out emergency operation............................................................882 Lifting/Lowering in emergency mode.............................................................882 Slewing in emergency mode......................................................................883 Raising/Lowering in emergency mode.............................................................884 15.6.7 After emergency operation...................................................................885 Switching off emergency operation..............................................................885 Switching over the crane operation.............................................................885 Disconnecting the hoses........................................................................885 15.6.8 Emergency supply of another crane...........................................................886 For emergency supply...........................................................................886 After emergency supply.........................................................................886 16 Technical information for the superstructure............................................................889 16.1 Technical data....................................................................................889 16.1.1 Maximum lifting capacity (DIN/ISO/EN).......................................................889 16.1.2 Maximum lifting capacity (ASME B 30.5)......................................................889 16.1.3 Dimensions and weights of the truck crane, axle loads.......................................890 16.1.4 Dimensions and weights of removable parts...................................................890 Hook blocks and hook tackle....................................................................890 Counterweight parts............................................................................891 Heavy duty equipment..........................................................................891 Auxiliary hoist................................................................................891 16.1.5 Superstructure..............................................................................892 Engine.........................................................................................892 Main hoist.....................................................................................892 Auxiliary hoist................................................................................892 Slewing gears..................................................................................893 Derricking gear................................................................................893 Main boom......................................................................................893 Lattice extension..............................................................................893 Operating speeds...............................................................................894 17 Index...................................................................................................897 A......................................................................................................899 B......................................................................................................899 C......................................................................................................900 D......................................................................................................902 E......................................................................................................903 F......................................................................................................905 H......................................................................................................905 I......................................................................................................906 K......................................................................................................907 L......................................................................................................907 M......................................................................................................907 O......................................................................................................908 P......................................................................................................909 R......................................................................................................909 S......................................................................................................911 T......................................................................................................912 V......................................................................................................914 W......................................................................................................914
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