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Grove Crane GMK 5220 Driving Operating Instructions Manual 3112378 – PDF DOWNLOAD
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Description
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112378 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112378 – PDF DOWNLOAD
Language : English
Pages : 920
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112378 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
The GMK 5220 is a state-of-the-art truck crane, designed in accordance with approved safety
regulations. Nevertheless, the operator or third parties can still be endangered and the crane or
other property put at risk while using it.
- Modifications may only be made to the truck crane following the approval of Deutsche GROVE GmbH.
- The GMK 5220 truck crane may only be used in a perfect technical condition as intended and with due
attention paid to safe operation and possible haz- ards.
Any malfunctions that could impair safety must be eliminated immediately. - The GMK 5220 truck crane may only be operated without the corresponding special equipment within
the permitted temperature range; à Technical in-
formation on the carrier, p. 8 – 1. - The GMK 5220 truck crane is designed solely for lifting loads which are with- in the permitted GMK
5220 lifting capacities. The load must be slung as pre- scribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also entails
– Observing the entire crane documentation, consisting of the operating in- structions, the
lifting capacity table, the outrigger pressure table and the safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual
TABLE OF CONTENTS:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112378 – PDF DOWNLOAD
Part 1......................................................................................................... 1 Additional page ... axle load over 12 t ................................................................... 3 Additional page............................................................................................ 5 Stop at 0°or 180°...................................................................................... 5 Correction sheet........................................................................................... 7 Fuses.................................................................................................. 7 Correction sheet........................................................................................... 9 Additional brakes...................................................................................... 9 Validity............................................................................................... 9 Reasons for the additional information................................................................. 9 Engine brake........................................................................................... 9 Switching on the engine brake...................................................................... 9 Switching off the engine brake..................................................................... 9 Retarder............................................................................................... 10 Switching on the retarder.......................................................................... 10 Switching off the retarder......................................................................... 10 Correction sheet........................................................................................... 11 Driving with a trailer (dolly)......................................................................... 11 Switching on boom floating position................................................................ 12 Switching on the slewing gear freewheel............................................................ 14 Switching on boom pre-tensioning................................................................... 16 Pressure relief for removing the main boom............................................................. 18 Correction sheet...........................................................................................397 Fuses.................................................................................................. 19 On the turntable...................................................................................397 In the driver's cab................................................................................398 Additional page Interruption during pressure build-up...................................................... 21 Additional page Rigging outrigger pads..................................................................... 22 Additional page Controls for crane cabin heating........................................................... 23 Correction sheet – Accepting the telescope status.......................................................... 25 1 Overview................................................................................................. 31 1.1 Identification..................................................................................... 31 1.2 EC Declaration of Conformity....................................................................... 35 1.3 Documentation supplied............................................................................. 36 1.4 Information about the operating instructions....................................................... 37 1.4.1 What do the symbols used mean?............................................................... 37 1.4.2 How are the operating instructions structured?............................................... 39 Division....................................................................................... 39 Structure of the chapters...................................................................... 39 Structure of the pages......................................................................... 40 1.4.3 How do I find the information I need?........................................................ 41 Cross-references example....................................................................... 42 1.4.4 What information is available for operations planning?....................................... 44 1.5 Conversion table for US measurements............................................................... 45 2 Basic safety instructions................................................................................ 49 2.1 Intended use....................................................................................... 49 2.1.1 Improper use................................................................................. 50 2.2 Organisational measures............................................................................ 51 2.3 Personnel qualification............................................................................ 53 2.4 Safety instructions for driving the truck crane.................................................... 54 2.5 Safety instructions for crane operation............................................................ 55 3 Operating elements when driving.......................................................................... 59 3.1 Overview of the operating elements................................................................. 59 3.1.1 On the outside of the truck crane............................................................ 60 3.1.2 In the driver's cab.......................................................................... 62 Top view of driver's cab...................................................................... 62 Below in the driver's cab..................................................................... 64 Above in the driver's cab..................................................................... 65 Behind the cover.............................................................................. 66 3.1.3 Front instrument panel....................................................................... 67 Left........................................................................................... 67 Tachograph version 1.......................................................................... 68 Middle......................................................................................... 69 Right.......................................................................................... 71 3.1.4 ECOS control unit............................................................................ 72 3.1.5 ECOS display – main menu..................................................................... 74 3.1.6 ECOS display – submenus...................................................................... 76 Level adjustment system submenu............................................................... 76 Settings submenu............................................................................... 78 Submenu Monitoring............................................................................. 79 Operating hours submenu....................................................................... 80 Warning submenu................................................................................ 80 Error submenu.................................................................................. 81 3.1.7 Side instrument panel........................................................................ 82 Standard heating............................................................................... 83 Auxiliary water heater....................................................................... 84 Auxiliary air heater........................................................................ 85 3.1.8 Transmission................................................................................. 86 3.1.9 Steering column.............................................................................. 87 3.1.10 Sockets for hand-held control............................................................... 88 3.1.11 Outrigger control units..................................................................... 89 3.2 Short description of the operating elements........................................................ 91 3.2.1 Definition of positional references.......................................................... 91 Basic rule..................................................................................... 91 Switches and buttons.......................................................................... 92 3.2.2 General information on the operating elements................................................ 92 3.2.3 General rules for buttons and symbols on the display......................................... 93 3.2.4 Engine....................................................................................... 94 Steering column................................................................................ 94 Multipurpose switch............................................................................ 94 Instrument panels.............................................................................. 95 3.2.5 Electrical system/electronics................................................................ 96 Electrical system.............................................................................. 96 3.2.6 ECOS crane control........................................................................... 97 Control unit................................................................................... 97 Instrument panel...............................................................................100 3.2.7 Transmission.................................................................................101 ECOS display...................................................................................101 Side instrument panel..........................................................................102 3.2.8 Transfer case................................................................................105 3.2.9 Final drive..................................................................................106 3.2.10 Brakes......................................................................................108 Service brake..................................................................................108 Parking brake..................................................................................109 Additional brakes..............................................................................110 3.2.11 Normal steering mode/separate steering......................................................111 Instrument panels..............................................................................111 ECOS display...................................................................................112 Driver's door..................................................................................113 3.2.12 Suspension..................................................................................114 3.2.13 Lighting/windscreen wipers/horn.............................................................115 Steering column................................................................................115 Instrument panels..............................................................................115 Overhead in the driver's cab...................................................................117 3.2.14 Level adjustment system.....................................................................118 3.2.15 Tachograph/Speedometer......................................................................120 Tachograph.....................................................................................120 Speedometer...................................................................................120 3.2.16 Roof ventilator.............................................................................121 3.2.17 Diagnostics.................................................................................122 Connections....................................................................................122 Display/submenu................................................................................122 3.2.18 Windows, doors, keys........................................................................123 Windows........................................................................................123 Doors..........................................................................................124 Keys...........................................................................................125 3.2.19 Front flap..................................................................................125 4 Starting/turning off the engine for driving..............................................................129 4.1 Starting the engine from the driver's cab..........................................................129 4.1.1 CHECKLIST: Starting the engine...............................................................129 4.1.2 CHECKLIST: In low temperatures...............................................................132 4.1.3 Access ladders and ladders...................................................................132 Access ladders.................................................................................132 Ladders........................................................................................133 4.1.4 Refuelling...................................................................................135 4.1.5 Checks before starting the engine............................................................136 On the hydraulic tank..........................................................................136 Battery master switch..........................................................................137 Checking the hand-held control.................................................................137 4.1.6 Ignition, switching on.......................................................................137 4.1.7 Lamp test/equalisation of the switching states...............................................138 Lamp test......................................................................................138 Equalisation of the switching states...........................................................139 4.1.8 Adjusting the brightness of the display......................................................141 4.1.9 Starting the engine..........................................................................142 Without flame start system.....................................................................143 With flame start system.......................................................................144 4.1.10 Checks after starting the engine............................................................145 Checks in the main menu........................................................................145 Checks on the instrument panels................................................................145 4.1.11 Monitoring submenu..........................................................................147 4.1.12 Setting the idling speed....................................................................148 4.2 Turning off the engine.............................................................................149 4.2.1 Usually with the ignition lock/with the hand-held control....................................149 Hand-held control not connected................................................................149 Hand-held control connected....................................................................149 After parking.................................................................................149 4.2.2 With emergency stop switches in emergencies..................................................150 Resetting the emergency stop switch............................................................150 4.3 Air intake inhibitor...............................................................................151 Removing the air intake inhibitor..................................................................151 5 Driving..................................................................................................155 5.1 Before driving.....................................................................................155 5.1.1 CHECKLIST: Checks before on-road driving.....................................................155 5.1.2 Checking the condition of the truck crane....................................................161 Windscreen washing system......................................................................161 Warning signs for vehicle width................................................................161 Electrical system..............................................................................162 Mirror setting.................................................................................162 Checking the vehicle height....................................................................163 Checking the compressed air and brake systems.................................................164 5.1.3 Adjusting the seats and steering column......................................................166 Adjusting the driver's seat..................................................................166 Adjusting the passenger seat.................................................................167 Adjusting the steering column.................................................................168 5.1.4 Switching the suspension on/off..............................................................169 Opening the submenu...........................................................................169 Switching on the suspension...................................................................170 Switching off the suspension..................................................................170 5.1.5 Setting the tachograph – version 1...........................................................171 Prerequisites..................................................................................171 Display of error messages.....................................................................171 Adjusting the tachograph......................................................................172 5.1.6 Displaying the operating hours...............................................................176 5.2 Operating the transmission.........................................................................177 5.2.1 Switching on.................................................................................177 5.2.2 Switching the transmission to neutral position...............................................178 While driving..................................................................................178 5.2.3 Changing the driving mode....................................................................179 5.2.4 Selecting the driving direction..............................................................180 5.2.5 Selecting highest gear/starting gear.........................................................181 5.2.6 Starting.....................................................................................181 5.2.7 Driving and changing gears...................................................................182 5.2.8 Changing the driving direction...............................................................183 5.2.9 Stopping.....................................................................................184 Stopping for a long period of time............................................................184 5.2.10 On the roller type dynamometer..............................................................184 5.2.11 Oil level gauge.............................................................................185 5.3 Driving and turning off the truck crane............................................................187 5.3.1 Checks while driving.........................................................................187 Directly after you start to move...............................................................187 While driving..................................................................................188 5.3.2 Tempomat.....................................................................................191 Activating the Tempomat.......................................................................191 Driving with the Tempomat.....................................................................192 Switching off the Tempomat....................................................................192 5.3.3 Driving downhill.............................................................................193 Starting.......................................................................................193 Checks when driving downhill..................................................................193 Shifting down from the highest gear............................................................194 Sustained action brake.........................................................................195 Retarder.......................................................................................196 5.3.4 Driving uphill...............................................................................197 Starting.......................................................................................197 Driving........................................................................................197 5.3.5 Warning submenu..............................................................................199 Opening the submenu...........................................................................199 Meaning of the symbols.........................................................................200 Exiting the submenu...........................................................................202 5.3.6 Error submenu................................................................................202 5.3.7 Parking the truck crane......................................................................203 Securing the truck crane against rolling away..................................................203 When standing still for more than 8 hours......................................................204 5.3.8 Folding berth................................................................................205 5.4 Off-road driving...................................................................................207 Adjustments to the transmission....................................................................207 Connections........................................................................................207 Changing the vehicle level........................................................................207 Rocking the vehicle free and towing...............................................................207 5.4.1 Transfer case – off-road gear on/off.........................................................208 Prerequisites..................................................................................208 Switching on...................................................................................208 Switching off..................................................................................209 Neutral position...............................................................................209 5.4.2 Operation of the longitudinal differential locks.............................................210 Switching on...................................................................................210 Switching off..................................................................................211 5.4.3 Operation of the transverse differential locks...............................................212 Switching on...................................................................................212 Switching off..................................................................................213 5.4.4 Operation of the level adjustment system.....................................................214 Opening the submenu...........................................................................214 Setting the on- road level....................................................................215 Pre-selecting suspension struts..............................................................215 Changing the vehicle level.....................................................................216 Viewing the current inclination................................................................216 Exiting the submenu...........................................................................217 5.4.5 Freeing the immobilised truck crane..........................................................218 Rocking the truck crane free..................................................................218 Towing free to the front......................................................................219 Towing free backwards.........................................................................219 5.5 Separate steering..................................................................................221 5.5.1 Switching on separate steering...............................................................222 5.5.2 Steering with separate steering..............................................................222 Manually.......................................................................................222 Automatically..................................................................................223 5.5.3 Switching off separate steering..............................................................224 5.6 Heating and ventilating the driver's cab...........................................................225 5.6.1 Standard heating.............................................................................225 Switching the heating on and off...............................................................225 Setting the temperature.......................................................................225 Setting recirculated/fresh air.................................................................226 Setting the air distribution.................................................................226 Ventilating the driver's cab...................................................................227 5.6.2 Auxiliary water heating system...............................................................228 Preheating the engine.........................................................................228 Preheating the driver's cab...................................................................228 Switching on the auxiliary heater..............................................................229 Switching off the auxiliary heater.............................................................230 Setting the time and weekday...................................................................230 Saving the automatic heating start............................................................231 Setting the heating period....................................................................232 Switching the automatic heating start on and off...............................................232 Setting the remaining time....................................................................233 5.6.3 Auxiliary air heater with timer..............................................................234 Switching on the auxiliary heater..............................................................234 Setting the temperature........................................................................235 Switching off the auxiliary heater............................................................235 Further functions..............................................................................235 5.6.4 Air-conditioning system......................................................................236 Switching on...................................................................................236 Setting the air distribution.................................................................236 Switching off..................................................................................237 Information on how to get the maximum benefit from the air conditioning .....................237 Dry air in the driver's cab...................................................................238 5.7 Towing a trailer...................................................................................239 Effects on the axle loads..........................................................................239 Coupling the trailer..............................................................................240 Connecting the supply lines.......................................................................241 Removing supply lines............................................................................242 Uncoupling the trailer............................................................................242 Checking the braking force........................................................................244 6 Information and rigging for on-road driving..............................................................247 6.1 Information........................................................................................247 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 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 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 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 Visual inspection..............................................................................549 Checking the position of the hoist ropes.......................................................550 Checking the electrical system.................................................................550 12.1.3 Adjusting the crane cab seat and front panel................................................551 Adjusting the crane cab seat...................................................................551 Adjusting the front panel......................................................................551 12.1.4 Checking the safety devices.................................................................552 Safe load indicator............................................................................552 Lifting limit switch...........................................................................552 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............................................................................651 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 13.8 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..........................................................................805 14.1 Route.............................................................................................805 14.2 Permissible rigging modes and axle loads..........................................................806 Axle load table....................................................................................806 14.3 Before driving....................................................................................808 14.3.1 Secure superstructure so it cannot slew.....................................................808 14.3.2 Checking the tyre pressure and the wind speed...............................................808 14.3.3 Putting the truck crane on the wheels.......................................................809 14.3.4 Transmission/Connections....................................................................811 Transmission...................................................................................811 Connections....................................................................................811 14.4 While driving.....................................................................................811 14.5 After driving.....................................................................................812 15 Malfunctions during crane operation.....................................................................815 15.1 Emergency stop devices............................................................................815 15.2 What to do when a malfunction occurs during crane operation.......................................817 Load can be lowered................................................................................817 Load cannot be lowered.............................................................................817 15.3 Fuses on the superstructure.......................................................................819 Notes on changing fuses............................................................................819 15.3.1 Fuses on the turntable......................................................................820 Fuse groups F1/F2..............................................................................820 Fuses on the circuit board.....................................................................822 Fuses on I/O circuit boards....................................................................822 15.3.2 Fuses in the crane cab......................................................................823 15.3.3 Fuses in the battery box....................................................................825 15.3.4 SLI fuses...................................................................................826 15.4 Finding and eliminating malfunctions..............................................................829 15.4.1 Malfunctions on the engine for crane operation..............................................829 15.4.2 Malfunctions when operating with the hand-held control......................................831 15.4.3 Malfunctions on the main hoist/auxiliary hoist..............................................832 15.4.4 Malfunctions on the derricking gear.........................................................833 15.4.5 Malfunctions on the slewing gear............................................................834 15.4.6 Malfunctions on the counterweight hoist unit................................................835 15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler...................................836 15.4.8 Malfunctions during the inclination of the crane cab........................................836 15.4.9 Malfunctions in the telescoping mechanism...................................................837 Telescoping mechanism error messages...........................................................839 15.4.10 Malfunctions on the outriggers.............................................................840 15.4.11 Troubleshooting on the SLI.................................................................841 General malfunctions...........................................................................841 Error messages in the Monitoring submenu.......................................................842 Displays in the Errors submenu................................................................844 Table of error codes...........................................................................846 Switch off sensor/ tachogenerator..............................................................849 15.4.12 Malfunctions ECOS – superstructure.........................................................850 ECOS program version...........................................................................850 General malfunctions...........................................................................850 Error messages.................................................................................851 Exiting the submenu............................................................................852 15.5 Emergency operations and programs.................................................................853 15.5.1 Mechanical emergency operation for retracting...............................................854 Check prior to the emergency operation.........................................................854 Procedure......................................................................................854 Mechanical emergency operation.................................................................855 15.5.2 Telescoping emergency program...............................................................857 Starting the emergency program.................................................................857 Determining the type of error..................................................................858 If there is an error on the length indicator...................................................859 If there is an error on a proximity switch.....................................................863 Terminating the emergency program..............................................................864 Tables for approaching the locking points......................................................865 15.5.3 Entering the current telescoping............................................................867 15.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....869 Preparations...................................................................................869 Operating a power unit.........................................................................870 Stopping movements.............................................................................872 Stopping movements in emergencies..............................................................872 Turning off the engine........................................................................872 15.6 Hydraulic emergency operation.....................................................................873 15.6.1 Important instructions for hydraulic emergency operation....................................873 15.6.2 Operating principle and accessories.........................................................875 For emergency operation.......................................................................875 For the emergency supply.......................................................................876 15.6.3 Connecting/Disconnecting hoses..............................................................877 Establishing connections.......................................................................877 Disconnecting..................................................................................878 15.6.4 Activating/Deactivating emergency mode......................................................879 15.6.5 Establishing the required hydraulic circuits................................................880 Switching over valves..........................................................................880 For lifting/lowering...........................................................................882 For slewing....................................................................................883 15.6.6 Carrying out emergency operation............................................................884 Lifting/Lowering in emergency mode.............................................................884 Slewing in emergency mode......................................................................885 Raising/Lowering in emergency mode.............................................................886 15.6.7 After emergency operation...................................................................887 Switching off emergency operation..............................................................887 Switching over the crane operation.............................................................887 Disconnecting the hoses........................................................................887 15.6.8 Emergency supply of another crane...........................................................888 For emergency supply...........................................................................888 After emergency supply.........................................................................888 16 Technical information for the superstructure............................................................891 16.1 Technical data....................................................................................891 16.1.1 Maximum lifting capacity (DIN/ISO/EN).......................................................891 16.1.2 Maximum lifting capacity (ASME B 30.5)......................................................891 16.1.3 Dimensions and weights of the truck crane, axle loads.......................................892 16.1.4 Dimensions and weights of removable parts...................................................892 Hook blocks and hook tackle....................................................................892 Counterweight parts............................................................................893 Heavy duty equipment..........................................................................893 Auxiliary hoist................................................................................893 16.1.5 Superstructure..............................................................................894 Engine.........................................................................................894 Main hoist.....................................................................................894 Auxiliary hoist................................................................................894 Slewing gears..................................................................................895 Derricking gear................................................................................895 Main boom......................................................................................895 Lattice extension..............................................................................895 Operating speeds...............................................................................896 17 Index...................................................................................................899 A......................................................................................................901 B......................................................................................................901 C......................................................................................................902 D......................................................................................................904 E......................................................................................................905 F......................................................................................................907 H......................................................................................................907 I......................................................................................................908 K......................................................................................................909 L......................................................................................................909 M......................................................................................................909 O......................................................................................................910 P......................................................................................................911 R......................................................................................................911 S......................................................................................................913 T......................................................................................................914 V......................................................................................................916 W......................................................................................................916
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