Grove Crane GMK 5220 Driving Operating Instructions Manual 3112630 – PDF DOWNLOAD

Description

Grove Crane GMK 5220 Driving Operating Instructions Manual 3112630 – PDF DOWNLOAD

FILE DETAILS:

Grove Crane GMK 5220 Driving Operating Instructions Manual 3112630 – PDF DOWNLOAD

Language : English
Pages : 916
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Grove Crane GMK 5220 Driving Operating Instructions Manual 3112630 – 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 3112630 – PDF DOWNLOAD

Additional pages...........................................................................................  3
	SLI override...........................................................................................  3
		Additional operating elements......................................................................  3
		Cancelling automatic mode..........................................................................  3
		Status display.....................................................................................  5
		SLI shutdown.......................................................................................  7
		Raising after SLI shutdown.........................................................................  8
		Overriding SLI or lifting limit switch for rigging work............................................  9
		Overriding the SLI in an emergency................................................................. 11
		Table – Errorcodes................................................................................. 13
	New outriggers control units........................................................................... 15
		New control unit................................................................................... 16
		Old control unit................................................................................... 16
		Outriggers......................................................................................... 17
		Outrigger pressure indicator....................................................................... 17
		Inclination indicators............................................................................. 17
Correction sheet........................................................................................... 21
	Accepting the telescope status......................................................................... 21
1 Overview................................................................................................. 27
	1.1 Identification..................................................................................... 27
	1.2 EC Declaration of Conformity....................................................................... 31
	1.3 Documentation supplied............................................................................. 32
	1.4 Information about the operating instructions....................................................... 33
		1.4.1 What do the symbols used mean?............................................................... 33
		1.4.2 How are the operating instructions structured?............................................... 35
			Division....................................................................................... 35
			Structure of the chapters...................................................................... 35
			Structure of the pages......................................................................... 36
		1.4.3 How do I find the information I need?........................................................ 37
			Cross-references example....................................................................... 38
		1.4.4 What information is available for operations planning?....................................... 40
	1.5 Conversion table for US measurements............................................................... 41
2 Basic safety instructions................................................................................ 45
	2.1 Intended use....................................................................................... 45
		2.1.1 Improper use................................................................................. 46
	2.2 Organisational measures............................................................................ 47
	2.3 Personnel qualification............................................................................ 49
	2.4 Safety instructions for driving the truck crane.................................................... 50
	2.5 Safety instructions for crane operation............................................................ 51
3 Operating elements when driving.......................................................................... 55
	3.1 Overview of the operating elements................................................................. 55
		3.1.1 On the outside of the truck crane............................................................ 56
		3.1.2 In the driver's cab.......................................................................... 58
			Top view of driver's cab...................................................................... 58
			Below in the driver's cab..................................................................... 60
			Above in the driver's cab..................................................................... 61
			Behind the cover.............................................................................. 62
		3.1.3 Front instrument panel....................................................................... 63
			Left........................................................................................... 63
			Tachograph version 1.......................................................................... 64
			Middle......................................................................................... 65
			Right.......................................................................................... 67
		3.1.4 ECOS control unit............................................................................ 68
		3.1.5 ECOS display – main menu..................................................................... 70
		3.1.6 ECOS display – submenus...................................................................... 72
			Level adjustment system submenu............................................................... 72
			Settings submenu............................................................................... 74
			Submenu Monitoring............................................................................. 75
			Operating hours submenu....................................................................... 76
			Warning submenu................................................................................ 76
			Error submenu.................................................................................. 77
		3.1.7 Side instrument panel........................................................................ 78
			Standard heating............................................................................... 79
			Auxiliary water heater....................................................................... 80
			Auxiliary air heater........................................................................ 81
		3.1.8 Transmission................................................................................. 82
		3.1.9 Steering column.............................................................................. 83
		3.1.10 Sockets for hand-held control............................................................... 84
		3.1.11 Outrigger control units..................................................................... 85
	3.2 Short description of the operating elements........................................................ 87
		3.2.1 Definition of positional references.......................................................... 87
			Basic rule..................................................................................... 87
			Switches and buttons.......................................................................... 88
		3.2.2 General information on the operating elements................................................ 88
		3.2.3 General rules for buttons and symbols on the display......................................... 89
		3.2.4 Engine....................................................................................... 90
			Steering column................................................................................ 90
			Multipurpose switch............................................................................ 90
			Instrument panels.............................................................................. 91
		3.2.5 Electrical system/electronics................................................................ 92
			Electrical system.............................................................................. 92
		3.2.6 ECOS crane control........................................................................... 93
			Control unit................................................................................... 93
			Instrument panel............................................................................... 96
		3.2.7 Transmission................................................................................. 97
			ECOS display................................................................................... 97
			Side instrument panel.......................................................................... 98
		3.2.8 Transfer case................................................................................101
		3.2.9 Final drive..................................................................................102
		3.2.10 Brakes......................................................................................104
			Service brake..................................................................................104
			Parking brake..................................................................................105
			Additional brakes..............................................................................106
		3.2.11 Normal steering mode/separate steering......................................................107
			Instrument panels..............................................................................107
			ECOS display...................................................................................108
			Driver's door..................................................................................109
		3.2.12 Suspension..................................................................................110
		3.2.13 Lighting/windscreen wipers/horn.............................................................111
			Steering column................................................................................111
			Instrument panels..............................................................................111
			Overhead in the driver's cab...................................................................113
		3.2.14 Level adjustment system.....................................................................114
		3.2.15 Tachograph/Speedometer......................................................................116
			Tachograph.....................................................................................116
			Speedometer...................................................................................116
		3.2.16 Roof ventilator.............................................................................117
		3.2.17 Diagnostics.................................................................................118
			Connections/buttons............................................................................118
			Display/submenu................................................................................118
		3.2.18 Windows, doors, keys........................................................................119
			Windows........................................................................................119
			Doors..........................................................................................120
			Keys...........................................................................................121
		3.2.19 Front flap..................................................................................121
4 Starting/turning off the engine for driving..............................................................125
	4.1 Starting the engine from the driver's cab..........................................................125
		4.1.1 CHECKLIST: Starting the engine...............................................................125
		4.1.2 CHECKLIST: In low temperatures...............................................................128
		4.1.3 Access ladders and ladders...................................................................128
			Access ladders.................................................................................128
			Ladders........................................................................................129
		4.1.4 Refuelling...................................................................................131
		4.1.5 Checks before starting the engine............................................................132
			On the hydraulic tank..........................................................................132
			Battery master switch..........................................................................133
			Checking the hand-held control.................................................................133
		4.1.6 Ignition, switching on.......................................................................133
		4.1.7 Lamp test/equalisation of the switching states...............................................134
			Lamp test......................................................................................134
			Equalisation of the switching states...........................................................135
		4.1.8 Adjusting the brightness of the display......................................................137
		4.1.9 Starting the engine..........................................................................138
			Without flame start system.....................................................................139
			With flame start system.......................................................................140
		4.1.10 Checks after starting the engine............................................................141
			Checks in the main menu........................................................................141
			Checks on the instrument panels................................................................142
		4.1.11 Monitoring submenu..........................................................................143
		4.1.12 Setting the idling speed....................................................................144
	4.2 Turning off the engine.............................................................................145
		4.2.1 Usually with the ignition lock/with the hand-held control....................................145
			Hand-held control not connected................................................................145
			Hand-held control connected....................................................................145
			After parking.................................................................................145
		4.2.2 With emergency stop switches in emergencies..................................................146
			Resetting the emergency stop switch............................................................146
	4.3 Air intake inhibitor...............................................................................147
		Removing the air intake inhibitor..................................................................147
5 Driving..................................................................................................151
	5.1 Before driving.....................................................................................151
		5.1.1 CHECKLIST: Checks before on-road driving.....................................................151
		5.1.2 Checking the condition of the truck crane....................................................157
			Windscreen washing system......................................................................157
			Warning signs for vehicle width................................................................157
			Electrical system..............................................................................158
			Mirror setting.................................................................................158
			Checking the vehicle height....................................................................159
			Checking the compressed air and brake systems.................................................160
		5.1.3 Adjusting the seats and steering column......................................................162
			Adjusting the driver's seat..................................................................162
			Adjusting the passenger seat.................................................................163
			Adjusting the steering column.................................................................164
		5.1.4 Switching the suspension on/off..............................................................165
			Opening the submenu...........................................................................165
			Switching on the suspension...................................................................166
			Switching off the suspension..................................................................166
		5.1.5 Setting the tachograph – version 1...........................................................167
			Prerequisites..................................................................................167
			Display of error messages.....................................................................167
			Adjusting the tachograph......................................................................168
		5.1.6 Displaying the operating hours...............................................................172
	5.2 Operating the transmission.........................................................................173
		5.2.1 Switching on.................................................................................173
		5.2.2 Switching the transmission to neutral position...............................................174
			While driving..................................................................................174
		5.2.3 Changing the driving mode....................................................................175
		5.2.4 Selecting the driving direction..............................................................176
		5.2.5 Selecting highest gear/starting gear.........................................................177
		5.2.6 Starting.....................................................................................177
		5.2.7 Driving and changing gears...................................................................178
		5.2.8 Changing the driving direction...............................................................179
		5.2.9 Stopping.....................................................................................180
			Stopping for a long period of time............................................................180
		5.2.10 On the roller type dynamometer..............................................................180
		5.2.11 Oil level gauge.............................................................................181
	5.3 Driving and turning off the truck crane............................................................183
		5.3.1 Checks while driving.........................................................................183
			Directly after you start to move...............................................................183
			While driving..................................................................................184
		5.3.2 Tempomat.....................................................................................187
			Activating the Tempomat.......................................................................187
			Driving with the Tempomat.....................................................................187
			Switching off the Tempomat....................................................................188
		5.3.3 Temposet.....................................................................................189
			Switching on the Temposet.....................................................................189
			Driving with the Temposet.....................................................................189
			Switching the Temposet off....................................................................189
		5.3.4 Driving downhill.............................................................................190
			Starting.......................................................................................190
			Checks when driving downhill..................................................................190
			Shifting down from the highest gear............................................................191
			Sustained action brake.........................................................................192
			Retarder.......................................................................................193
		5.3.5 Driving uphill...............................................................................194
			Starting.......................................................................................194
			Driving........................................................................................194
		5.3.6 Warning submenu..............................................................................195
			Opening the submenu...........................................................................195
			Meaning of the symbols.........................................................................196
			Exiting the submenu...........................................................................199
		5.3.7 Error submenu................................................................................199
		5.3.8 Parking the truck crane......................................................................200
			Securing the truck crane against rolling away..................................................201
			When standing still for more than 8 hours......................................................202
		5.3.9 Folding berth................................................................................203
	5.4 Off-road driving...................................................................................205
		Adjustments to the transmission....................................................................205
		Connections........................................................................................205
		Changing the vehicle level........................................................................205
		Rocking the vehicle free and towing...............................................................205
		5.4.1 Transfer case – off-road gear on/off.........................................................206
			Prerequisites..................................................................................206
			Switching on...................................................................................206
			Switching off..................................................................................207
			Neutral position...............................................................................207
		5.4.2 Operation of the longitudinal differential locks.............................................208
			Switching on...................................................................................208
			Switching off..................................................................................209
		5.4.3 Operation of the transverse differential locks...............................................210
			Switching on...................................................................................210
			Switching off..................................................................................211
		5.4.4 Operation of the level adjustment system.....................................................212
			Opening the submenu...........................................................................212
			Setting the on- road level....................................................................213
			Pre-selecting suspension struts..............................................................213
			Changing the vehicle level.....................................................................214
			Viewing the current inclination................................................................214
			Exiting the submenu...........................................................................215
		5.4.5 Freeing the immobilised truck crane..........................................................216
			Rocking the truck crane free..................................................................216
			Towing free to the front......................................................................217
			Towing free backwards.........................................................................217
	5.5 Separate steering..................................................................................219
		5.5.1 Switching on separate steering...............................................................220
		5.5.2 Steering with separate steering..............................................................220
			Manually.......................................................................................220
			Automatically..................................................................................221
		5.5.3 Switching off separate steering..............................................................222
	5.6 Heating and ventilating the driver's cab...........................................................223
		5.6.1 Standard heating.............................................................................223
			Switching the heating on and off...............................................................223
			Setting the temperature.......................................................................223
			Setting recirculated/fresh air.................................................................224
			Setting the air distribution.................................................................224
			Ventilating the driver's cab...................................................................225
		5.6.2 Auxiliary water heating system...............................................................226
			Preheating the engine.........................................................................226
			Preheating the driver's cab...................................................................226
			Switching on the auxiliary heater..............................................................227
			Switching off the auxiliary heater.............................................................228
			Setting the time and weekday...................................................................228
			Saving the automatic heating start............................................................229
			Setting the heating period....................................................................230
			Switching the automatic heating start on and off...............................................230
			Setting the remaining time....................................................................231
		5.6.3 Auxiliary air heater with timer..............................................................232
			Switching on the auxiliary heater..............................................................232
			Setting the temperature........................................................................233
			Switching off the auxiliary heater............................................................233
			Further functions..............................................................................233
		5.6.4 Air-conditioning system......................................................................234
			Switching on...................................................................................234
			Setting the air distribution.................................................................234
			Switching off..................................................................................235
			Information on how to get the maximum benefit from the air conditioning .....................235
			Dry air in the driver's cab...................................................................236
	5.7 Towing a trailer...................................................................................237
		Effects on the axle loads..........................................................................237
		Coupling the trailer..............................................................................238
		Connecting the supply lines.......................................................................239
		Removing supply lines............................................................................240
		Uncoupling the trailer............................................................................240
		Checking the braking force........................................................................242
6 Driving modes and rigging for on-road driving............................................................245
	6.1 Driving modes......................................................................................245
		Information on the axle loads......................................................................245
		6.1.1 Information on how to use the tables.........................................................246
		6.1.2 Tables for maximum axle load 12t (26500lbs)...............................................247
			For 385/95 R25 (14.00 R25) tyres...............................................................247
			For 445/95 R25 / 525/80 R25 (16.00 R25/20.5R25) tyres........................................248
	6.2 Rigging work for driving with a trailer............................................................249
		6.2.1 Switching on the slewing gear freewheel......................................................249
			Prerequisites..................................................................................249
		6.2.2 Switching on boom floating position..........................................................251
		6.2.3 Switching on boom pre-tensioning.............................................................252
		6.2.4 Switching the superstructure driving lights on/off...........................................254
			Switching off..................................................................................254
			Switching on...................................................................................254
	6.3 Rigging the main boom..............................................................................255
		Additional equipment required......................................................................255
		6.3.1 CHECKLIST: Removing the main boom............................................................256
			Prerequisites..................................................................................256
			Checklist......................................................................................256
		6.3.2 CHECKLIST: Mounting the main boom............................................................259
			Prerequisites..................................................................................259
			Checklist......................................................................................259
		6.3.3 Slinging the main boom.......................................................................262
			Marking........................................................................................262
			Installing the sling gear......................................................................262
			Removing the sling gear........................................................................263
		6.3.4 Removing/attaching the clamp.................................................................264
		6.3.5 Switching the pressure relief on/off.........................................................265
		6.3.6 Retracting/fitting the derricking cylinder head pin..........................................266
			Derricking cylinder...........................................................................266
			Operation of the lifting device................................................................266
			Retracting the derricking cylinder head axle...................................................267
			Fitting the derricking cylinder head axle......................................................268
		6.3.7 Retracting/extending the boom pivot pin......................................................269
			Before retracting..............................................................................269
			After extension................................................................................269
			Retracting/extending the pivot pin.............................................................270
		6.3.8 Separate the hydraulic/electrical connection.................................................271
			Lifting in front of the turntable..............................................................271
			Breaking.......................................................................................272
		6.3.9 Establishing the hydraulic/electrical connection.............................................273
			Lifting onto the turntable.....................................................................273
			Establishing...................................................................................274
		6.3.10 Aligning the connecting points..............................................................275
		6.3.11 Securing/releasing derricking cylinder......................................................275
		6.3.12 Transporting the main boom..................................................................276
		6.3.13 Checks after main boom installation.........................................................277
	6.4 Rigging the outrigger beam.........................................................................279
		6.4.1 CHECKLIST: Removing the outrigger beams......................................................280
		6.4.2 CHECKLIST: Mounting the outrigger beams......................................................282
		6.4.3 Preparing the truck crane....................................................................285
			Prerequisites..................................................................................285
			For removal....................................................................................285
		6.4.4 Removing/attaching outrigger pads............................................................286
			Removing the outrigger pad.....................................................................286
			Applying the outrigger pads....................................................................287
		6.4.5 Disconnecting/establishing the hydraulic connection..........................................288
		6.4.6 Establishing/disconnecting the electrical connection.........................................289
		6.4.7 Unscrewing/screwing in the spacers...........................................................290
			Unscrewing.....................................................................................290
			Screwing in....................................................................................291
		6.4.8 Disconnecting/establishing the connections to the outrigger box..............................292
		6.4.9 Pulling out/Inserting the outrigger beam.....................................................292
			Pulling out the outrigger beam.................................................................292
			Inserting the outrigger beam...................................................................294
		6.4.10 Transporting the outrigger beams............................................................296
	6.5 Rig the auxiliary hoist............................................................................297
		6.5.1 Slinging the auxiliary hoist.................................................................297
		6.5.2 CHECKLIST: Installing the auxiliary hoist....................................................298
		6.5.3 CHECKLIST: Removing the auxiliary hoist......................................................299
		6.5.4 Creating/loosening the connection to the turntable...........................................300
		6.5.5 Establishing/disconnecting the hydraulic connection..........................................301
		6.5.6 Making/breaking the electrical connection....................................................302
		6.5.7 Securing the hoist rope......................................................................303
		6.5.8 Transporting the auxiliary hoist.............................................................304
		6.5.9 Check that the auxiliary hoist is functioning properly.......................................305
			Slewing direction..............................................................................305
			Slewing indicator..............................................................................305
7 Malfunctions in driving mode.............................................................................309
	7.1 Emergency stop devices.............................................................................309
	7.2 What to do when a malfunction occurs in road traffic...............................................311
	7.3 Towing the truck crane.............................................................................313
		7.3.1 Towing in the event of engine or transmission damage.........................................313
			Compressed-air supply..........................................................................314
			Electric power supply..........................................................................314
			Axle drives....................................................................................314
			Transmission...................................................................................314
			Transfer case..................................................................................315
			Parking brake..................................................................................315
			Towing the truck crane out of the danger area..................................................316
		7.3.2 Starting to tow..............................................................................316
	7.4 Wheels and tyres...................................................................................317
		7.4.1 Wheel change.................................................................................317
			Removing a damaged wheel.......................................................................318
			On the spare wheel holder......................................................................318
			Wheel, installing..............................................................................319
		7.4.2 Filling the tyres yourself...................................................................321
			Connecting the filling hose....................................................................321
			Filling the tyres..............................................................................322
			Remove the filling hose........................................................................322
	7.5 Fuses on the carrier...............................................................................323
		Information on replacing fuses...................................................................323
		7.5.1 Fuses in the driver's cab....................................................................324
		7.5.2 Fuses in the battery box.....................................................................328
		7.5.3 Fuses on I/O boards..........................................................................329
	7.6 Finding and eliminating malfunctions...............................................................331
		7.6.1 Malfunctions on the engine for driving.......................................................331
		7.6.2 Differential lock malfunctions...............................................................333
		7.6.3 Malfunctions on the transmission.............................................................334
		7.6.4 Malfunctions of the transfer case............................................................335
		7.6.5 Service brake malfunctions...................................................................335
		7.6.6 Steering malfunctions........................................................................336
		7.6.7 Malfunctions to the suspension...............................................................337
		7.6.8 Level adjustment system malfunctions.........................................................337
		7.6.9 Malfunctions in the hydraulic system/hydraulic oil cooler....................................338
		7.6.10 Malfunctions on the ECOS carrier............................................................339
			ECOS program version...........................................................................339
			General malfunctions..........................................................................339
			Error messages.................................................................................340
			Exiting the submenu...........................................................................341
			Error display on the control units.............................................................342
	7.7 Procedure in the event of malfunctions.............................................................343
		7.7.1 Switching on emergency operation in coolant circuit..........................................343
		7.7.2 Malfunctions on the engine...................................................................344
		7.7.3 Malfunctions to the transmission.............................................................345
			General malfunctions...........................................................................345
			Display E......................................................................................345
			Transmission malfunction.......................................................................346
			Reading error codes...........................................................................347
8 Technical information on the carrier.....................................................................351
	8.1 Technical data.....................................................................................351
		8.1.1 Dimensions and weights of the truck crane, axle loads........................................352
			Dimensions.....................................................................................353
			Weight and axle loads..........................................................................353
		8.1.2 Dimensions and weights of removable parts....................................................354
			Spare wheel....................................................................................354
			Outriggers.....................................................................................354
			Main boom......................................................................................355
			Auxiliary hoist................................................................................355
		8.1.3 Carrier......................................................................................355
			Engine.........................................................................................355
			Transmission...................................................................................355
			Transfer case..................................................................................355
			Axle lines.....................................................................................356
			Steering.......................................................................................356
			Tyres..........................................................................................356
			Vehicle's electrical system....................................................................357
			Tools..........................................................................................357
			Towing coupling...............................................................................357
			Outriggers.....................................................................................357
			Driving speeds.................................................................................358
			Climbing ability...............................................................................358
			Turning circle radiuses........................................................................358
9 Index....................................................................................................361
	A......................................................................................................363
	B......................................................................................................363
	C......................................................................................................364
	D......................................................................................................366
	E......................................................................................................367
	F......................................................................................................369
	H......................................................................................................369
	I......................................................................................................370
	K......................................................................................................371
	L......................................................................................................371
	M......................................................................................................371
	O......................................................................................................372
	P......................................................................................................373
	R......................................................................................................373
	S......................................................................................................375
	T......................................................................................................376
	V......................................................................................................378
	W......................................................................................................378
Additional pages...........................................................................................385
	SLI override...........................................................................................385
		Additional operating elements......................................................................385
		Cancelling automatic mode..........................................................................385
		Status display.....................................................................................387
		SLI shutdown.......................................................................................389
		Raising after SLI shutdown.........................................................................390
		Overriding SLI or lifting limit switch for rigging work............................................391
		Overriding the SLI in an emergency.................................................................393
		Table – Errorcodes.................................................................................395
	New outriggers control units...........................................................................397
		New control unit...................................................................................398
		Old control unit...................................................................................398
		Outriggers.........................................................................................399
		Outrigger pressure indicator.......................................................................399
		Inclination indicators.............................................................................399
Correction sheet...........................................................................................403
	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
			Rear panel.....................................................................................418
			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
			Rear panel.....................................................................................464
			ECOS display...................................................................................464
		10.2.4 Engine for driving..........................................................................465
			Side panel.....................................................................................465
			Outriggers submenu.............................................................................465
		10.2.5 Seat contact switch and dead man's switch...................................................466
		10.2.6 ECOS crane control..........................................................................467
			Control unit...................................................................................467
		10.2.7 Outriggers..................................................................................471
			Hand-held control..............................................................................471
			In the Outriggers submenu......................................................................472
			In the Settings submenu........................................................................473
			On the outrigger control units.................................................................474
		10.2.8 Inclination displays........................................................................476
		10.2.9 Outrigger pressure displays.................................................................477
			Outriggers submenu............................................................................477
			Outrigger control units........................................................................477
		10.2.10 Anemometer displays........................................................................477
		10.2.11 Counterweight submenu......................................................................478
			Counterweight submenu..........................................................................478
		10.2.12 Main hoist.................................................................................481
		10.2.13 Auxiliary hoist............................................................................483
		10.2.14 Slewing gear...............................................................................484
			Control panels.................................................................................484
			Submenu........................................................................................485
		10.2.15 Derricking gear............................................................................487
		10.2.16 Telescoping mechanism......................................................................488
			Control panels.................................................................................488
			Submenu........................................................................................489
			In the Settings submenu........................................................................493
		10.2.17 Hydraulic system...........................................................................495
		10.2.18 Houselock..................................................................................496
		10.2.19 Safe load indicator (SLI)..................................................................497
			Control unit...................................................................................497
			Main menu......................................................................................499
			Enter rigging mode submenu.....................................................................500
			Monitoring submenu.............................................................................503
			Lifting capacity table submenu.................................................................506
			Working range submenu..........................................................................507
			Other..........................................................................................508
		10.2.20 Electrical system..........................................................................509
		10.2.21 Lighting, windscreen wiper/washing system..................................................509
			Lighting.......................................................................................509
			Windscreen wiper/washing system...............................................................511
		10.2.22 Hand-held control..........................................................................512
			Sockets on truck crane.........................................................................512
			Engine control panel...........................................................................513
			Horn...........................................................................................513
			Outriggers control panel.......................................................................514
		10.2.23 Diagnostics................................................................................516
		10.2.24 Windows, doors, keys.......................................................................517
			Windows........................................................................................517
			Crane cab door.................................................................................517
			Keys...........................................................................................518
11 Starting/turning off the engine – for crane operation..................................................521
	11.1 Starting the engine – from the crane cab..........................................................521
		11.1.1 CHECKLIST: Starting the engine..............................................................521
		11.1.2 CHECKLIST: for low temperatures.............................................................524
		11.1.3 Refuelling..................................................................................525
			For standard equipment.........................................................................525
			For additional equipment.......................................................................526
		11.1.4 Checks before starting the engine...........................................................527
			On the hydraulic tank..........................................................................527
			Battery master switch..........................................................................527
			Checking the hand-held control.................................................................528
		11.1.5 Switching on the ignition...................................................................528
		11.1.6 Lamp test...................................................................................529
			Lamp test......................................................................................529
		11.1.7 Adjusting the brightness of the display.....................................................531
		11.1.8 Starting the engine.........................................................................532
			Without flame start system.....................................................................532
			With flame start system........................................................................533
		11.1.9 Checks after starting the engine............................................................534
		11.1.10 Monitoring submenu.........................................................................535
		11.1.11 Setting the idling speed...................................................................536
	11.2 Starting the engine – with the hand-held control..................................................537
		Prerequisites......................................................................................537
		Starting the engine................................................................................537
	11.3 Turning off the engine............................................................................539
		11.3.1 During normal operation, with the ignition lock/with the hand- held control.................539
			Hand-held control not connected................................................................539
			Hand-held control connected....................................................................539
			After parking..................................................................................539
		11.3.2 In emergencies, with the emergency-stop switches............................................540
			Resetting the emergency stop switch............................................................540
	11.4 Air intake inhibitor..............................................................................541
		Releasing the air intake inhibitor.................................................................541
12 Crane operation.........................................................................................545
	12.1 Before crane operation............................................................................545
		12.1.1 CHECKLIST: Inspections before operating the crane...........................................545
		12.1.2 Checking the condition of the truck crane...................................................549
			Windscreen washing system......................................................................549
			Auxiliary heater...............................................................................549
			Visual inspection..............................................................................550
			Checking the position of the hoist ropes.......................................................550
			Checking the electrical system.................................................................551
		12.1.3 Adjusting the crane cab seat and front panel................................................551
			Adjusting the crane cab seat...................................................................551
			Adjusting the front panel......................................................................552
		12.1.4 Checking the safety devices.................................................................552
			Safe load indicator............................................................................552
			Lifting limit switch...........................................................................553
			Emergency stop switch..........................................................................553
			Seat contact switch and dead man's switch......................................................554
		12.1.5 Earthing the load...........................................................................555
		12.1.6 Preheating the hydraulic oil................................................................557
		12.1.7 Switching the houselock on/off..............................................................558
			Switching on the houselock.....................................................................558
			Switching off the houselock....................................................................560
	12.2 Operation of the safe load indicator..............................................................561
		12.2.1 Switching on the SLI........................................................................562
			Switching on...................................................................................562
			Brightness of the displays.....................................................................564
		12.2.2 Entering the rigging mode...................................................................565
			Entering individual components.................................................................566
			Entering the SLI code..........................................................................569
			Entering the reeving...........................................................................570
			Accept rigging mode............................................................................570
		12.2.3 Checks prior to crane operation.............................................................572
			Open the submenu...............................................................................572
			Checks.........................................................................................573
		12.2.4 Displays during crane operation.............................................................575
		12.2.5 SLI early warning...........................................................................578
		12.2.6 SLI shutdown................................................................................578
			Shutdown due to overload.......................................................................578
		12.2.7 Display in the event of errors..............................................................580
		12.2.8 SLI override................................................................................581
		12.2.9 Displaying the lifting capacity tables......................................................582
		12.2.10 Entering the time/date.....................................................................584
	12.3 Crane operation with main boom....................................................................585
		12.3.1 Checks during crane operation...............................................................585
			Horizontal alignment...........................................................................585
			Safe distances.................................................................................585
			Checking the wind speed........................................................................586
		12.3.2 Permissible slewing ranges and working positions for crane operation.......................587
			360 slewing range.............................................................................587
			0 to the rear working position................................................................587
			180 to the front rigging position.............................................................587
		12.3.3 Main hoist..................................................................................589
			Switching on the main hoist....................................................................590
			Lifting and lowering...........................................................................590
			Switching off the main hoist...................................................................591
		12.3.4 Auxiliary hoist.............................................................................592
			Switching on the auxiliary hoist...............................................................592
			Lifting and lowering...........................................................................593
			Switching off the auxiliary hoist..............................................................594
		12.3.5 Lifting limit switch and lowering limit switch..............................................595
			Lifting limit switch...........................................................................595
			Lowering limit switch..........................................................................597
		12.3.6 Derricking gear.............................................................................598
			Switching on the derricking gear...............................................................598
			Raising and lowering the boom..................................................................598
			Switching off the derricking gear..............................................................599
			Lowering the main boom to a horizontal position................................................600
		12.3.7 Telescoping mechanism.......................................................................601
			Overview.......................................................................................602
			Telescoping process...........................................................................602
			Assignment to display..........................................................................604
			Fixed length, intermediate length, telescoping length..........................................606
			Telescoping....................................................................................607
			Telescoping sequence..........................................................................607
			Checks prior to starting operations............................................................608
			Switching on the telescoping mechanism.........................................................609
			Function of the control lever..................................................................609
			Switching off the telescoping mechanism........................................................611
			Manual telescoping.............................................................................612
			Checking the initial position..................................................................612
			Unlocking the telescoping cylinder............................................................615
			Extending/Retracting the telescoping cylinder..................................................617
			Locking the telescoping cylinder...............................................................618
			Unlocking a telescopic section.................................................................619
			Telescope telescopic section...................................................................621
			Locking the telescopic section.................................................................622
			Locking the telescopic section for on-road driving.............................................623
			Telescopic extension with teleautomation.......................................................624
			Telescoping the main boom in horizontal position...............................................629
		12.3.8 High speed..................................................................................630
			Switch on function.............................................................................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
			Braking the slewing movement...................................................................636
			Slewing gear freewheel.........................................................................636
			Switching off the slewing gear.................................................................637
		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
		12.4.8 Displaying the operating hours..............................................................648
		12.4.9 Warning submenu.............................................................................649
			Opening the submenu............................................................................649
			Meaning of the symbols.........................................................................649
			Exiting the submenu............................................................................652
		12.4.10 Error submenu..............................................................................652
	12.5 Working range limiter.............................................................................653
		12.5.1 Opening the Working range limiter submenu...................................................654
		12.5.2 Viewing current settings....................................................................654
		12.5.3 Entering limit values.......................................................................656
			Overall height/ Working radius.................................................................656
			Slewing angle..................................................................................657
			Entering objects...............................................................................659
		12.5.4 Entering limit values/objects manually......................................................662
			Limit values...................................................................................662
			Objects........................................................................................663
		12.5.5 Switching monitoring functions on/off.......................................................664
		12.5.6 Shutdown by working range limiter...........................................................665
	12.6 Work break........................................................................................667
		12.6.1 Short work breaks...........................................................................667
		12.6.2 Work breaks of more than 8 hours............................................................668
			Securing the truck crane against unauthorised use..............................................668
	12.7 Heating and air-conditioning system...............................................................669
		12.7.1 Standard heating system.....................................................................669
			Switching on...................................................................................669
			Heating........................................................................................669
			Air distribution...............................................................................670
			Switching off..................................................................................671
			Notes..........................................................................................671
			Switching on/off...............................................................................672
			Cooling........................................................................................672
			Drying the air.................................................................................673
		12.7.3 Auxiliary water heating system..............................................................673
			Preheating the engine..........................................................................674
			Preheating the crane cab.......................................................................674
			Switching on...................................................................................675
			Setting the day and time.......................................................................676
			Storing the heating start......................................................................677
			Setting the heating period.....................................................................678
			Switching heating start on/off.................................................................678
			Switching off..................................................................................679
			Setting the remaining run time.................................................................679
		12.7.4 Auxiliary air heater........................................................................680
			Switching on the heater........................................................................680
			Setting the temperature........................................................................681
			Switching off the heater.......................................................................681
			Additional functions...........................................................................681
13 Rigging work............................................................................................685
	13.1 Rigging work checklists for crane operation with the main boom....................................685
		13.1.1 CHECKLIST: Rigging..........................................................................685
		13.1.2 CHECKLIST: Unrigging........................................................................689
	13.2 Choosing a suitable site..........................................................................693
		13.2.1 Determining the required ground bearing area................................................693
		13.2.2 Safe distance from slopes and pits..........................................................696
		13.2.3 Earthing the truck crane....................................................................697
		13.2.4 Safe distance from electrical lines.........................................................698
	13.3 Rigging work after driving with a trailer.........................................................701
		13.3.1 Switching off the slewing gear freewheel....................................................702
			Prerequisites..................................................................................702
			Before slewing.................................................................................702
		13.3.2 Switching off the boom floating position....................................................703
		13.3.3 Switching off boom pre-tensioning...........................................................704
	13.4 Connecting/Disconnecting the hand-held control....................................................705
	13.5 Starting the engine for driving for rigging work..................................................707
		13.5.1 Starting/Turning off the engine with the hand-held control..................................707
			Prerequisites..................................................................................707
			Starting theengine............................................................................708
			Turning off theengine.........................................................................708
		13.5.2 Starting/Turning off the engine from the crane cab..........................................709
			Prerequisites..................................................................................709
			Starting theengine............................................................................709
			After starting theengine......................................................................710
			Turning off theengine.........................................................................710
	13.6 Outriggers........................................................................................711
		13.6.1 CHECKLIST: Extending the outriggers.........................................................711
		13.6.2 CHECKLIST: Retract outriggers...............................................................713
		13.6.3 Permissible outrigger spans.................................................................714
		13.6.4 Preparing the truck crane...................................................................715
			In the driver's cab............................................................................715
			Outrigger control units........................................................................715
		13.6.5 Setting the outrigger spans.................................................................716
			For on-road driving...........................................................................718
		13.6.6 Extending/Retracting the outrigger beams....................................................719
			From the control units.........................................................................719
			With the hand- held control....................................................................721
			From the crane cab.............................................................................723
		13.6.7 Moving the outrigger pads into working/driving position.....................................725
		13.6.8 Enlarging the ground bearing area...........................................................726
		13.6.9 Extending/Retracting outrigger cylinders....................................................727
			From the control units.........................................................................728
			With the hand- held control....................................................................729
			From the crane cab.............................................................................730
		13.6.10 Levelling the truck crane on outriggers....................................................732
			Inclination displays..........................................................................732
			Prerequisites..................................................................................733
			Manual alignment...............................................................................734
			Automatic alignment...........................................................................735
		13.6.11 Outrigger pressure display.................................................................737
	13.7 Rigging/Unrigging the counterweight...............................................................739
		13.7.1 Counterweight parts.........................................................................739
		13.7.2 Identification..............................................................................741
		13.7.3 Slinging points.............................................................................743
		13.7.4 CHECKLIST: Rigging counterweight............................................................744
		13.7.5 CHECKLIST: Unrigging counterweight..........................................................745
		13.7.6 Assemble counterweight versions.............................................................746
			With Version A.................................................................................748
			With Version B.................................................................................750
		13.7.7 Counterweight hoist unit....................................................................752
			Counterweight submenu..........................................................................752
			Extending/ retracting the lifting cylinders..................................................753
			Automatic mode, rigging........................................................................754
			Automatic mode, unrigging......................................................................756
			Cancel automatic mode..........................................................................758
		13.7.8 Screwing the counterweight section to the turntable.........................................759
		13.7.9 Slewing with rigged counterweight...........................................................760
		13.7.10 Assembling counterweight parts for driving the truck crane.................................762
	13.8 Rigging work on the main boom.....................................................................763
		13.8.1 Hook block on the bumper....................................................................763
			Picking up the hook block......................................................................763
			Attaching the hook block.......................................................................764
		13.8.2 Hook block on a separate vehicle............................................................765
			Picking up the hook block......................................................................766
			Setting down the hook block....................................................................766
		13.8.3 Reeving and unreeving the hoist rope........................................................768
			Fastening the rope end clamp...................................................................768
			Reeving the hoist rope.........................................................................770
			Unreeving the hoist rope.......................................................................774
		13.8.4 Possible reevings with 8 head sheaves.......................................................775
		13.8.5 Possible reevings with 9 head sheaves.......................................................779
		13.8.6 Installing/Removing the lifting limit switch................................................783
			Installing the lifting limit switch............................................................783
			Removing the lifting limit switch.............................................................787
		13.8.7 Locking/Unlocking the lifting limit switch..................................................789
			Locking........................................................................................789
			Removing the lock..............................................................................790
		13.8.8 Anemometer and air traffic control light....................................................791
			Installing.....................................................................................791
			Removing.......................................................................................792
	13.9 Other rigging work................................................................................793
		13.9.1 Folding mirrors in and out and adjusting them...............................................793
		13.9.2 Installing/removing the heavy duty equipment................................................795
			Additional equipment required..................................................................795
			Equipment required............................................................................795
			Installing.....................................................................................796
			Maximum reeving................................................................................797
			Removing.......................................................................................798
14 Driving the rigged truck crane..........................................................................801
	14.1 Route.............................................................................................801
	14.2 Permissible rigging modes and axle loads..........................................................802
		Axle load table....................................................................................802
	14.3 Before driving....................................................................................804
		14.3.1 Secure superstructure so it cannot slew.....................................................804
		14.3.2 Checking the tyre pressure and the wind speed...............................................804
		14.3.3 Putting the truck crane on the wheels.......................................................805
		14.3.4 Transmission/Connections....................................................................807
			Transmission...................................................................................807
			Connections....................................................................................807
	14.4 While driving.....................................................................................807
	14.5 After driving.....................................................................................808
15 Malfunctions during crane operation.....................................................................811
	15.1 Emergency stop devices............................................................................811
	15.2 What to do when a malfunction occurs during crane operation.......................................813
		Load can be lowered................................................................................813
		Load cannot be lowered.............................................................................813
	15.3 Fuses on the superstructure.......................................................................815
		Notes on changing fuses............................................................................815
		15.3.1 Fuses on the turntable......................................................................816
			Fuse groups F1/F2..............................................................................816
			Fuses on the circuit board.....................................................................818
			Fuses on I/O circuit boards....................................................................818
		15.3.2 Fuses in the crane cab......................................................................819
		15.3.3 Fuses in the battery box....................................................................821
		15.3.4 SLI fuses...................................................................................822
	15.4 Finding and eliminating malfunctions..............................................................825
		15.4.1 Malfunctions on the engine for crane operation..............................................825
		15.4.2 Malfunctions when operating with the hand-held control......................................827
		15.4.3 Malfunctions on the main hoist/auxiliary hoist..............................................828
		15.4.4 Malfunctions on the derricking gear.........................................................829
		15.4.5 Malfunctions on the slewing gear............................................................830
		15.4.6 Malfunctions on the counterweight hoist unit................................................831
		15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler...................................832
		15.4.8 Malfunctions during the inclination of the crane cab........................................832
		15.4.9 Malfunctions in the telescoping mechanism...................................................833
			Telescoping mechanism error messages...........................................................835
		15.4.10 Malfunctions on the outriggers.............................................................836
		15.4.11 Troubleshooting on the SLI.................................................................837
			General malfunctions...........................................................................837
			Error messages in the Monitoring submenu.......................................................838
			Displays in the Errors submenu................................................................840
			Table of error codes...........................................................................842
			Switch off sensor/ tachogenerator..............................................................845
		15.4.12 Malfunctions ECOS – superstructure.........................................................846
			ECOS program version...........................................................................846
			General malfunctions...........................................................................846
			Error messages.................................................................................847
			Exiting the submenu............................................................................848
	15.5 Emergency operations and programs.................................................................849
		15.5.1 Mechanical emergency operation for retracting...............................................850
			Check prior to the emergency operation.........................................................850
			Procedure......................................................................................850
			Mechanical emergency operation.................................................................851
		15.5.2 Telescoping emergency program...............................................................853
			Starting the emergency program.................................................................853
			Determining the type of error..................................................................854
			If there is an error on the length indicator...................................................855
			If there is an error on a proximity switch.....................................................859
			Terminating the emergency program..............................................................860
			Tables for approaching the locking points......................................................861
		15.5.3 Entering the current telescoping............................................................863
		15.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....865
			Preparations...................................................................................865
			Operating a power unit.........................................................................866
			Stopping movements.............................................................................868
			Stopping movements in emergencies..............................................................868
			Turning off the engine........................................................................868
	15.6 Hydraulic emergency operation.....................................................................869
		15.6.1 Important instructions for hydraulic emergency operation....................................869
		15.6.2 Operating principle and accessories.........................................................871
			For emergency operation.......................................................................871
			For the emergency supply.......................................................................872
		15.6.3 Connecting/Disconnecting hoses..............................................................873
			Establishing connections.......................................................................873
			Disconnecting..................................................................................874
		15.6.4 Activating/Deactivating emergency mode......................................................875
		15.6.5 Establishing the required hydraulic circuits................................................876
			Switching over valves..........................................................................876
			For lifting/lowering...........................................................................878
			For slewing....................................................................................879
		15.6.6 Carrying out emergency operation............................................................880
			Lifting/Lowering in emergency mode.............................................................880
			Slewing in emergency mode......................................................................881
			Raising/Lowering in emergency mode.............................................................882
		15.6.7 After emergency operation...................................................................883
			Switching off emergency operation..............................................................883
			Switching over the crane operation.............................................................883
			Disconnecting the hoses........................................................................883
		15.6.8 Emergency supply of another crane...........................................................884
			For emergency supply...........................................................................884
			After emergency supply.........................................................................884
16 Technical information for the superstructure............................................................887
	16.1 Technical data....................................................................................887
		16.1.1 Maximum lifting capacity (DIN/ISO/EN).......................................................887
		16.1.2 Maximum lifting capacity (ASME B 30.5)......................................................887
		16.1.3 Dimensions and weights of the truck crane, axle loads.......................................888
		16.1.4 Dimensions and weights of removable parts...................................................888
			Hook blocks and hook tackle....................................................................888
			Counterweight parts............................................................................889
			Heavy duty equipment..........................................................................889
			Auxiliary hoist................................................................................889
		16.1.5 Superstructure..............................................................................890
			Engine.........................................................................................890
			Main hoist.....................................................................................890
			Auxiliary hoist................................................................................890
			Slewing gears..................................................................................891
			Derricking gear................................................................................891
			Main boom......................................................................................891
			Lattice extension..............................................................................891
			Operating speeds...............................................................................892
17 Index...................................................................................................895
	A......................................................................................................897
	B......................................................................................................897
	C......................................................................................................898
	D......................................................................................................900
	E......................................................................................................901
	F......................................................................................................903
	H......................................................................................................903
	I......................................................................................................904
	K......................................................................................................905
	L......................................................................................................905
	M......................................................................................................905
	O......................................................................................................906
	P......................................................................................................907
	R......................................................................................................907
	S......................................................................................................909
	T......................................................................................................910
	V......................................................................................................912
	W......................................................................................................912

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