Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112996 – PDF DOWNLOAD
$34.95
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112996 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112996 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112996 – PDF DOWNLOAD
Language : English
Pages : 910
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112996 – PDF DOWNLOAD
Basic safety instructions:
Intended use:
- The GMK 5220 truck crane is constructed in accordance with the latest tech- nology and the
recognised safety regulations. Nevertheless, the operator or third parties can still be endangered
and the crane or other property put at risk while using it. - The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
- The GMK 5220 truck crane may only be used when it is in perfect technical condition and for its
intended purpose and with due attention paid to safe operation and possible hazards.
Any malfunctions that could impair safety must be eliminated immediately. - Without the corresponding special equipment, the GMK 5220 truck crane may only be operated within
the permitted temperature range; à Technical
data, p. 1 – 7. - The GMK 5220 truck crane is designed solely for lifting loads which are within the permitted GMK
5220 lifting capacities. The load must be slung as prescribed to a hook block which is positioned
vertically over the load prior to lifting.
Intended use also includes
– observing the entire crane documentation, consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– adhering to the inspection and maintenance requirements specified in the maintenance manual.
The GMK 5220 may only be operated with parts of equipment which are permitted by Manitowoc Crane
Group Germany GmbH and which are labelled with the serial number of the GMK 5220.
The manufacturer is not liable for any damage caused by improper or unauthorized use of the GMK
5220 truck crane. The user alone bears the
risk.
TABLE OF CONTENTS:
Grove Crane GMK 5220 Driving Operating Instructions Manual 3112996 – PDF DOWNLOAD
1 Overview................................................................................................. 7 1.1 Accidents.......................................................................................... 7 1.2 Branch offices..................................................................................... 9 1.2.1 Manitowoc Crane Care......................................................................... 9 1.2.2 Dealer list.................................................................................. 9 1.3 Warranty specifications............................................................................ 9 1.4 Terms used......................................................................................... 10 1.5 Technical data..................................................................................... 13 1.5.1 Maximum lifting capacity (DIN/ISO/EN)........................................................ 13 1.5.2 Maximum lifting capacity (ASME B 30.5)....................................................... 13 1.5.3 Dimensions and weights of the truck crane, axle loads........................................ 14 Dimensions..................................................................................... 15 Weight and axle loads.......................................................................... 15 1.5.4 Dimensions and weights of removable parts.................................................... 16 Spare wheel.................................................................................... 16 Outriggers..................................................................................... 16 Hook blocks and hook tackle.................................................................... 17 Counterweight parts............................................................................ 17 Heavy duty equipment........................................................................... 18 Main boom...................................................................................... 18 Auxiliary hoist................................................................................ 18 1.5.5 Carrier...................................................................................... 19 Engine......................................................................................... 19 Gears.......................................................................................... 19 Transfer case.................................................................................. 19 Axle lines..................................................................................... 20 Steering....................................................................................... 20 Tyres.......................................................................................... 20 Outriggers..................................................................................... 21 Vehicle electrical system...................................................................... 21 Tool........................................................................................... 21 Towing couplings............................................................................... 21 Driving speeds................................................................................. 22 Climbing ability............................................................................... 22 Turning radii.................................................................................. 22 1.5.6 Superstructure............................................................................... 23 Engine......................................................................................... 23 Main hoist..................................................................................... 23 Auxiliary hoist................................................................................ 23 Slewing gears.................................................................................. 24 Derricking gear................................................................................ 24 Main boom...................................................................................... 24 Lattice extension.............................................................................. 24 Operating speeds............................................................................... 25 1.6 Documentation supplied............................................................................. 27 1.6.1 Questions on documentation................................................................... 28 1.7 Notes on the operating instructions................................................................ 29 1.7.1 What do the symbols used mean?............................................................... 29 1.7.2 How are the operating instructions structured?............................................... 31 Division....................................................................................... 31 Structure of the chapters...................................................................... 31 Structure of the pages......................................................................... 32 1.7.3 How do I find the information I need?........................................................ 33 Cross-references example....................................................................... 34 1.7.4 What information is available for operations planning?....................................... 36 1.8 Conversion table for US measuring units............................................................ 37 1.9 Training – Information............................................................................. 39 1.10 Identification.................................................................................... 40 1.11 EC Declaration of Conformity...................................................................... 42 2 Basic safety instructions................................................................................ 45 2.1 Intended use....................................................................................... 45 2.1.1 Improper use................................................................................. 46 2.2 Organisational measures............................................................................ 47 2.3 Personnel qualifications........................................................................... 49 2.4 Safety instructions for driving the truck crane.................................................... 50 2.5 Safety instructions for crane operation............................................................ 51 2.6 Notes on transporting persons...................................................................... 53 Equipment for lifting persons...................................................................... 53 Personnel.......................................................................................... 53 Operation.......................................................................................... 54 Truck crane........................................................................................ 55 3 Operating elements for driving........................................................................... 59 3.1 Overview of the operating elements................................................................. 59 3.1.1 On the outside of the truck crane............................................................ 60 3.1.2 In the driver's cab.......................................................................... 62 Top view of driver's cab....................................................................... 62 Below in the driver's cab...................................................................... 64 Overhead in the driver's cab................................................................... 65 Behind the cover............................................................................... 66 3.1.3 Front instrument panel....................................................................... 67 Left........................................................................................... 67 Middle......................................................................................... 68 Right.......................................................................................... 69 3.1.4 ECOS control unit............................................................................ 70 3.1.5 ECOS display – main menu..................................................................... 72 3.1.6 ECOS display – submenus...................................................................... 74 Level adjustment system submenu................................................................ 74 Settings submenu............................................................................... 76 Monitoring submenu............................................................................. 77 Warning submenu................................................................................ 78 Operating hours submenu........................................................................ 80 Errors submenu................................................................................. 81 3.1.7 Side instrument panel........................................................................ 82 Standard heating............................................................................... 83 Auxiliary water heater......................................................................... 84 Auxiliary air heater........................................................................... 85 3.1.8 Gears........................................................................................ 86 3.1.9 Steering column.............................................................................. 87 3.1.10 Sockets for hand-held control............................................................... 88 3.1.11 Outrigger control units..................................................................... 89 3.2 Short description of the operating elements........................................................ 91 3.2.1 Definition of direction information.......................................................... 91 Basic rule..................................................................................... 91 Switches and buttons........................................................................... 92 3.2.2 General notes on the operating elements...................................................... 92 3.2.3 General rules for buttons and symbols on the display......................................... 93 3.2.4 Engine....................................................................................... 94 Steering column................................................................................ 94 Multipurpose switch............................................................................ 94 Instrument panels.............................................................................. 95 3.2.5 DEF system................................................................................... 96 Instrument panel............................................................................... 96 3.2.6 Electrical system/electronics................................................................ 97 Electrical system.............................................................................. 97 3.2.7 ECOS crane control........................................................................... 97 Control unit................................................................................... 97 Instrument panel...............................................................................100 3.2.8 Transmission.................................................................................101 ECOS display...................................................................................101 Side instrument panel..........................................................................102 3.2.9 Reverse camera...............................................................................105 Submenu for reverse camera.....................................................................105 3.2.10 Transfer case...............................................................................106 3.2.11 Final drive.................................................................................107 3.2.12 Brakes......................................................................................109 Service brake..................................................................................109 Parking brake..................................................................................110 Additional brakes..............................................................................111 3.2.13 Normal steering mode/separate steering......................................................112 Instrument panels..............................................................................112 ECOS display...................................................................................113 Driver's door..................................................................................114 3.2.14 Suspension..................................................................................115 3.2.15 Lighting/windscreen wipers/horn.............................................................116 Steering column................................................................................116 Instrument panels..............................................................................116 Overhead in the driver's cab...................................................................118 3.2.16 Level adjustment system.....................................................................119 3.2.17 Tachograph/speedometer......................................................................121 Tachograph.....................................................................................121 Speedometer....................................................................................121 3.2.18 Roof ventilator.............................................................................122 3.2.19 Diagnostics.................................................................................123 Connections/ buttons...........................................................................123 Displays/ submenu..............................................................................123 3.2.20 Windows, doors, keys........................................................................124 Windows........................................................................................124 Doors..........................................................................................125 Keys...........................................................................................126 3.2.21 Front flap..................................................................................126 4 Starting/turning off the engine for driving..............................................................129 4.1 Starting the engine from the driver's cab..........................................................129 4.1.1 CHECKLIST: Starting the engine...............................................................129 4.1.2 CHECKLIST: At low temperatures...............................................................132 4.1.3 Access ladders and ladders...................................................................132 Access ladders.................................................................................132 Ladders........................................................................................133 4.1.4 Refuel.......................................................................................135 Fuel tank......................................................................................135 DEF tank.......................................................................................136 Tank – auxiliary heater........................................................................137 4.1.5 Checks before starting the engine............................................................138 On hydraulic tank..............................................................................138 Battery master switch..........................................................................138 Checking hand- held control....................................................................139 4.1.6 Switching on the ignition....................................................................139 4.1.7 Lamp test/switching state equalisation.......................................................140 Lamp test......................................................................................140 Equalisation of the switching states...........................................................141 4.1.8 Adjusting display brightness.................................................................142 4.1.9 Starting the engine..........................................................................143 Without flame start system.....................................................................144 With flame start system........................................................................145 4.1.10 Checks after starting the engine............................................................146 Checking in the main menu......................................................................146 Checking the instrument panels.................................................................147 4.1.11 Monitoring submenu..........................................................................148 4.1.12 Setting idling speed........................................................................149 4.2 Turning off the engine.............................................................................151 4.2.1 During normal operation, with the ignition lock/with the hand- held control..................151 Hand-held control not connected................................................................151 Hand-held control connected....................................................................151 After turning off..............................................................................151 4.2.2 With emergency stop switches in emergencies..................................................152 Resetting the emergency stop switch............................................................152 4.3 Air intake inhibitor...............................................................................153 Releasing the air intake inhibitor.................................................................153 5 Driving..................................................................................................157 5.1 Before driving.....................................................................................157 5.1.1 CHECKLIST: Checks before on-road driving.....................................................157 5.1.2 Checking the condition of the truck crane....................................................163 Warning plates for vehicle width...............................................................163 Electrical system..............................................................................163 Adjusting the mirrors..........................................................................164 Reverse camera.................................................................................165 Checking the vehicle height....................................................................165 Checking the compressed air and brake systems..................................................166 5.1.3 Adjusting the seat and the steering column...................................................168 Driver's seat..................................................................................168 Passenger's seat...............................................................................169 Steering column................................................................................170 5.1.4 Switching the suspension on/off..............................................................171 Opening the submenu............................................................................171 Switching on the suspension....................................................................172 Switching off the suspension...................................................................172 5.1.5 Setting the tachograph.......................................................................173 Prerequisites..................................................................................173 Display of error messages......................................................................173 Setting the tachograph.........................................................................174 5.1.6 Displaying the operating hours...............................................................178 5.2 Operating the transmission.........................................................................179 5.2.1 Switching on.................................................................................179 5.2.2 Switching the transmission to neutral position...............................................180 While driving..................................................................................180 5.2.3 Changing the driving mode....................................................................181 5.2.4 Selecting the driving direction..............................................................181 5.2.5 Changing highest gear/starting gear..........................................................183 5.2.6 Starting.....................................................................................183 5.2.7 Driving and changing gears...................................................................184 5.2.8 Changing the driving direction...............................................................185 5.2.9 Stopping.....................................................................................185 Stopping for a long period of time.............................................................185 5.2.10 On the roller type dynamometer..............................................................186 5.2.11 Oil level gauge.............................................................................186 5.3 Driving and turning off the truck crane............................................................189 5.3.1 Checks while driving.........................................................................189 Immediately after you start to move............................................................189 While driving..................................................................................190 5.3.2 Tempomat.....................................................................................193 Switching on the Tempomat......................................................................193 Driving with the Tempomat......................................................................193 Switching off the Tempomat.....................................................................194 5.3.3 Temposet.....................................................................................195 Switching Temposet on..........................................................................195 Driving with the Temposet......................................................................195 Switching Temposet off.........................................................................195 5.3.4 Driving downhill.............................................................................196 Starting.......................................................................................196 Checks when driving downhill...................................................................196 Shifting down from the highest gear............................................................197 Additional brakes..............................................................................198 5.3.5 Driving uphill...............................................................................199 Starting.......................................................................................199 Driving........................................................................................199 5.3.6 Warning submenu..............................................................................200 Opening the submenu............................................................................200 Meaning of the symbols.........................................................................201 Exiting the submenu............................................................................204 5.3.7 Overriding torque reduction..................................................................205 5.3.8 Error submenu................................................................................206 5.3.9 Turning off the truck crane..................................................................206 Securing the truck crane against moving unintentionally........................................207 When stationary for more than 8hours..........................................................208 5.3.10 Folding berth...............................................................................209 5.4 Off-road driving...................................................................................211 Adjustments to the transmission....................................................................211 Connections........................................................................................211 Changing the vehicle level.........................................................................211 Rocking the vehicle free andtowing................................................................211 5.4.1 Transfer case – switching the off-road gear on/off...........................................212 Prerequisites..................................................................................212 Switching on...................................................................................212 Switching off..................................................................................213 Neutral position...............................................................................213 5.4.2 Longitudinal and transverse differential locks...............................................214 5.4.3 Operating the level adjustment system........................................................216 Opening the submenu............................................................................216 Setting the onroad level......................................................................217 Pre-selecting suspension struts................................................................217 Changing the vehicle level.....................................................................218 Viewing the current inclination................................................................218 Exiting the submenu............................................................................219 5.4.4 Freeing truck crane stuck in terrain.........................................................220 Rocking the truck crane free...................................................................220 Towing free forwards...........................................................................221 Towing free in reverse gear....................................................................221 5.5 Separate steering..................................................................................223 5.5.1 Switching on separate steering...............................................................224 5.5.2 Steering with separate steering..............................................................225 Manual.........................................................................................225 Automatic......................................................................................225 5.5.3 Switching off separate steering..............................................................226 5.6 Heating and ventilating the driver's cab...........................................................227 5.6.1 Standard heating system......................................................................227 Switching the heater on and off................................................................227 Setting the temperature........................................................................227 Setting recirculated air/fresh air.............................................................228 Setting the air distribution...................................................................228 Ventilating the driver's cab...................................................................229 5.6.2 Auxiliary water heater.......................................................................230 Preheating the engine..........................................................................230 Preheating the driver's cab....................................................................230 Switching on the auxiliary heater..............................................................231 Switching off the auxiliary heater.............................................................232 Setting time and weekday.......................................................................232 Saving automatic heating start.................................................................233 Setting the heating period.....................................................................234 Switching the automatic heating start on and off...............................................234 Setting the remaining time.....................................................................235 5.6.3 Auxiliary air heater with timer..............................................................236 Switching on the auxiliary heater..............................................................236 Setting the temperature........................................................................237 Switching off the auxiliary heater.............................................................237 Other functions................................................................................237 5.6.4 Air-conditioning system......................................................................238 Switching on...................................................................................238 Setting the air distribution...................................................................238 Switching off..................................................................................239 For pleasant air conditioning..................................................................239 Drying the air in the driver's cab.............................................................240 5.7 Towing a trailer...................................................................................241 Effects on the axle loads..........................................................................241 Coupling the trailer...............................................................................242 Connecting the supply lines........................................................................243 Removing the supply lines..........................................................................244 Uncoupling the trailer.............................................................................244 Checking the braking force.........................................................................246 6 Driving modes and rigging for on-road driving............................................................249 6.1 Driving modes......................................................................................249 Information about the axle loads...................................................................249 6.1.1 Information on how to use the tables.........................................................250 6.1.2 Tables for maximum axle load 12 t (26,500 lbs)...............................................251 6.2 Rigging work for driving with a trailer............................................................253 6.2.1 Switching on the slewing gear freewheel......................................................253 6.2.2 Switching on boom floating position..........................................................255 6.2.3 Switching on boom pre-tensioning.............................................................256 6.2.4 Switching the superstructure driving lights on/off...........................................258 Switching off..................................................................................258 Switching on...................................................................................258 6.3 Rigging the main boom..............................................................................259 Additional equipment required......................................................................259 6.3.1 CHECKLIST: Removing the main boom............................................................260 Prerequisites..................................................................................260 Checklist......................................................................................260 6.3.2 CHECKLIST: Mounting the main boom............................................................263 Prerequisites..................................................................................263 Checklist......................................................................................263 6.3.3 Slinging the main boom.......................................................................266 Marking........................................................................................266 Installing the lifting gear....................................................................266 Removing the lifting gear......................................................................267 6.3.4 Removing/attaching the clamps................................................................268 6.3.5 Switching the pressure relief on/off.........................................................269 6.3.6 Retracting/fitting the derricking cylinder head pin..........................................270 Derricking cylinder support....................................................................270 Operating the lifting device...................................................................270 Retracting the derricking cylinder head axle...................................................271 Fitting the derricking cylinder head axle......................................................272 6.3.7 Retracting/extending the boom pivot pin......................................................273 Before retracting..............................................................................273 After extending................................................................................273 Retracting/ extending the pivot pin............................................................274 6.3.8 Disconnecting the hydraulic/electrical connections...........................................275 Lifting in front of the turntable..............................................................275 Disconnecting..................................................................................276 6.3.9 Establishing the hydraulic/electrical connection.............................................277 Lifting onto the turntable.....................................................................277 Establishing...................................................................................278 6.3.10 Aligning the connecting points..............................................................279 6.3.11 Securing/releasing the derricking cylinder..................................................279 6.3.12 Transporting the main boom..................................................................280 6.3.13 Inspections after main boom mounting........................................................281 6.4 Rigging the outrigger beams........................................................................283 6.4.1 CHECKLIST: Removing the outrigger beams......................................................284 6.4.2 CHECKLIST: Installing the outrigger beams....................................................286 6.4.3 Preparing the truck crane....................................................................289 Prerequisites..................................................................................289 For removal...................................................................................289 6.4.4 Removing/attaching outrigger pads............................................................290 Removing the outrigger pads....................................................................290 Attaching the outrigger pads...................................................................291 6.4.5 Disconnecting/establishing the hydraulic connection..........................................292 6.4.6 Separating/establishing the electrical connection............................................293 6.4.7 Unscrewing/screwing in the spacers...........................................................294 Unscrewing.....................................................................................294 Screwing in....................................................................................295 6.4.8 Separating/establishing the connections to the outrigger box.................................296 6.4.9 Extending/retracting the outrigger beam......................................................296 Extending the outrigger beam...................................................................296 Inserting the outrigger beam...................................................................298 6.4.10 Transporting the outrigger beams............................................................300 6.5 Rigging the auxiliary hoist........................................................................301 6.5.1 Slinging the auxiliary hoist.................................................................301 6.5.2 CHECKLIST: Installing the auxiliary hoist....................................................302 6.5.3 CHECKLIST: Removing the auxiliary hoist......................................................303 6.5.4 Creating/loosening the connection to the turntable...........................................304 6.5.5 Establishing/disconnecting the hydraulic connection..........................................305 6.5.6 Establishing/disconnecting the electrical connection.........................................306 6.5.7 Securing the hoist rope......................................................................307 6.5.8 Transporting the auxiliary hoist.............................................................308 6.5.9 Check that the auxiliary hoist is functioning properly.......................................309 Slewing direction..............................................................................309 Slewing indicator..............................................................................309 7 Malfunctions in driving mode.............................................................................313 7.1 Emergency stop devices.............................................................................313 7.2 What to do when a malfunction occurs in road traffic...............................................315 7.3 Towing the truck crane.............................................................................317 7.3.1 Towing after engine/transmission damage......................................................317 Compressed-air supply..........................................................................318 Electric power supply..........................................................................318 Axle drives....................................................................................318 Transmission...................................................................................318 Transfer case..................................................................................319 Parking brake..................................................................................319 Towing the truck crane out of the danger area.................................................320 7.3.2 Tow starting.................................................................................320 7.4 Wheels and tyres...................................................................................321 7.4.1 Wheel change.................................................................................321 Removing adamaged wheel.......................................................................322 On the spare wheel holder......................................................................322 Mounting a wheel...............................................................................323 7.4.2 Inflating the tyres yourself.................................................................325 Connecting the filling hose....................................................................325 Inflating the tyres............................................................................326 Removing the filling hose......................................................................326 7.5 Fuses on the carrier...............................................................................327 Notes on changing fuses............................................................................327 7.5.1 Fuses in the driver's cab....................................................................328 7.5.2 Fuses in the battery box.....................................................................332 7.5.3 Fuses on I/O circuit boards..................................................................333 7.6 Troubleshooting....................................................................................335 7.6.1 Malfunctions on the engine for driving.......................................................335 7.6.2 Faults on the DEF system.....................................................................337 7.6.3 Differential lock malfunctions...............................................................338 7.6.4 Malfunctions in the transmission.............................................................339 7.6.5 Transfer case malfunctions...................................................................340 7.6.6 Malfunctions of the service brake............................................................340 7.6.7 Malfunctions of the steering.................................................................341 7.6.8 Malfunctions on the suspension...............................................................342 7.6.9 Malfunctions of the level adjustment system..................................................342 7.6.10 Malfunctions of the reverse camera..........................................................343 7.6.11 Malfunctions in the hydraulic system/hydraulic oil cooler...................................343 7.6.12 Malfunctions on the ECOS carrier............................................................345 ECOS program version...........................................................................345 General malfunctions...........................................................................345 Error messages.................................................................................346 Exiting the submenu............................................................................347 Error display on the control units.............................................................348 7.7 Procedure in the event of malfunctions.............................................................349 7.7.1 Switching on emergency operation in coolant circuit..........................................349 7.7.2 Malfunctions on the engine...................................................................350 7.7.3 Malfunctions in the transmission.............................................................351 General malfunctions...........................................................................351 Display E......................................................................................351 Transmission malfunction.......................................................................352 Reading out error codes........................................................................353 7.8 Emergency operation................................................................................355 7.8.1 External starting socket.....................................................................355 Performing a jump start........................................................................356 7.8.2 Battery charger..............................................................................356 8 Index....................................................................................................359 A......................................................................................................361 B......................................................................................................361 C......................................................................................................362 D......................................................................................................364 E......................................................................................................365 F......................................................................................................367 G......................................................................................................368 H......................................................................................................368 I......................................................................................................369 K......................................................................................................369 L......................................................................................................369 M......................................................................................................370 O......................................................................................................371 P......................................................................................................372 R......................................................................................................372 S......................................................................................................373 T......................................................................................................375 V......................................................................................................376 W......................................................................................................376 9 Operating elements for crane operation...................................................................387 9.1 Overview of the operating elements.................................................................387 9.1.1 Exterior of the truck crane..................................................................388 9.1.2 Crane cab....................................................................................392 9.1.3 Front panel..................................................................................394 9.1.4 Side panel...................................................................................395 Below..........................................................................................395 Top............................................................................................396 Console, rear..................................................................................398 Standard heating system........................................................................399 Auxiliary water heater.........................................................................400 Auxiliary air heater...........................................................................401 9.1.5 Control panels...............................................................................402 Left-hand control panel........................................................................402 Right-hand control panel.......................................................................403 9.1.6 Control lever configuration..................................................................404 Version 1......................................................................................404 Version 2......................................................................................405 9.1.7 ECOS control unit............................................................................406 9.1.8 ECOS display – main menu.....................................................................408 9.1.9 ECOS display – submenus......................................................................410 Counterweight submenu..........................................................................410 Slewing gear/ houselock submenu................................................................411 Outriggers submenu.............................................................................412 Telescoping submenu............................................................................414 Power unit speeds submenu......................................................................416 Monitoring submenu.............................................................................417 Settings submenu...............................................................................418 Warning submenu................................................................................420 Operating hours submenu........................................................................422 Error submenu..................................................................................423 Working range limiter submenu.................................................................424 9.1.10 RCL control unit............................................................................426 9.1.11 RCL display – main menu.....................................................................428 9.1.12 RCL display – submenus......................................................................429 Submenu Rigging mode entry.....................................................................429 Monitoring submenu.............................................................................430 Rigging mode monitoring submenu................................................................432 Submenu Lifting capacity table.................................................................433 Working range submenu..........................................................................434 Error submenu..................................................................................435 Settings submenu...............................................................................437 9.1.13 Hand-held control...........................................................................438 Outrigger control panel........................................................................439 9.1.14 Outrigger control units.....................................................................440 Outrigger......................................................................................441 Outrigger pressure display.....................................................................441 Inclination indicator..........................................................................441 9.2 Short description of the operating elements........................................................443 9.2.1 Definition of direction information..........................................................443 Basic rule.....................................................................................443 Switches.......................................................................................443 9.2.2 General rules for buttons and symbols on the display.........................................444 9.2.3 Engine for crane operation...................................................................445 Side panel.....................................................................................445 ECOS display...................................................................................446 9.2.4 DEF system...................................................................................446 ECOS display...................................................................................446 9.2.5 Engine for driving...........................................................................447 Outriggers submenu.............................................................................447 9.2.6 Seat contact switch and dead man's switch....................................................448 9.2.7 ECOS crane control...........................................................................449 Control unit...................................................................................449 9.2.8 Outrigger....................................................................................452 Hand-held control..............................................................................452 In the Outrigger submenu.......................................................................453 In the Settings submenu........................................................................454 On the outrigger control units.................................................................455 9.2.9 Inclination indicators.......................................................................457 9.2.10 Outrigger pressure displays.................................................................458 Outriggers submenu.............................................................................458 Outrigger control units........................................................................458 9.2.11 Anemometer displays.........................................................................458 9.2.12 Counterweight submenu.......................................................................459 Counterweight submenu..........................................................................459 9.2.13 Main hoist..................................................................................462 9.2.14 Auxiliary hoist.............................................................................463 9.2.15 Slewing gear................................................................................464 Control panels.................................................................................464 Submenu........................................................................................465 9.2.16 Derricking gear.............................................................................466 9.2.17 Telescoping mechanism.......................................................................467 Control panels.................................................................................467 Submenu........................................................................................468 In the Settings submenu........................................................................472 9.2.18 Hydraulic system............................................................................474 9.2.19 Houselock...................................................................................475 9.2.20 Rated capacity limiter (RCL)................................................................477 Control unit...................................................................................477 Main menu......................................................................................479 Submenu Rigging mode entry.....................................................................480 Monitoring submenu.............................................................................484 Submenu Lifting capacity table.................................................................487 Working range submenu..........................................................................488 RCL override..................................................................................489 External displays..............................................................................490 9.2.21 Electrical system...........................................................................491 9.2.22 Lighting, windscreen wiper/washing system...................................................491 Lighting.......................................................................................491 Windscreen wiper/washing system................................................................493 9.2.23 Hand-held control...........................................................................494 Hand-held control sockets......................................................................494 Engine control panel...........................................................................495 Horn...........................................................................................495 Outriggers control panel.......................................................................496 9.2.24 Diagnostics.................................................................................498 9.2.25 Windows, doors, keys........................................................................499 Windows........................................................................................499 Crane cab door.................................................................................499 Keys...........................................................................................500 10 Starting/stopping the engine – for crane operation......................................................503 10.1 Starting the engine – from the crane cab..........................................................503 10.1.1 CHECKLIST: Starting the engine..............................................................503 10.1.2 CHECKLIST: At low temperatures..............................................................506 10.1.3 Refuel......................................................................................507 Fuel tank......................................................................................507 DEF tank.......................................................................................508 Tank – auxiliary heater........................................................................509 10.1.4 Checks before starting the engine...........................................................510 On hydraulic tank..............................................................................510 Battery master switch..........................................................................510 Checking the hand-held control.................................................................511 10.1.5 Switching on the ignition...................................................................511 10.1.6 Lamp test...................................................................................512 Lamp test......................................................................................512 10.1.7 Adjusting display brightness................................................................514 10.1.8 Starting the engine.........................................................................515 Without flame start system.....................................................................515 With flame start system........................................................................516 10.1.9 Checks after starting the engine............................................................517 At the ECOS control unit.......................................................................517 On the side panel..............................................................................517 10.1.10 Monitoring submenu.........................................................................519 10.1.11 Setting idling speed.......................................................................520 10.2 Starting the engine – with the hand-held control..................................................521 Prerequisites......................................................................................521 Starting the engine................................................................................521 10.3 Turning off the engine............................................................................523 10.3.1 During normal operation, with the ignition lock/with the handheld control..................523 Hand-held control not connected................................................................523 Hand-held control connected....................................................................523 After turning off..............................................................................523 10.3.2 In emergencies, with the emergency stop switches............................................524 Resetting the emergency stop switch............................................................524 10.4 Air intake inhibitor..............................................................................525 Releasing the air intake inhibitor.................................................................525 11 Crane operation.........................................................................................529 11.1 Before operating the crane........................................................................529 11.1.1 CHECKLIST: Checks before operating the crane................................................529 11.1.2 Checking the condition of the truck crane...................................................533 Visual inspection..............................................................................533 Checking the position of the hoist ropes.......................................................533 Checking the electrical system.................................................................534 11.1.3 Adjusting the crane cab seat and front control panel........................................534 Crane cab seat.................................................................................534 Adjusting the front panel......................................................................535 11.1.4 Checking the safety equipment...............................................................536 Rated capacity limiter.........................................................................536 Lifting limit switch...........................................................................536 Emergency stop switch..........................................................................537 Seat contact switch and dead man's switch......................................................538 11.1.5 Earthing the load...........................................................................539 11.1.6 Preheating the hydraulic oil................................................................540 11.1.7 Locking/unlocking the turntable.............................................................541 11.1.8 Switching the houselock on/off..............................................................542 Switching on the houselock.....................................................................542 Switching off the houselock....................................................................544 11.2 Operation of the rated capacity limiter...........................................................545 11.2.1 Switching on the RCL........................................................................546 Switching on...................................................................................546 Brightness of the displays.....................................................................548 11.2.2 Enter rigging mode..........................................................................549 Entering individual components.................................................................550 Entering the RCL code..........................................................................554 Entering the reeving...........................................................................555 Accepting the rigging mode.....................................................................555 11.2.3 Checks before operating the crane...........................................................557 Opening the submenu............................................................................557 Checks.........................................................................................558 11.2.4 Displays during crane operation.............................................................560 11.2.5 RCL early warning...........................................................................563 11.2.6 RCL shutdown................................................................................563 Shutdown due to overload.......................................................................563 11.2.7 Display in the event of errors..............................................................565 11.2.8 RCL override – version A....................................................................566 11.2.9 RCL override – version B....................................................................567 Overview status display........................................................................567 When rigging...................................................................................568 To raise the boom..............................................................................569 In emergency...................................................................................570 11.2.10 Displaying the lifting capacity tables.....................................................571 11.2.11 Entering the time/date.....................................................................573 11.3 Crane operation with main boom....................................................................575 11.3.1 Checks during crane operation...............................................................575 Horizontal alignment...........................................................................575 Safe distances.................................................................................575 Checking the wind speed........................................................................576 11.3.2 Permissible slewing ranges and working positions for crane operation........................577 360 slewing range.............................................................................577 Working position 0 to the rear................................................................577 180 to the front rigging position.............................................................577 11.3.3 Main hoist..................................................................................579 Switching on the main hoist....................................................................580 Lifting and lowering...........................................................................581 Switching off the main hoist...................................................................581 11.3.4 Auxiliary hoist.............................................................................582 Switching on the auxiliary hoist...............................................................583 Lifting and lowering...........................................................................584 Switching off the auxiliary hoist..............................................................584 11.3.5 Lifting limit switch and lowering limit switch..............................................585 Lifting limit switch...........................................................................585 Lowering limit switch..........................................................................587 11.3.6 Derricking gear.............................................................................588 Switching on the derricking gear...............................................................588 Raising and lowering...........................................................................589 Re-enable raising function.....................................................................590 Switching off the derricking gear..............................................................590 Lowering the main boom to ahorizontal position................................................591 11.3.7 Telescoping mechanism.......................................................................593 Overview.......................................................................................594 Telescoping process............................................................................594 Assignment for display.........................................................................596 Fixed length, intermediate length, telescoping length..........................................598 Telescoping....................................................................................599 Telescoping sequence...........................................................................599 Checks before starting work....................................................................600 Switching on the telescoping mechanism.........................................................601 Function of the control lever..................................................................601 Switching off the telescoping mechanism........................................................603 Manual telescoping.............................................................................604 Checking the initial position..................................................................604 Unlocking the telescoping cylinder.............................................................607 Extending/ retracting the telescoping cylinder.................................................609 Lock telescoping cylinder......................................................................610 Unlocking the telescopic section...............................................................611 Telescoping the telescopic section.............................................................613 Locking the telescopic section.................................................................614 Locking the telescopic section for on-road driving.............................................615 Telescoping with teleautomation................................................................616 Telescoping the main boom when horizontal......................................................620 11.3.8 High-speed mode.............................................................................621 Switch on function.............................................................................621 Derricking gear/ telescoping mechanism.........................................................621 Hoists.........................................................................................622 11.3.9 Slewing gear................................................................................623 Switching on the slewing gear..................................................................623 Slew...........................................................................................624 Braking the slewing movement...................................................................626 Slewing gear freewheel.........................................................................626 Switching off the slewing gear.................................................................626 11.3.10 Possible movement combinations.............................................................627 11.3.11 Hydraulic oil cooling......................................................................628 11.4 Settings and displays for crane operation.........................................................629 11.4.1 Limiting the power unit speeds..............................................................629 11.4.2 Setting the characteristic curves for the control levers....................................631 11.4.3 Inclining the crane cab.....................................................................632 11.4.4 Setting idling speed........................................................................632 11.4.5 Critical load control.......................................................................633 Function.......................................................................................633 Switching on and off...........................................................................633 11.4.6 Adjusting the wiper stroke interval of the windscreen wiper.................................634 11.4.7 Using the slewable spotlights...............................................................635 11.4.8 Displaying the operating hours..............................................................636 11.4.9 Warning submenu.............................................................................637 Opening the submenu............................................................................637 Meaning of the symbols.........................................................................637 Exiting the submenu............................................................................640 11.4.10 Overriding torque reduction................................................................641 11.4.11 Error submenu..............................................................................642 11.5 Working range limiter.............................................................................643 11.5.1 Opening the working range limiter submenu...................................................644 11.5.2 Viewing current settings....................................................................644 11.5.3 Entering limit values.......................................................................646 Overall height/ Working radius.................................................................646 Slewing angle..................................................................................647 Entering objects...............................................................................649 11.5.4 Entering limit values/objects manually......................................................652 Limit values...................................................................................652 Objects........................................................................................653 11.5.5 Switching monitoring functions on/off.......................................................654 11.5.6 Shutdown by working range limiter...........................................................655 11.6 Work break........................................................................................657 11.6.1 In case of short work breaks................................................................657 11.6.2 In case of work breaks of more than 8 hours.................................................658 Securing the truck crane against unauthorised use..............................................658 11.7 Heating and air-conditioning system...............................................................659 11.7.1 Standard heating system.....................................................................659 Switching on...................................................................................659 Heating........................................................................................659 Air distribution...............................................................................660 Switching off..................................................................................661 Warnings.......................................................................................661 Switching on/off...............................................................................662 Cooling........................................................................................662 Drying the air.................................................................................663 11.7.3 Auxiliary water heater......................................................................663 Preheating the engine..........................................................................664 Preheating the crane cab.......................................................................664 Switching on...................................................................................665 Setting the day and time.......................................................................666 Storing the heating start......................................................................667 Setting the heating period.....................................................................668 Switching heating start on/off.................................................................668 Switching off..................................................................................669 Setting the remaining time.....................................................................669 11.7.4 Auxiliary air heater........................................................................670 Switching on...................................................................................670 Temperature....................................................................................671 Switching off..................................................................................671 Other functions................................................................................671 11.8 CraneSTAR system..................................................................................673 11.8.1 Overview....................................................................................673 11.8.2 Position of the components..................................................................673 12 Rigging work............................................................................................677 12.1 Rigging work checklists for crane operation with the main boom....................................677 12.1.1 CHECKLIST: Rigging..........................................................................677 12.1.2 CHECKLIST: Unrigging........................................................................681 12.2 Choosing a suitable site..........................................................................685 12.2.1 Determining the required ground bearing area................................................685 12.2.2 Safe distance from slopes and pits..........................................................688 12.2.3 Earthing the truck crane....................................................................689 12.2.4 Safe distance from electrical cables........................................................690 12.3 Rigging work after driving with a trailer.........................................................693 12.3.1 Switching off the slewing gear freewheel....................................................694 Before slewing.................................................................................694 12.3.2 Switching off the boom floating position....................................................695 12.3.3 Switching off boom pre-tensioning...........................................................696 12.4 Connecting/disconnecting the hand-held control....................................................697 12.5 Starting the engine for driving for rigging work..................................................699 12.5.1 Starting/turning off the engine with the hand-held control..................................699 Prerequisites..................................................................................699 Starting the engine............................................................................700 Turning off the engine.........................................................................700 12.5.2 Starting/turning off the engine from the crane cab..........................................701 Prerequisites..................................................................................701 Starting the engine............................................................................701 After starting the engine......................................................................702 Turning off the engine.........................................................................702 12.6 Outrigger.........................................................................................703 12.6.1 CHECKLIST: Extending the outriggers.........................................................703 12.6.2 CHECKLIST: Retracting the outriggers........................................................705 12.6.3 Permissible outrigger spans.................................................................706 12.6.4 Preparing the truck crane...................................................................707 In the driver's cab............................................................................707 Outrigger control units........................................................................707 12.6.5 Setting the outrigger spans.................................................................708 For on-road driving............................................................................710 12.6.6 Extending/retracting outrigger beams........................................................711 From the control units.........................................................................711 With the handheld control.....................................................................713 From the crane cab.............................................................................715 12.6.7 Moving the outrigger pads into working/driving position.....................................717 12.6.8 Enlarging the ground bearing area...........................................................718 12.6.9 Extending/retracting supporting cylinders...................................................719 From the control units.........................................................................720 With the handheld control.....................................................................721 From the crane cab.............................................................................722 12.6.10 Level the truck crane on outriggers........................................................724 Inclination indicators.........................................................................724 Prerequisites..................................................................................725 Manual alignment...............................................................................726 Automatic alignment............................................................................727 12.6.11 Outrigger pressure display.................................................................729 12.7 Rigging/unrigging the counterweight...............................................................731 12.7.1 Counterweight sections......................................................................731 12.7.2 Identification..............................................................................734 12.7.3 Slinging points.............................................................................735 12.7.4 CHECKLIST: Rigging the counterweight........................................................736 12.7.5 CHECKLIST: Unrigging the counterweight......................................................737 12.7.6 Assembling counterweight combination........................................................738 With version A.................................................................................740 With version B.................................................................................742 12.7.7 Counterweight hoist unit....................................................................744 Counterweight submenu..........................................................................744 Extending/ retracting the lifting cylinders....................................................745 Automatic mode, rigging........................................................................746 Automatic mode, unrigging......................................................................748 Cancel automatic mode..........................................................................750 12.7.8 Screwing the counterweight section to the turntable.........................................751 12.7.9 Slewing with rigged counterweight...........................................................752 12.7.10 Assembling counterweight sections for driving..............................................754 12.8 Rigging work on the main boom.....................................................................755 12.8.1 Hook block on the bumper....................................................................755 Picking up the hook block......................................................................755 Attaching the hook block.......................................................................756 12.8.2 Hook block on a separate vehicle............................................................757 Picking up the hook block......................................................................758 Setting down the hook block....................................................................758 12.8.3 Reeving and unreeving the hoist rope........................................................760 Rope end fitting...............................................................................760 Fastening the rope end clamp...................................................................761 Reeving the hoist rope.........................................................................763 Unreeving the hoist rope.......................................................................766 12.8.4 Possible reeving methods on the main boom...................................................767 With 8 head sheaves............................................................................767 With 9 head sheaves............................................................................771 12.8.5 Installing/removing the lifting limit switch................................................775 Installing the lifting limit switch............................................................775 Removing the lifting limit switch..............................................................778 12.8.6 Locking/unlocking the lifting limit switch..................................................780 Locking........................................................................................780 Removing the lock..............................................................................780 12.8.7 Anemometer and air traffic control light....................................................781 Installing.....................................................................................781 Removing.......................................................................................782 12.9 Other rigging works............................................................................... 0 12.9.1 Folding mirrors in/out and adjusting........................................................ 0 12.9.2 Cameras for crane operation.................................................................784 Cameras on the hoists..........................................................................784 Camera on main boom............................................................................784 Turning the monitor on/off and switching.......................................................786 12.9.3 Installing/removing the heavy duty equipment................................................787 Additional equipment required..................................................................787 Equipment required.............................................................................787 Installing.....................................................................................788 Maximum reeving................................................................................789 Removing.......................................................................................790 13 Driving with rigged truck crane.........................................................................793 13.1 Driving distance..................................................................................793 13.2 Permissible rigging modes and axle loads..........................................................795 Axle load table....................................................................................795 13.3 Before driving....................................................................................797 13.3.1 Secure the counterweight to the turntable...................................................797 13.3.2 Securing the superstructure against slewing.................................................797 13.3.3 Checking tyre pressure and wind speed.......................................................798 13.3.4 Putting the truck crane on the wheels.......................................................799 13.3.5 Gears/connections...........................................................................801 Gears..........................................................................................801 Connections....................................................................................801 13.4 While driving.....................................................................................802 13.5 After driving.....................................................................................803 13.5.1 Restoring to its original condition.........................................................803 13.5.2 Supporting the truck crane..................................................................803 13.5.3 Releasing counterweight.....................................................................804 14 Malfunctions during crane operation.....................................................................807 14.1 Emergency stop devices............................................................................807 14.2 What to do when malfunctions occur during crane operation.........................................809 Load can be lowered................................................................................809 Load cannot be lowered.............................................................................809 14.3 Fuses on the superstructure.......................................................................811 Notes on changing fuses............................................................................811 14.3.1 Fuses on the turntable......................................................................812 Fuse groups F1/F2..............................................................................812 Fuses on the circuit board.....................................................................814 Fuses on I/O circuit boards....................................................................814 14.3.2 Fuses in the crane cab......................................................................815 14.3.3 Fuses in the battery box....................................................................817 14.3.4 RCL fuses...................................................................................819 14.4 Finding and eliminating malfunctions..............................................................821 14.4.1 Malfunctions on the engine for crane operation..............................................821 14.4.2 Faults on the DEF system....................................................................823 14.4.3 Malfunctions when operating with the hand-held control......................................823 14.4.4 Malfunctions on the main hoist/auxiliary hoist..............................................824 14.4.5 Malfunctions in the hoist cameras...........................................................825 14.4.6 Malfunctions in the main boom camera........................................................826 14.4.7 Malfunctions on the derricking gear.........................................................827 14.4.8 Malfunctions on the slewing gear............................................................828 14.4.9 Malfunctions on the counterweight hoist unit................................................829 14.4.10 Malfunctions in the hydraulic system/hydraulic oil cooler..................................830 14.4.11 Malfunctions when inclining the crane cab..................................................830 14.4.12 Malfunctions in the telescoping mechanism..................................................831 Telescoping mechanism error messages...........................................................833 14.4.13 Malfunctions of the outriggers.............................................................834 14.4.14 Troubleshooting the RCL....................................................................835 General malfunctions...........................................................................835 Error messages in the Monitoring submenu.......................................................836 Displays in the Error submenu..................................................................838 Table of error codes..........................................................................840 Switching off thesensor/ tachogenerator.......................................................843 14.4.15 Malfunctions ECOS – superstructure.........................................................844 ECOS programme version.........................................................................844 General malfunctions...........................................................................844 Error messages.................................................................................845 Exiting the submenu............................................................................846 14.4.16 Malfunctions on the CraneSTAR system.......................................................847 14.5 Emergency operations and programmes...............................................................851 14.5.1 Mechanical emergency activation for retracting..............................................852 Prior to the emergency operation, check........................................................852 Procedure......................................................................................852 Mechanical emergency activation................................................................853 14.5.2 Telescoping emergency programme.............................................................855 Starting the emergency program.................................................................855 Determining the error type.....................................................................856 Error on length indicator......................................................................857 If there is an error at a proximity switch.....................................................861 Terminating the emergency program..............................................................862 Tables for approaching the locking points......................................................863 14.5.3 Entering the current telescoping............................................................865 14.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....867 Preparations...................................................................................867 Operating a power unit.........................................................................868 Stopping movements.............................................................................870 Stopping movements in emergencies..............................................................870 Turning off the engine.........................................................................870 14.5.5 Switching on emergency operation in coolant circuit.........................................871 14.6 Hydraulic emergency operation.....................................................................873 14.7 Other emergency operations........................................................................885 14.7.1 External starting socket....................................................................885 Performing a jump start........................................................................886 14.7.2 Battery charger.............................................................................886 15 Index...................................................................................................889 A......................................................................................................891 B......................................................................................................891 C......................................................................................................892 D......................................................................................................894 E......................................................................................................895 F......................................................................................................897 G......................................................................................................898 H......................................................................................................898 I......................................................................................................899 K......................................................................................................899 L......................................................................................................899 M......................................................................................................900 O......................................................................................................901 P......................................................................................................902 R......................................................................................................902 S......................................................................................................903 T......................................................................................................905 V......................................................................................................906 W......................................................................................................906
IMAGES PREVIEW OF THE MANUAL:
Questions? Email us: [email protected]
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V
