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Grove Crane GMK 6220 L Carrier Operating Instruction Manual 2084715 – PDF DOWNLOAD
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Description
Grove Crane GMK 6220 L Carrier Operating Instruction Manual 2084715 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6220 L Carrier Operating Instruction Manual 2084715 – PDF DOWNLOAD
Language : English
Pages : 808
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 6220 L Carrier Operating Instruction Manual 2084715 – PDF DOWNLOAD
Overview:
1.1 Vehicle identification:
These operating instructions are intended only for the truck crane whose serial number is specified on the front cover.
The following plates and numbers have been fitted to the truck crane for identification:
1 the chassis number on the front right-hand side behind the first axle line,
2 the model plate on the passenger seat console containing the chassis number and designation of the crane model,
3 the name plate at the front of the crane operator’s cab containing serial number and designation of the crane model,
4 the CE mark on the name plate.
The location of ID numbers for removable rigging parts (e.g. counterweights, lattice extension, auxiliary hoist) is specified in the corresponding chapters.
Overview and contents of truck crane user information
1.3.1 Operating instructions
- These instructions contain the information required to operate the truck crane.
The operating instructions are divided into two parts. Part 1 with chapters 1 to 10 contains the
description of the vehicle parts of the truck crane, Part 2 with chapters 11 to 18 contains the
description of the crane parts. - In Chapter 2 you will find Basic safety instructions. Please read and observe these instructions,
even if you are familiar with the safety manual. The Basic safety instructions are only contained
in this chapter. Special safety instruc- tions that relate to specific hazards are described in the
section containing the operation with which the hazard is associated. - Chapter 3 contains Information for applications engineering. It is intended primarily for the truck
crane operator and those responsible for applications engineering.
This chapter contains
– The qualifications required for those involved in operations planning for the truck crane,
– Special safety instructions,
– Information that is relevant to operations planning.
- In Chapter 4 to 6 you will find information which is necessary for driving the truck crane: a
description of all structural and operational components, clear- ly defined check lists for rigging
modes and work, and the operating instruc- tions for on-road and off-road driving and the removal
and installation of the auxiliary hoist. - Rigging for on-road drivingis described in Chapter 7.
- In Chapter 8 there is information on troubleshooting on the vehicle part of the truck crane.
- Chapter 9 contains the technical description of the individual parts and func- tional elements of
the vehicle parts as well as the technical data. - Chapter 10 contains the Index. This helps you when you are looking for cer-
tain procedures and terms in the operating instructions.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 6220 L Carrier Operating Instruction Manual 2084715 – PDF DOWNLOAD
GMK 6220-L ............................................................................................................. 1 Operating instructions Part 1 Carrier............................................................................... 1 1 Overview...................................................................................................... 7 1.1 Vehicle identification.................................................................................. 7 1.2 EC Conformity Declaration............................................................................... 10 1.3 Overview and contents of truck crane user information................................................... 11 1.3.1 Operating instructions............................................................................ 11 1.3.2 Operating instructions for the lattice extension (additionalequipment)........................... 12 1.3.3 Maintenance manual................................................................................ 12 1.3.4 Lifting capacity tables........................................................................... 13 1.3.5 Outrigger pressure tables......................................................................... 13 1.3.6 Safety manual..................................................................................... 13 1.3.7 Circuit diagrams.................................................................................. 13 1.3.8 Spare parts list.................................................................................. 14 1.4 Instructions for using this documentation............................................................... 14 1.4.1 How are the operating instructions laid out?...................................................... 14 1.4.2 How are the pages of the operating instructions formatted?........................................ 15 1.4.3 How can I find the necessary information quickly and easily?...................................... 16 Example of cross- reference usage................................................................... 17 How to use the index............................................................................... 22 1.4.4 Definition of stated directions................................................................... 22 Basic rule.......................................................................................... 22 Buttons and switches............................................................................... 22 1.4.5 Conversion table for US measurements.............................................................. 23 2 Basic safety instructions for crane operators................................................................. 27 2.1 Warnings and symbols.................................................................................... 27 2.2 Intended use............................................................................................ 28 2.3 Organisational measures................................................................................. 30 2.4 Personnel qualifications................................................................................ 32 2.5 Safety instructions that apply to truck crane driving................................................... 33 2.6 Safety instructions for truck crane work................................................................ 33 3 Information for operations planning........................................................................... 37 3.1 Safety instructions..................................................................................... 37 3.1.1 Intended use...................................................................................... 37 3.1.2 Organisational measures........................................................................... 37 3.1.3 Personnel qualifications.......................................................................... 38 3.2 Operations planning..................................................................................... 39 3.2.1 Prerequisites for operations planning............................................................. 39 3.2.2 Information for operations planning contained in the information for use ........................ 40 4 Description of the truck crane – Vehicle section.............................................................. 43 4.1 Overview of the operating and display instruments....................................................... 43 4.1.1 Vehicle overview.................................................................................. 43 4.1.2 Driver's cab overview............................................................................. 46 Above the front window.............................................................................. 48 4.1.3 Front instrument panel............................................................................ 50 4.1.4 Side instrument panel............................................................................. 58 4.1.5 Switch boxes for outrigger box locking pin (additionalequipment)................................. 64 4.2 Functional description of the display and operatingelements........................................... 65 4.2.1 On the instrument panels.......................................................................... 65 Vehicle engine...................................................................................... 65 Automatic gearbox.................................................................................. 66 Transfer case....................................................................................... 69 Axle drive.......................................................................................... 69 Brakes.............................................................................................. 71 Suspension.......................................................................................... 72 Hydraulic system.................................................................................... 73 Steering............................................................................................ 74 Electrics........................................................................................... 75 Level adjustment system............................................................................ 77 Heating system in the driver's cab.................................................................. 78 Auxiliary heater with timer (additional equipment)................................................. 80 Air-conditioning system (additional equipment)...................................................... 81 Cab lighting........................................................................................ 83 Other operating instruments........................................................................ 83 4.2.2 Other operating instruments in the vehicle section................................................ 84 Keys, doors, windows................................................................................ 84 Access ladders...................................................................................... 85 Ladders............................................................................................. 86 Vehicle engine diagnostics plug..................................................................... 87 Fire extinguisher (additional equipment)............................................................ 88 Folding berth (additional equipment)................................................................ 88 5 Vehicle engine................................................................................................ 91 5.1 Starting/turning off the vehicle engine................................................................. 91 5.1.1 CHECKLIST: Starting the vehicle engine............................................................ 91 5.1.2 CHECKLIST: In winter.............................................................................. 94 5.1.3 Checks prior to starting vehicle engine........................................................... 95 Checking the hydraulic system stop cocks............................................................ 95 Switching on the battery master switch............................................................. 95 Pre-checking the oil level in the automatic gearbox................................................. 96 Checking coolant level.............................................................................. 97 Checking the hydraulic oil level.................................................................... 98 Draining off water from the fuel filter............................................................. 98 Visual inspection of the drive belts................................................................100 Checking the crankcase ventilation.................................................................101 Visual inspection of the combustion air system......................................................102 Checking the overall condition of the vehicle engine...............................................104 Checking the engine oil level......................................................................105 Topping up motoroil...............................................................................105 5.1.4 Refuelling........................................................................................106 5.1.5 Starting the vehicle engine.......................................................................107 Switching on the ignition..........................................................................107 Starting the vehicle engine........................................................................109 5.1.6 Checks after the engine has been started..........................................................112 Checking instruments...............................................................................112 Checking the oillevel in theautomatic gearbox....................................................114 5.1.7 Turning off the vehicle engine....................................................................117 6 Driving the truck crane.......................................................................................121 6.1 Checks on the truck crane before driving................................................................121 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving.......................................121 6.1.2 On-the-road mode table............................................................................125 Axle loads in driving mode..........................................................................126 6.1.3 Checking the condition of the hoist rope..........................................................128 Checking the reservoir of the windscreen washing system...........................................128 Warning plates for vehicle width....................................................................128 Checking the tyres.................................................................................129 Checking the electrical system......................................................................129 Checking the mirror setting........................................................................130 Checking the compressed-air and braking system....................................................130 Checking suspension................................................................................131 Checking on-the- road level........................................................................131 Checking the transverse differential locks..........................................................132 Checking the drive of the second axle line/longitudinal differential locks..........................132 Checking the transfer case..........................................................................132 Checking the steering locks.......................................................................132 Checking the Boom not set down warning lamp.........................................................133 6.1.4 Adjusting the seat and the steering column........................................................134 Adjusting the driver's seat........................................................................134 Adjusting the steering column......................................................................134 6.1.5 Trip recorder.....................................................................................135 Inserting the 24hour disc in the trip recorder.....................................................135 6.2 General operation.......................................................................................137 6.2.1 Operating the automatic gearbox...................................................................137 Transmission mode of the automatic gear box........................................................137 Diagnostics switch automatic gearbox...............................................................139 Driving modes of the automatic gear box............................................................139 Starting and stopping..............................................................................140 What to do when shifting up the automatic gearbox..................................................141 6.2.2 Monitoring the control instruments while driving..................................................142 6.2.3 Driving downhill..................................................................................147 Activating and deactivating the engine brake........................................................147 6.2.4 Driving uphill....................................................................................148 6.2.5 Tempomat..........................................................................................149 Activating the tempomat:...........................................................................149 Driving with the tempomat..........................................................................150 Switching off the Tempomat.........................................................................150 Eddy currentretarder (additional equipment)........................................................150 6.2.6 Parking the truck crane...........................................................................152 Applying the holding brake..........................................................................152 Automatic gearboxinneutral position...............................................................152 Turning off the vehicle engine.....................................................................152 Securing the truck crane against rolling............................................................152 Switch off the battery master switch if the truck crane is idle for a longer period of time.........153 Securing the truck crane against unauthorized use...................................................153 6.3 Off-road driving........................................................................................155 6.3.1 Off-road gear.....................................................................................156 Engaging the offroad gear.........................................................................156 Deactivating the off-road gear.....................................................................156 6.3.2 Drive of the second axle line/longitudinal differential locks.....................................157 Switching on drive/longitudinal differential locks..................................................157 Switching off drive/longitudinal differential locks.................................................158 6.3.3 Transverse differential locks in all driven axle lines............................................159 Activating the transverse differential locks........................................................159 Deactivating the transverse differential locks......................................................160 6.3.4 Level adjustment system...........................................................................161 Activating the level adjustment system..............................................................161 Raising or lowering the entire truck crane..........................................................162 tilting the truck crane lengthwise or crosswise.....................................................163 Bring the truck crane into On- road level...........................................................164 Deactivating the level adjustment system............................................................164 6.3.5 Freeing an immobilized truck crane................................................................165 Freeing the truck crane by its own power..........................................................165 Towing free to the rear............................................................................166 Towing free to the front...........................................................................166 6.4 Separate steering.......................................................................................167 6.4.1 Switching on separate steering....................................................................169 6.4.2 Steering axle lines with separate steering........................................................170 All-wheel steering..................................................................................170 Crab travel mode....................................................................................170 6.4.3 Switching off separate steering and locking the steering..........................................171 Locking the steering in straight ahead position.....................................................171 Locking in other positions..........................................................................172 6.4.4 Matching steering angle...........................................................................173 6.5 Heating and ventilation.................................................................................175 6.5.1 Heating in the driver's cab.......................................................................175 Ventilating the driver's cab........................................................................177 6.5.2 Auxiliary water heating system (additional equipment).............................................178 Preheating the vehicle engine......................................................................178 Preheating the driver's cab........................................................................178 Switching on the auxiliary heating system...........................................................178 Switching off the auxiliary heating system..........................................................179 6.5.3 Auxiliary heater with timer (additional equipment)................................................180 Preheating the diesel engine.......................................................................180 Preheating the driver's cab........................................................................180 Switching the auxiliary heater on/off...............................................................180 Displaying and setting the current time.............................................................181 Switching on and saving the automatic heating start.................................................181 Switching on and saving the switching off...........................................................182 6.5.4 Roof ventilator(additional equipment).............................................................183 6.6 Air-conditioning system (additional equipment)..........................................................185 6.6.1 Switching on......................................................................................185 6.6.2 To switch off.....................................................................................185 6.6.3 Air conditioning..................................................................................186 How to use the air conditioning effectively.........................................................186 Dehumidifying the air in the driver's cab...........................................................187 6.7 Towing a trailer (additional equipment).................................................................189 Effects on the axleloads...............................................................................189 Coupling the trailer...................................................................................190 Connecting the supply lines............................................................................191 Removing supplylines..................................................................................192 Uncoupling the trailer.................................................................................192 Test position of the parking brake when towing a trailer................................................194 7 Rigging for on-road driving...................................................................................197 7.1 Rigging work for driving with a trailer.................................................................199 7.1.1 Switch on slewing gear freewheel..................................................................200 7.1.2 Switching on boom floating position...............................................................202 Setting the main boom down on the trailer...........................................................202 7.1.3 Switching on boom pretensioning...................................................................204 7.2 Rigging the outrigger beams (additional equipment)......................................................207 Equipment...............................................................................................207 7.2.1 CHECKLIST: Removal of support beams...............................................................208 7.2.2 CHECKLIST: Installation of outrigger beams........................................................210 7.2.3 Preparing the truck crane for removal/installation................................................212 Prerequisites for installation/ removal.............................................................212 Preparing the truck crane..........................................................................212 7.2.4 Removing/inserting outrigger pads.................................................................213 Removing outrigger pads.............................................................................213 Inserting outrigger pads............................................................................214 7.2.5 Disconnecting/establishing hydraulic connection...................................................214 Detach the hydraulic connection....................................................................215 Establishing the hydraulic connection...............................................................216 7.2.6 Establishing/disconnecting the electrical connection for the outrigger pressure indicator.........217 7.2.7 Transport position/operating position of the holding angle........................................218 7.2.8 Locking/releasing the sliding cylinder locking pin................................................219 Releasing the locking pin...........................................................................219 Locking the sliding cylinder........................................................................220 7.2.9 Extending/reinserting outrigger beams.............................................................220 Extending the outrigger beams.......................................................................220 Using outrigger beams...............................................................................223 7.2.10 Transporting the outrigger beams/boom pads.......................................................225 7.3 Setting up the rear outrigger box (additional equipment)................................................227 7.3.1 CHECKLIST: Removing the outrigger box.............................................................228 7.3.2 CHECKLIST: Installing the outrigger box...........................................................230 7.3.3 Preparing the truck crane for removal / installation..............................................232 Preparing for removal...............................................................................232 Preparing for installation..........................................................................232 7.3.4 Slinging points on the rear outrigger box.........................................................233 7.3.5 Establishing/disconnecting the electrical connection..............................................234 7.3.6 Breaking/establishing the hydraulic connection....................................................235 Establishing the hydraulic connection...............................................................235 Breaking the hydraulic connection...................................................................235 7.3.7 Attaching/removing the outrigger box with the truck crane.........................................236 Removing the outrigger box.........................................................................237 Attaching the outrigger box........................................................................237 7.3.8 Locking the outrigger box to the carrier, unlocking...............................................238 Locking the outrigger box..........................................................................238 Releasing the locking pin...........................................................................238 Extending and retracting the pins...................................................................239 7.3.9 Establishing/disconnecting the pneumatic connection...............................................239 7.3.10 Slewing with the rear outrigger box removed......................................................240 Prerequisites for slewing...........................................................................240 7.3.11 Transportation on a separate vehicle.............................................................241 7.3.12 Setting down the main boom on a trailer with the rear outrigger box removed......................242 Supporting the truck crane..........................................................................242 Setting down the main boom..........................................................................243 7.4 Rigging the main boom...................................................................................245 Additional equipment required...........................................................................245 7.4.1 CHECKLIST: Removing the main boom.................................................................247 Prerequisites.......................................................................................247 Removing the main boom..............................................................................247 7.4.2 CHECKLIST: Mounting the main boom.................................................................250 Prerequisites.......................................................................................250 Installing the main boom............................................................................250 7.4.3 Supporting the truck crane while installing/removing themainboom................................254 7.4.4 Rigging work with the auxiliary crane.............................................................255 Lifting the main boom from the turntable............................................................255 Lifting the main boom onto the turntable............................................................256 7.4.5 Establishing/disconnecting the hydraulic connection to the lattice extension (additional eq.......257 Breaking the hydraulic connection...................................................................257 Establishing the hydraulic connection...............................................................258 7.4.6 Pulling device on the bottom axle of the boom (additional equipment)..............................259 Bottom axle pin- type keepers.......................................................................259 Hydraulic connection................................................................................260 Retracting/ extending pins..........................................................................261 7.4.7 Locking pin at derricking cylinder head eyelet....................................................262 Operating the lifting equipment.....................................................................262 Retracting/ extending pins..........................................................................264 7.4.8 Hydraulic connections on the main boom............................................................265 Removing/ attaching the guide plates...............................................................266 Establishing hydraulic connection...................................................................266 Breaking the hydraulic connection...................................................................267 7.4.9 Electrical connections on the main boom...........................................................268 7.4.10 Checks following installation of the main boom...................................................269 Hydraulic system check.............................................................................269 Checking the electrical system.....................................................................270 7.4.11 Before road driving..............................................................................272 Securing the derricking cylinder for on-road driving................................................272 Transporting the main boom..........................................................................272 7.4.12 Derricking cylinder pressure relief..............................................................273 Activating pressure relief..........................................................................273 Deactivating pressure relief........................................................................274 7.5 Installing/removing the auxiliary hoist (additional equipment)..........................................275 7.5.1 Slinging points and transport.....................................................................275 Slinging points.....................................................................................275 Transport...........................................................................................276 7.5.2 Mounting the auxiliary hoist......................................................................277 Removing pin- type keeper and pins..................................................................277 Attach the auxiliary hoist to the main hoist........................................................277 Locking the auxiliary hoist.........................................................................278 Establishing hydraulic andelectrical connections..................................................278 7.5.3 Removing the auxiliary hoist......................................................................279 7.5.4 Permitted applications for the auxiliary hoist....................................................280 Replacement for the main hoist......................................................................280 Alternating operation with the main and auxiliary hoists............................................281 8 Malfunctions on the carrier...................................................................................285 8.1 Emergency stop device on carrier........................................................................285 Turning off the vehicle engine.........................................................................285 8.2 Breakdown in road traffic...............................................................................287 8.3 Towing the truck crane..................................................................................289 Towing with running vehicle engine......................................................................289 Towing when the vehicle engine is off..................................................................290 Compressed air supply in the event of engine failure....................................................291 Electric power supply...................................................................................291 Gears...................................................................................................292 Vehicle engine..........................................................................................292 Permanent brake.........................................................................................292 Mechanically releasing the parking brake................................................................293 Towing procedure........................................................................................294 Removing mechanical locking from all spring- loaded brake cylinders.....................................294 Tow starting............................................................................................294 8.4 Wheel change............................................................................................295 Removing a damaged wheel................................................................................295 Removing the wheel from the spare wheel holder..........................................................296 Mounting a damaged wheel on the spare wheel holder......................................................297 Mounting the spare wheel...............................................................................298 8.5 Replace the starter fuel cartridge (additional equipment)...............................................299 8.6 Electrical system.......................................................................................301 8.6.1 Inserts...........................................................................................302 Front plug-in module...............................................................................302 8.6.2 Fuses.............................................................................................304 Groups F1 to F6...................................................................................304 Groups F7 to F9...................................................................................308 8.7 Troubleshooting and remedy..............................................................................311 8.7.1 Vehicle engine malfunctions.......................................................................311 8.7.2 Automatic gearbox malfunctions....................................................................313 8.7.3 Transfer case malfunctions........................................................................314 8.7.4 Differential lock malfunctions....................................................................315 8.7.5 Service brake malfunctions........................................................................316 8.7.6 Steering malfunctions.............................................................................317 8.7.7 Outrigger malfunctions............................................................................318 8.7.8 Suspension locking system malfunctions............................................................318 8.7.9 Level adjustment system malfunctions..............................................................318 8.8 Procedure in the event of malfunctions..................................................................319 8.8.1 Switch the fan thermostat to emergency operation..................................................319 8.8.2 Troubleshooting for malfunctions in the automatic gearbox.........................................320 Resetting the gearbox control.......................................................................320 8.8.3 Emergency operation of the solenoid valves for the outriggers.....................................321 8.8.4 Separate steering emergency operation.............................................................324 Moving the steeringinto on-roaddriving............................................................325 9 Technical information for the carrier.........................................................................329 9.1 Technical description of the carrier....................................................................329 9.1.1 Crane carrier.....................................................................................329 9.1.2 Driver's cab......................................................................................329 9.1.3 Drive units.......................................................................................330 9.1.4 Engine and gearbox cooling system.................................................................330 9.1.5 Hydraulic system..................................................................................330 9.1.6 Steering..........................................................................................331 9.1.7 Suspension system.................................................................................331 9.1.8 Outriggers........................................................................................332 9.1.9 Compressed air system.............................................................................332 9.1.10 Service brake....................................................................................333 9.1.11 Holding brake....................................................................................333 9.1.12 Retarder.........................................................................................333 9.1.13 Secondary consumers..............................................................................334 9.1.14 Towing the crane.................................................................................334 9.1.15 Towing a trailer.................................................................................334 9.1.16 Electrical system................................................................................334 9.1.17 Rotary transmission..............................................................................334 9.2 Technical data..........................................................................................335 9.2.1 Measurements and weights of the truck crane.......................................................336 Dimensions for driving on public roads.............................................................337 9.2.2 Dimensions and weights of removable parts.........................................................338 Spare wheel (additional equipment).................................................................338 Main boom...........................................................................................338 Outriggers..........................................................................................338 9.2.3 Carrier technical data............................................................................339 Vehicle engine......................................................................................339 On-load shift gearbox..............................................................................339 Transfer case.......................................................................................339 Axle lines..........................................................................................339 Steering............................................................................................339 Tyres...............................................................................................340 Vehicle's electrical system.........................................................................340 Tools...............................................................................................340 Outriggers..........................................................................................341 Driving speeds......................................................................................342 Climbing ability....................................................................................342 Turning circle radiuses.............................................................................343 10 Index........................................................................................................347 A...........................................................................................................349 B...........................................................................................................350 C...........................................................................................................350 D...........................................................................................................352 E...........................................................................................................353 F...........................................................................................................354 H...........................................................................................................354 I...........................................................................................................354 K...........................................................................................................355 L...........................................................................................................355 M...........................................................................................................355 O...........................................................................................................356 P...........................................................................................................357 R...........................................................................................................357 S...........................................................................................................358 T...........................................................................................................359 U...........................................................................................................360 V...........................................................................................................361 W...........................................................................................................361 Operating instructions Part 2 Crane operation.......................................................................365 11 Description of the crane section of the truck crane..........................................................371 11.1 Overview of the operating and display instruments......................................................371 11.1.1 Crane section overview...........................................................................371 11.1.2 Overview of crane cab............................................................................374 11.1.3 Instrument panel.................................................................................376 Front instrumentpanel..............................................................................376 Controls and fittings behind the crane driver's seat................................................389 11.1.4 Left-hand control console........................................................................390 11.1.5 Right-hand control console.......................................................................391 11.1.6 Control lever configuration......................................................................392 Version 1 (standard)................................................................................392 Version 2 (additional equipment)....................................................................393 11.1.7 Switch box for operating the outriggers..........................................................394 11.1.8 Counterweight hoisting gear switch unit..........................................................395 11.1.9 Switch box for electronic level..................................................................396 11.2 Functional description of the display and operating elements.........................................397 11.2.1 Working with the crane...........................................................................397 Crane engine........................................................................................397 Outriggeroperation.................................................................................398 Counterweight hoist gear and locking................................................................400 Crane control.......................................................................................402 Main hoist..........................................................................................404 Auxiliary hoist (additional equipment)..............................................................405 Slewing gear........................................................................................406 Derricking gear.....................................................................................407 Telescoping gear....................................................................................408 Safe load indicator................................................................................413 Hydraulic system....................................................................................420 Electricity.........................................................................................420 Other operating instruments........................................................................421 Electronic level in the crane cab...................................................................423 Changeover switch Change over measuring range.......................................................423 Crane cab heating..................................................................................424 Houselock (additional equipment)....................................................................424 Anemometer..........................................................................................425 Outrigger pressure display (additional equipment)...................................................425 Air-conditioning system (additional equipment)......................................................426 11.2.2 Other operating instruments on the crane cab.....................................................427 Doors, keys, windows...............................................................................427 Fire extinguisher (additional equipment)............................................................428 VDO electronics crane engine........................................................................429 11.3 Functional description of the safety devices...........................................................431 11.3.1 Safe load indicator (SLI)........................................................................431 11.3.2 Lowering limit switch............................................................................432 11.3.3 Lifting limit switch.............................................................................433 Overriding lifting limit switch shutdown............................................................433 11.3.4 Dead man's and seat contact switches.............................................................434 12 Crane engine.................................................................................................437 12.1 Starting/turning off the crane engine..................................................................437 12.1.1 CHECKLIST: Starting the crane engine.............................................................437 12.1.2 CHECKLIST: In winter.............................................................................439 12.1.3 Inspections before starting the crane engine.....................................................440 Check the stop cock on the hydraulic system.........................................................440 Switching on the battery master switch.............................................................440 Checking coolant level..............................................................................441 Checking the hydraulic oil level....................................................................442 Checking the oil level in the crane engine........................................................443 Topping up motor oil...............................................................................444 Refuelling..........................................................................................445 Draining off water from the fuel filter.............................................................446 Checking the overall condition of the crane engine.................................................447 12.1.4 Starting the crane engine........................................................................448 Switching on the ignition..........................................................................448 Starting the crane engine..........................................................................449 12.1.5 Inspections after starting the crane engine......................................................452 Checking instruments...............................................................................452 12.2 Switching off the crane engine.........................................................................455 13 Crane operation..............................................................................................459 13.1 Checking the truck crane before working with the crane.................................................459 13.1.1 CHECKLIST: When truck crane is rigged............................................................459 13.1.2 Adjusting the crane operator's seat..............................................................463 13.1.3 Checking the condition of the hoist rope.........................................................464 Checking the reservoir of the windscreen washing system.............................................464 Visual inspection of the entire crane...............................................................464 Check the position of the hoist ropes...............................................................465 Electrical system...................................................................................465 13.1.4 Checking the safety devices......................................................................466 Safe load indicator.................................................................................466 Lifting limit switch................................................................................466 Dead man's switch system............................................................................467 Emergency stop switch for the crane control.........................................................467 13.1.5 Preheating the hydraulic oil.....................................................................468 With an oil temperature of between –15 C and 0 C (5 F and 32 F).................................468 With an oil temperature below –15 C (5 F).........................................................468 13.1.6 Superstructure lock..............................................................................469 Removing the lock..................................................................................470 Engaging the lock..................................................................................470 13.1.7 Houselock (additional equipment).................................................................471 Switching on the houselock..........................................................................471 Switching off the houselock.........................................................................472 13.1.8 Adjust the mirrors...............................................................................473 13.2 Operating the safe load indicator (SLI)................................................................475 13.2.1 Switching on the SLI.............................................................................475 Switching on........................................................................................475 Lamp test on the SLI................................................................................477 Dimmers for the SLI displays........................................................................477 13.2.2 Setting rigging mode.............................................................................478 Setting via the SLI code............................................................................478 Setting using individual components.................................................................478 General instructions................................................................................479 Sequence during setting.............................................................................479 Switching on entry mode.............................................................................480 Entering values.....................................................................................481 Confirming entry....................................................................................483 Accepting values....................................................................................483 Switching over hoists indicator lamps...............................................................484 13.2.3 Checks before working with the crane.............................................................485 13.2.4 During crane work................................................................................487 Continuous displays...............................................................................487 Optional displays..................................................................................488 SLI early warning...................................................................................489 SLI shutdown........................................................................................489 Error message.......................................................................................490 Error messages with additional optical displays.....................................................491 SLIoverride.......................................................................................492 13.3 Crane work with main boom..............................................................................493 13.3.1 External influences during crane operation.......................................................493 Horizontal alignment................................................................................493 Safe distances.....................................................................................493 Effect of wind on crane operations..................................................................494 Anemometer..........................................................................................494 Permissible wind load..............................................................................495 Earthing the load...................................................................................496 13.3.2 Slewing ranges permitted for working with the crane..............................................497 360 slewing range..................................................................................497 Working position 0 to the rear.....................................................................497 13.3.3 Hoists...........................................................................................498 Main hoist..........................................................................................498 Auxiliary hoist (additional equipment)..............................................................501 13.3.4 Derricking gear..................................................................................503 13.3.5 Slewing gear.....................................................................................505 Slewing gear permanent brake........................................................................505 Slewing.............................................................................................505 Slewing speed.......................................................................................506 Tracking the slewing gear...........................................................................506 Maximum permitted slewing speed.....................................................................507 13.3.6 Telescoping gear.................................................................................509 Structure of the chapter............................................................................509 Description of functioning..........................................................................510 Main boom fixed length, intermediate length, telescoping length.....................................511 Telescoping.........................................................................................512 Notes on the telescoping sequence...................................................................515 Check before telescoping for the first time.........................................................515 Function of the control lever.......................................................................516 Example of the procedure for telescoping............................................................518 Checking initial position...........................................................................519 Unlocking the telescoping cylinder..................................................................522 Extending/retracting telescoping cylinder and locking...............................................524 Telescopic section unlocking........................................................................527 Telescoping a telescopic section to a fixed length and locking it...................................529 Telescoping the telescopic section to an intermediate length........................................533 Locking the telescopic section......................................................................534 Telescoping with fully automatic control............................................................535 Example of telescoping with teleautomation.........................................................537 Lowering the main boom for maintenance.............................................................539 Telescoping the main boom into a horizontal position................................................539 13.3.7 High-speed mode..................................................................................540 13.3.8 Menus on the crane control display...............................................................541 Menu display states.................................................................................541 Display telescope status and teleautomation menu....................................................545 Menu power unit speeds/critical load control........................................................545 Menu Access emergency operation.....................................................................549 Display of an error message.........................................................................550 13.3.9 Setting a constant engine speed..................................................................552 13.3.10 Critical load control...........................................................................553 13.3.11 Inclining the crane cab.........................................................................554 13.3.12 Cooling the hydraulic oil.......................................................................555 Standard oil cooler................................................................................555 Additional oil cooler..............................................................................555 13.3.13 Possible movement combinations..................................................................556 13.4 Driving with a rigged crane............................................................................557 13.4.1 Driving route....................................................................................557 13.4.2 Rigging mode and axle loads......................................................................558 Boom positions......................................................................................558 13.4.3 Driving the rigged crane.........................................................................560 Locking the superstructure and engaging the slewing gear permanent brake............................560 Retracting the outrigger...........................................................................560 Switching over the suspension locking system........................................................560 Switching on separate steering......................................................................561 Driving.............................................................................................562 Extending the outrigger............................................................................562 13.5 Work breaks............................................................................................563 13.5.1 Short work breaks................................................................................563 13.5.2 Work breaks lasting more than 8 hours............................................................563 13.6 Crane cab heating and ventilation......................................................................565 13.6.1 Heating the crane cab............................................................................565 Auxiliary water heating system (additional equipment)...............................................566 Switching on the auxiliary heating system...........................................................566 Switching off the auxiliary heating system..........................................................567 13.6.2 Ventilating the crane cab........................................................................568 13.7 Air-conditioning system (additional equipment).........................................................569 13.7.1 Switching on.....................................................................................569 13.7.2 To switch off....................................................................................569 13.7.3 Air-conditioning.................................................................................570 How to use the air conditioning effectively.........................................................570 Dehumidifying the crane cab air.....................................................................571 14 Rigging work.................................................................................................575 14.1 Checklists for rigging work for crane operation with main boom.........................................577 14.1.1 CHECKLIST: Rigging...............................................................................577 14.1.2 CHECKLIST: Unrigging.............................................................................581 14.2 Choosing a suitable site...............................................................................583 14.2.1 Load bearing capacity of the ground and the outrigger............................................583 Enlarging the enlarge...............................................................................585 14.2.2 Safe distance from banks and pits................................................................586 14.2.3 Earthing the truck crane.........................................................................587 Earthing the truck crane............................................................................587 14.2.4 Safe distance from electrical lines..............................................................588 14.3 Rigging work after driving with trailer................................................................591 14.3.1 Switch off slewing gear freewheel (additional equipment).........................................592 Before slewing......................................................................................593 14.3.2 Switching off the boom floating position (additional equipment)..................................594 14.3.3 Switching off boom pre-tensioning (additional equipment).........................................595 14.4 Outriggers.............................................................................................597 14.4.1 CHECKLIST: Extending the outrigger...............................................................597 14.4.2 CHECKLIST: Retracting the outrigger..............................................................599 14.4.3 Outrigger span...................................................................................601 Outrigger span 8.70x8.50m (28.5 x 27.9 ft).......................................................601 Outrigger span 8.70x6.00m (28.5 x 19.7 ft).......................................................602 Outrigger span 8.70x2.68m (28.5x8.8 ft)........................................................602 Outrigger span 8.70x8.50/2.4m (28.5 x 27.9/7.9 ft)...............................................603 14.4.4 Preparing the outrigger..........................................................................604 Aligning the truck crane horizontally...............................................................604 Locking the suspension.............................................................................604 Safety for on-road driving..........................................................................604 Safety during crane operation.......................................................................605 14.4.5 Extending/retracting the outrigger beams.........................................................606 Extend outrigger beams..............................................................................606 Retracting outrigger beam..........................................................................610 14.4.6 Moving the outrigger pads into working/driving position..........................................611 Moving the outrigger pads into working position.....................................................611 Moving the outrigger pads into driving position ...................................................612 14.4.7 Extending/retracting the support cylinders......................................................613 Extending the support cylinders.....................................................................613 Retracting the outrigger cylinders.................................................................614 14.4.8 Aligning the truck crane horizontally............................................................616 Reading the status display..........................................................................616 Switching over the measuring range..................................................................617 Aligning the truck crane horizontally...............................................................617 14.4.9 Outrigger pressure display (additional equipment)................................................618 Reading the status displays.........................................................................618 14.5 Counterweight..........................................................................................619 14.5.1 Counterweight parts and identification...........................................................619 Counterweight parts.................................................................................619 Identification......................................................................................619 14.5.2 Counterweight versions...........................................................................620 14.5.3 Slinging points on the counterweight sections....................................................624 14.5.4 CHECKLIST: Rigging the counterweight.............................................................626 Counterweight unrigging.............................................................................626 14.5.5 CHECKLIST: Unrigging the counterweight...........................................................628 Counterweight unrigging.............................................................................628 14.5.6 Placing counterweight sections...................................................................631 5.4 t base plate on counterweight platform..........................................................631 Stackingcounterweight sections.....................................................................632 14.5.7 Establishing/releasing hydraulic connection......................................................633 Establishing thehydraulic connection.............................................................633 Disconnecting the hydraulic connection..............................................................634 14.5.8 Assembling the counterweight version.............................................................635 14.5.9 3.5 t counterweight section......................................................................640 Equipping with installation rods (additional equipment)............................................640 3.5 t counterweight section locking.................................................................641 14.5.10 Extending/retracting the 5.4 t base plate or raising/lowering the counterweight.................642 Lifting cylinders: extend...........................................................................643 Lifting cylinders: retracting.......................................................................644 14.5.11 Locking/unlocking the counterweight to the turntable............................................644 Hasp positions......................................................................................645 Safety cock.........................................................................................645 Locking the counterweight...........................................................................646 Unlocking the counterweight.........................................................................646 14.5.12 Equipping 3.75t counterweight section (additionalequipment)...................................647 14.5.13 Equipping 3 t counterweight block (additional equipment).......................................648 14.5.14 Slewing with the rigged counterweight...........................................................649 14.6 Rigging work on the main boom..........................................................................651 14.6.1 Hook block on the bumper.........................................................................651 Picking up the hook block...........................................................................651 Attaching the hook block............................................................................652 14.6.2 Hook block on a separate vehicle.................................................................653 Picking up the hook block...........................................................................653 Setting down the hook block and securing the hoist rope for on-road driving.........................654 14.6.3 Reeving and unreeving the hoist rope.............................................................655 Cable end clamp.....................................................................................655 Reeving the hoist rope.............................................................................657 Lifting limit switch on the main boom...............................................................659 14.6.4 Possible reeving methods on the main boom........................................................663 14.6.5 Anemometer.......................................................................................667 Installing the anemometer...........................................................................667 Remove the anemometer..............................................................................668 14.6.6 Rigging heavy duty equipment.....................................................................669 Heavy duty equipment parts..........................................................................669 Equipment required.................................................................................669 Rigging heavy duty equipment........................................................................670 Unrigging heavy duty equipment......................................................................673 Reevings with heavy duty equipment..................................................................675 15 Malfunctions on the superstructure...........................................................................679 15.1 Superstructure emergency stop device...................................................................679 Switching off the crane engine.........................................................................679 Crane control emergency stop switch.....................................................................680 15.2 What to do in the event of a malfunction when working with the crane..................................681 Load cannot be lowered..................................................................................681 15.3 Replace the starter fuel cartridge (additional equipment)..............................................683 15.4 Electrical system......................................................................................685 15.4.1 Plug-in modules and consoles.....................................................................686 15.4.2 Fuses............................................................................................688 Groups F1 to F9...................................................................................688 Groups F10 to F13.................................................................................692 15.4.3 SLI fuses........................................................................................693 Replacing fuses.....................................................................................693 15.5 Troubleshooting and remedy.............................................................................695 15.5.1 Crane engine malfunctions........................................................................695 15.5.2 Main hoist malfunctions..........................................................................696 15.5.3 Auxiliary hoist malfunctions.....................................................................698 15.5.4 Derricking gear malfunctions.....................................................................700 15.5.5 Telescoping gear malfunctions....................................................................702 15.5.6 Slewing gear malfunctions........................................................................704 15.5.7 Locking pin/counterweight lifting gear malfunctions..............................................705 15.5.8 Hydraulic system/hydraulic oil cooler malfunctions...............................................706 15.5.9 Crane control malfunctions.......................................................................706 15.5.10 Malfunctions on the SLI.........................................................................707 Other malfunctions on the SLI.......................................................................707 SLI error message table.............................................................................708 Switch off sensor/ indicator during malfunction.....................................................715 Check that the remaining sensor/ indicator is working..............................................716 Take over telescoping from the values...............................................................717 Checking SLI lines and connections..................................................................718 15.5.11 Emergency retract operation.....................................................................721 Check before each emergency operation...............................................................721 Procedure for retracting telescope..................................................................722 Mechanical emergency operation......................................................................723 Hydraulic emergency operation.......................................................................725 15.6 Crane control error messages...........................................................................737 15.6.1 Error messages concerning control units..........................................................737 15.6.2 Error messages concerning power units............................................................738 Defective a defective part..........................................................................739 Determining the area of error.......................................................................740 Error causes and effects............................................................................741 15.6.3 Telescoping error messages.......................................................................743 15.6.4 Changing the connections in the control units....................................................744 Connections and control units.......................................................................744 Unrigging truck crane with defective control unit...................................................744 Plugging in and removing connections................................................................747 15.6.5 Control lever emergency program..................................................................748 Indication on the display...........................................................................748 Executing emergency program.........................................................................749 15.6.6 Emergency operation submenu......................................................................750 Retracting with an error on the length indicator....................................................751 Retracting with an error on the proximity switch....................................................754 Table for approaching the locking points............................................................755 15.6.7 Menu Entering telescope status after emergency operation.........................................756 15.7 Hydraulic emergency stop according to ZH1/461 (additional equipment)...................................759 15.7.1 Important instructions for hydraulic emergency operation.........................................759 15.7.2 Functioning and accessories......................................................................761 15.7.3 Connecting the transformer.......................................................................762 15.7.4 Switching emergency operation on/off.............................................................763 15.7.5 Establishing required hydraulic circuits.........................................................764 Make connections on the plug-in field...............................................................764 Additional switches for hoisting gear and slewing gear.............................................765 15.7.6 Executing emergency operation....................................................................766 Driving hoisting gear emergency operation...........................................................766 Emergency operation driving derricking gear.........................................................767 Emergency operation driving the slewing gear........................................................767 15.7.7 After the emergency operation....................................................................768 16 Technical information for superstructure.....................................................................771 16.1 Technical description of the superstructure............................................................771 16.1.1 Turntable........................................................................................771 16.1.2 Crane operator's cab.............................................................................771 16.1.3 Crane engine and hydraulic system................................................................772 16.1.4 Control system...................................................................................772 16.1.5 Main boom........................................................................................773 16.1.6 Telescoping gear.................................................................................773 16.1.7 Hoists...........................................................................................774 16.1.8 Slewing gear.....................................................................................774 16.1.9 Houselock (additional equipment).................................................................774 16.1.10 Derricking cylinder.............................................................................775 16.1.11 Electrical system...............................................................................775 16.1.12 Counterweight...................................................................................775 16.1.13 Safety devices..................................................................................776 16.2 Technical data.........................................................................................777 16.2.1 Maximum lifting capacity.........................................................................777 DIN/ISO/EN..........................................................................................777 ANSI B 30.5 (85%)...................................................................................777 16.2.2 Guaranteed value specifications..................................................................777 16.2.3 Dimensions and weights of the truck crane........................................................778 Dimensions for driving on public roads.............................................................779 16.2.4 Dimensions and weights of removable parts........................................................780 Counterweightparts.................................................................................780 Hook blocks and hook tackle.........................................................................781 Auxiliary hoist.....................................................................................781 Main boom...........................................................................................782 Heavy duty equipment................................................................................782 Counterweight versions..............................................................................782 16.2.5 Technical data for superstructure................................................................786 Switching off.......................................................................................786 Crane's electrical system...........................................................................786 Main hoist..........................................................................................786 Auxiliary hoist(additional equipment)...............................................................787 Slewing gear........................................................................................787 Derricking gear.....................................................................................787 main boom...........................................................................................787 Operating speeds and times without a load..........................................................788 17 Index........................................................................................................791 A...........................................................................................................793 B...........................................................................................................794 C...........................................................................................................794 D...........................................................................................................796 E...........................................................................................................797 F...........................................................................................................798 H...........................................................................................................798 I...........................................................................................................798 K...........................................................................................................799 L...........................................................................................................799 M...........................................................................................................799 O...........................................................................................................800 P...........................................................................................................801 R...........................................................................................................801 S...........................................................................................................802 T...........................................................................................................803 U...........................................................................................................804 V...........................................................................................................805 W...........................................................................................................805
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