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Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084766 – PDF DOWNLOAD
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Description
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084766 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084766 – PDF DOWNLOAD
Language : English
Pages : 790
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084766 – 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.
Operating Instructions:
- These operating instructions contain 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 section of the truck crane; Part 2 with chapters 11 to 18 contains the
Description of the crane section. - In Kapitel 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 contained in
this chapter only. Special safety instruc- tions that relate to specific hazards are described in
the section containing the operation with which the hazard is associated. - Kapitel 3 contains Information for applications engineering. It is intended prima- rily for the
truck crane operator and those responsible for applications engi- neering.
This chapter contains
– the required qualifications of those involved in applications engineering,
– special safety instructions,
– information that is relevant to applications engineering.
- In Kapitel 4 to 6 you will find information required for Driving the truck crane: a description of
all structural and operational components, clearly defined checklists for rigging modes and work,
and the operating instructions for on-road and off-road driving and the removal and installation of
the auxilia- ry hoist. - Rigging for on-road driving is described in Kapitel 7.
- In Kapitel 8, there is information on Troubleshooting on the vehicle section of the truck crane.
- Kapitel 9 contains the Technical description of the individual parts and functio- nal elements of
the vehicle parts as well as the Technical data. - Kapitel 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 Driving Operating Instructions Manual 2084766 – PDF DOWNLOAD
GMK 6220–L ............................................................................................................. 1 Operating instructions Part 1 Driving............................................................................... 1 Additional pages - Emergency operation/Emergency program telescoping ........................................... 3 1 Overview...................................................................................................... 7 1.1 Vehicle identification.................................................................................. 9 1.2 EC declaration of conformity............................................................................ 12 1.3 Overview and contents of truck crane user information................................................... 13 1.3.1 Operating Instructions............................................................................ 13 1.3.2 Lattice extension operating manual (additional equipment)......................................... 14 1.3.3 Maintenance manual................................................................................ 14 1.3.4 Lifting capacity table............................................................................ 15 1.3.5 Outrigger load table.............................................................................. 15 1.3.6 Safety manual..................................................................................... 15 1.3.7 Circuit diagrams.................................................................................. 15 1.3.8 Spare parts list.................................................................................. 16 1.4 Instructions for use of this document................................................................... 16 1.4.1 How are the operating instructions laid out?...................................................... 16 1.4.2 How are the pages of the operating manual formatted?.............................................. 17 1.4.3 How can I find the necessary information quickly and easily?...................................... 18 Example of cross- reference usage................................................................... 19 Explanations of how to use the index............................................................... 24 1.4.4 Definition of direction information............................................................... 24 Basic rule.......................................................................................... 24 Buttons and switches............................................................................... 24 1.4.5 Conversion table for US measurements.............................................................. 25 2 Fundamental safety instructions for crane operators.......................................................... 27 2.1 Warnings and symbols.................................................................................... 29 2.2 Proper use.............................................................................................. 30 2.3 Organisational measures................................................................................. 32 2.4 Personnel qualifications................................................................................ 34 2.5 Safety instructions that apply to truck crane driving................................................... 35 2.6 Safety instructions for truck crane work................................................................ 35 3 Information for applications engineering...................................................................... 37 3.1 Safety instructions..................................................................................... 39 3.1.1 Proper use........................................................................................ 39 3.1.2 Organizational measures........................................................................... 39 3.1.3 Personnel qualifications.......................................................................... 40 3.2 Applications engineering................................................................................ 41 3.2.1 Application engineering requirements.............................................................. 41 3.2.2 Details about applications engineering contained in the user information......................... 42 4 Description of the truck crane – vehicle section.............................................................. 43 4.1 Overview of the operating and display instruments....................................................... 45 4.1.1 Overview of the vehicle........................................................................... 45 4.1.2 Overview of driver’s cab.......................................................................... 48 Over the windscreen................................................................................. 50 4.1.3 Front instrument panel............................................................................ 52 4.1.4 Side instrument panel............................................................................. 60 4.2 Functional description of the display and operating instruments........................................ 67 4.2.1 On the instrument panels.......................................................................... 67 Vehicle engine...................................................................................... 67 Automatic gearbox.................................................................................. 68 Transfer case....................................................................................... 70 Axle drive.......................................................................................... 71 Brakes.............................................................................................. 72 Suspension.......................................................................................... 73 Hydraulics.......................................................................................... 74 Steering............................................................................................ 75 Electrical system................................................................................... 76 Level adjustment.................................................................................... 78 Driver’s cab heating system........................................................................ 79 Auxiliary heater with timer (additional equipment).................................................. 81 Air-conditioning system additional equipment........................................................ 82 Cab lighting........................................................................................ 84 Other operating instruments........................................................................ 84 4.2.2 Other operating instruments in the vehicle section................................................ 85 Keys, doors, windows................................................................................ 85 Access ladders...................................................................................... 86 Ladders............................................................................................. 87 Vehicle engine diagnostic plug...................................................................... 88 Fire extinguisher (additional equipment)........................................................... 89 Folding bunk (additional equipment)................................................................. 89 5 Vehicle engine................................................................................................ 91 5.1 Starting/turning off vehicle engine..................................................................... 93 5.1.1 CHECKLIST: Starting vehicle engine................................................................ 93 5.1.2 CHECKLIST: In winter.............................................................................. 96 5.1.3 Checks before starting up vehicle engine.......................................................... 97 Checking the hydraulic system stop cocks........................................................... 97 Switching on the battery master switch.............................................................. 97 Pre-checking the oil level in the automatic gearbox................................................. 98 Checking the coolant level......................................................................... 99 Checking hydraulic oil level........................................................................100 Checking the engine oil level......................................................................100 Topping up engine oil...............................................................................101 5.1.4 Refuelling........................................................................................102 5.1.5 Starting vehicle engine...........................................................................103 Activating the ignition............................................................................103 Starting the vehicle engine........................................................................105 5.1.6 Inspections after the engine has been started.....................................................107 Checking instruments...............................................................................107 Checking oil level in the automatic gearbox.........................................................108 5.1.7 Turning off the vehicle engine....................................................................111 5.1.8 Emergency stop via the air intake inhibitor (additional equipment)................................112 Switching on the air intake inhibitor...............................................................112 Releasing the air intake inhibitor manually.........................................................113 6 Driving the truck crane.......................................................................................115 6.1 Checking the truck crane before driving.................................................................117 6.1.1 CHECKLIST: Condition of the truck crane for on-road driving.......................................117 6.1.2 On-road driving mode table........................................................................121 Axle loads in driving mode..........................................................................122 6.1.3 Checking the condition of the truck crane.........................................................124 Checking the reservoir of the windscreen washing system...........................................124 Warning plates for vehicle width....................................................................124 Checking the tyres.................................................................................125 Checking the electrical system......................................................................125 Adjusting the mirrors..............................................................................126 Check the compressed air and brake systems..........................................................126 Checking suspension.................................................................................127 Check the on-the- road level........................................................................127 Checking the transverse differential locks..........................................................128 Check the drive of the second axle line/longitudinal differential locks.............................128 Checking the transfer case..........................................................................128 Checking the steering locks........................................................................128 Checking the Boom not set down warning lamp.........................................................129 6.1.4 Adjusting the seat and the steering column........................................................130 Adjusting the driver’s seat.......................................................................130 Adjusting the steering column......................................................................130 6.1.5 Trip recorder.....................................................................................131 Inserting the 24hour disc in the trip recorder.....................................................131 6.2 General operation.......................................................................................133 6.2.1 Operating the automatic gearbox...................................................................133 Driving range of the automatic gearbox.............................................................133 Automatic gearbox diagnosis switch.................................................................135 Automatic gearbox driving modes....................................................................135 Starting and stopping..............................................................................136 Upshifting the automatic gearbox...................................................................137 6.2.2 Monitoring the control instruments while driving..................................................138 6.2.3 Driving on downhill slopes........................................................................143 Retarder............................................................................................143 Preselecting gears..................................................................................144 6.2.4 Driving on uphill slopes..........................................................................144 6.2.5 Cruise control....................................................................................145 Activating the cruise control.......................................................................145 Driving with cruise control........................................................................146 Deactivating the cruise control.....................................................................146 Eddy current retarder (additional equipment)........................................................146 6.2.6 Turning off the truck crane.......................................................................148 Locking the parking brake..........................................................................148 Automatic gearbox in neutral position............................................................148 Turning off the vehicle engine.....................................................................148 Securing the truck crane from rolling...............................................................148 Switch off the battery master switch if the truck crane is idle for a longer period of time........149 Securing the truck crane against unauthorised use..................................................149 6.3 Off-the-road driving....................................................................................151 6.3.1 Off-the-road gear.................................................................................152 Engage the off- the-road gear.......................................................................152 Deactivating off- the-road gear....................................................................152 6.3.2 Drive of the second axle line/longitudinal differential locks.....................................153 Switching on drive/longitudinal differential locks.................................................153 Switching off drive/longitudinal differential locks.................................................154 6.3.3 Transverse differential locks in all driven axle lines............................................155 Activating transverse differential locks............................................................155 Deactivating transverse differential locks.........................................................156 6.3.4 Level adjustment system...........................................................................157 Activating the level adjustment system.............................................................157 Raising or lowering the entire truck crane.........................................................158 Tilting the truck crane lengthwise or crosswise.....................................................159 Moving the truck crane into position On-the-road level.............................................160 Deactivating the level adjustment system............................................................160 6.3.5 Freeing an immobilised truck crane................................................................161 Freeing the truck crane by oneself..................................................................161 Towing in reverse..................................................................................162 Towing free forward................................................................................162 6.4 Separate steering.......................................................................................163 6.4.1 Switching on separate steering....................................................................165 6.4.2 Steering axle lines with separate steering........................................................166 All-wheel steering..................................................................................166 Crab travel mode....................................................................................166 6.4.3 Switching off separate steering and locking steering..............................................167 Locking the steering in straight ahead position.....................................................167 Locking in other positions..........................................................................168 6.4.4 Matching steering angle...........................................................................169 6.5 Heating and ventilation.................................................................................171 6.5.1 Driver’s cab heating system.......................................................................171 Ventilating the driver’s cab........................................................................173 6.5.2 Additional water heating system (additional equipment)............................................174 Preheating the vehicle engine......................................................................174 Preheating the driver’s cab........................................................................174 Switching on the additional heating system.........................................................174 Deactivating the additional heating system.........................................................175 6.5.3 Additional heating system with timer (additional equipment).......................................176 Preheating the vehicle engine......................................................................176 Preheating the driver’s cab........................................................................176 Switching the auxiliary heater on/off...............................................................176 Displaying and setting the current time.............................................................177 Switching on and saving automatic heating start.....................................................177 Switching off automatic heating start...............................................................178 6.5.4 Roof blower (additional equipment)................................................................179 6.6 Air-conditioning system (additional equipment)..........................................................181 6.6.1 Switching on......................................................................................181 6.6.2 Switching off.....................................................................................181 6.6.3 Air conditioning..................................................................................182 How to ensure pleasant air- conditioning............................................................182 Dehumidifying the air in the driver’s cab..........................................................183 6.7 Towing a trailer (additional equipment).................................................................185 Effects on the axleloads...............................................................................185 Coupling the trailer...................................................................................186 Connecting supply cables................................................................................187 Removing the supply lines...............................................................................188 Uncoupling the trailer..................................................................................188 Test position of the parking brake when towing a trailer................................................190 7 Rigging for on-road driving...................................................................................191 7.1 Rigging work for driving with a trailer.................................................................195 7.1.1 Switch on slewing gear freewheel..................................................................196 7.1.2 Switching on boom floating position...............................................................198 Setting the main boom down on the trailer...........................................................198 7.1.3 Switching on boom pretensioning...................................................................200 7.2 Rigging the outrigger beams (additional equipment)......................................................203 Equipment...............................................................................................203 7.2.1 CHECKLIST: Removal of support beams...............................................................204 7.2.2 CHECKLIST: Installation of outrigger beams........................................................206 7.2.3 Preparing the truck crane for removal/installation................................................208 Prerequisites for installation/removal..............................................................208 Preparing the truck crane..........................................................................208 7.2.4 Removing/inserting outrigger pads.................................................................209 Removing spare wheel holder.........................................................................209 Removing outrigger pads.............................................................................210 7.2.5 Disconnecting/establishing hydraulic connection...................................................210 Detach the hydraulic connection.....................................................................211 Establishing the hydraulic connection...............................................................212 7.2.6 Establishing/disconnecting the electrical connection for the outrigger pressure indicator.........213 7.2.7 Transport position/operating position of the holding angle........................................214 7.2.8 Locking/releasing the sliding cylinder locking pin................................................215 Releasing the lokking pin...........................................................................215 Locking the sliding cylinder........................................................................216 7.2.9 Extending/reinserting outrigger beams.............................................................216 Extending the outrigger beams.......................................................................216 Reinserting the outrigger beams.....................................................................219 7.2.10 Transporting the outrigger beams/outrigger pads..................................................221 7.3 Rigging the main boom...................................................................................223 Additional equipment required...........................................................................223 7.3.1 CHECKLIST: Removing the main boom.................................................................225 Prerequisites.......................................................................................225 Main boom removing..................................................................................225 7.3.2 CHECKLIST: Mounting the main boom.................................................................228 Prerequisites.......................................................................................228 Installing the mainboom............................................................................228 7.3.3 Supporting the truck crane while installing/removing the mainboom................................232 7.3.4 Rigging work with the auxiliary crane.............................................................233 Lifting the main boom from the turntable............................................................233 Lifting the main boom onto the turntable............................................................234 7.3.5 Establishing/disconnecting the hydraulic connection to the lattice extension additional equ.......235 Breaking the hydraulic connection...................................................................235 Establishing the hydraulic connection...............................................................236 7.3.6 Pulling device on the bottom axle of the boom additional equipment................................237 Bottom axle pin- type keepers.......................................................................237 Hydraulic connection................................................................................238 Retracting/extending pins...........................................................................239 7.3.7 Locking pin at derricking cylinder head eyelet....................................................240 Operating the lifting equipment....................................................................240 Retracting/ extending pins.........................................................................242 7.3.8 Hydraulic connections on the main boom............................................................243 Removing/attaching the guide plates.................................................................244 Establishing hydraulic connection...................................................................244 Breaking the hydraulic connection...................................................................245 7.3.9 Electrical connections on the main boom...........................................................246 7.3.10 Checks following main jib mounting...............................................................247 Hydraulic system check.............................................................................247 Checking the electrical system.....................................................................248 7.3.11 Before road driving..............................................................................250 Securing the derricking cylinder for on-road driving................................................250 Transporting the main boom..........................................................................250 7.3.12 Derricking cylinder pressure relief..............................................................251 Activating pressure relief..........................................................................251 Deactivating pressure relief.......................................................................252 7.4 Installing/removing the auxiliary hoist additional equipment............................................253 7.4.1 Slinging points and transport.....................................................................253 Slinging points.....................................................................................253 Transport...........................................................................................254 7.4.2 Mounting the auxiliary hoist......................................................................255 Removing pin- type keeper and pins..................................................................255 Attach the auxiliary hoist to the main hoist........................................................255 Locking the auxiliary hoist.........................................................................256 Establishing hydraulic and electrical connections...................................................256 7.4.3 Removing the auxiliary hoist......................................................................257 7.4.4 Permitted applications for the auxiliary hoist....................................................258 Replacement for the main hoist......................................................................258 Alternating operation with the main and auxiliary hoists............................................259 8 Malfunctions on the carrier...................................................................................261 8.1 Emergency stop device on carrier........................................................................263 Turning off the vehicle engine.........................................................................263 8.2 Breakdown in road traffic...............................................................................265 8.3 Towing the truck crane..................................................................................267 Towing with running vehicle engine.....................................................................267 Towing when the vehicle engine isoff...................................................................268 Compressed-air supply in the event of engine failure....................................................269 Power supply............................................................................................269 Gearbox.................................................................................................270 Vehicle engine..........................................................................................270 Parking brake...........................................................................................270 Mechanically releasing the parking brake..............................................................271 Towing procedure........................................................................................272 Removing the mechanical locking from all spring- loaded brake cylinders...............................272 Tow starting............................................................................................272 8.4 Wheels..................................................................................................273 8.4.1 Wheel change......................................................................................273 Removing a damaged tyre............................................................................273 Removing the wheel from the spare wheel holder.....................................................274 Mounting a damaged wheel on the spare wheel holder.................................................275 Mounting the spare wheel...........................................................................276 8.4.2 Filling the tyres yourself........................................................................277 Connecting the filling hose.........................................................................277 Filling the tyres...................................................................................278 Removing the tyre inflator hose.....................................................................278 8.5 Electrical system.......................................................................................279 8.5.1 Inserts...........................................................................................280 Front plug-in module................................................................................280 8.5.2 Fuses.............................................................................................282 Group F1 to F6....................................................................................282 Groups F7 to F9...................................................................................286 8.6 Troubleshooting and malfunction correction..............................................................287 8.6.1 Vehicle engine malfunctions.......................................................................287 8.6.2 Automatic gearbox malfunctions....................................................................289 8.6.3 Transfer case malfunctions........................................................................290 8.6.4 Differential lock malfunctions....................................................................291 8.6.5 Service brake malfunctions........................................................................292 8.6.6 Steering system malfunctions......................................................................293 8.6.7 Outrigger malfunctions............................................................................294 8.6.8 Suspension locking system malfunctions............................................................294 8.6.9 Level adjustment system malfunctions..............................................................294 8.7 Procedure in the event of malfunctions..................................................................295 8.7.1 Switching the fan thermostat to emergency operation...............................................295 8.7.2 Troubleshooting for malfunctions in the automatic gearbox.........................................296 Resetting the gearbox control......................................................................296 8.7.3 Emergency operation of the solenoid valves for the outriggers.....................................297 8.7.4 Separate steering emergency operation.............................................................300 Moving the steering into on-road driving............................................................301 9 Technical specifications carrier..............................................................................303 9.1 Technical description of the carrier....................................................................305 9.1.1 Crane carrier.....................................................................................305 9.1.2 Driver’s cab......................................................................................305 9.1.3 Drive units.......................................................................................306 9.1.4 Engine and gearbox cooling system................................................................306 9.1.5 Hydraulic system..................................................................................306 9.1.6 Steering..........................................................................................307 9.1.7 Suspension system................................................................................307 9.1.8 Outrigger.........................................................................................308 9.1.9 Compressed air system.............................................................................308 9.1.10 Service brake....................................................................................309 9.1.11 Parking brake....................................................................................309 9.1.12 Retarder.........................................................................................309 9.1.13 Secondary consumers.............................................................................309 9.1.14 Towing the crane.................................................................................309 9.1.15 Towing a trailer.................................................................................310 9.1.16 Electrical system................................................................................310 9.1.17 Slewing duct.....................................................................................310 9.2 Technical specifications................................................................................311 9.2.1 Measurements and weights of the truck crane.......................................................312 Dimensions for driving on public roads.............................................................313 9.2.2 Dimensions and weights of removable parts.........................................................314 Spare wheel (additional equipment)..................................................................314 Main boom...........................................................................................314 Outriggers..........................................................................................314 9.2.3 Carrier technical data............................................................................315 Vehicle engine......................................................................................315 Power shift gear...................................................................................315 Transfer case.......................................................................................315 Axle lines..........................................................................................315 Steering............................................................................................315 Tyres...............................................................................................316 Vehicle's electrical system.........................................................................316 Tools...............................................................................................316 Outriggers..........................................................................................317 Driving speeds......................................................................................318 Climbing ability....................................................................................318 Turning circle radiuses............................................................................319 10 Index........................................................................................................321 A...........................................................................................................325 B...........................................................................................................326 C...........................................................................................................326 D...........................................................................................................328 E...........................................................................................................329 F...........................................................................................................330 H...........................................................................................................330 I...........................................................................................................331 K...........................................................................................................331 L...........................................................................................................331 M...........................................................................................................331 O...........................................................................................................332 P...........................................................................................................333 R...........................................................................................................333 S...........................................................................................................334 T...........................................................................................................335 U...........................................................................................................337 V...........................................................................................................337 W...........................................................................................................337 Operating instructions Part 2 Crane operation.......................................................................341 Additional pages -Emergency operation/Emergency program telescoping ............................................343 11 Description of the truck crane – crane section...............................................................347 11.1 Overview of the operating and display instruments......................................................349 11.1.1 Overview of crane section........................................................................349 11.1.2 Crane cab overview...............................................................................352 11.1.3 Instrument panel.................................................................................354 Front instrument panel..............................................................................354 Fittings behind the crane driver seat...............................................................367 11.1.4 Left control console.............................................................................368 11.1.5 Right control console............................................................................369 11.1.6 Control lever configuration......................................................................370 Version 1 (standard)................................................................................370 Version 2 (additional equipment)....................................................................371 11.1.7 Control box for operating the outriggers.........................................................372 11.1.8 Counterweight hoisting gear switch unit..........................................................373 11.1.9 Switch box for electronic level..................................................................374 11.2 Functional description of the display and operating instruments.......................................375 11.2.1 Crane work.......................................................................................375 Crane engine........................................................................................375 Outrigger operation................................................................................376 Counterweight lifting gear and lock................................................................378 Crane control.......................................................................................380 Main hoist..........................................................................................382 Auxiliary hoist (additional equipment).............................................................383 Slewing gear........................................................................................384 Derricking gear.....................................................................................385 Telescoping gear....................................................................................386 Safe load indicator................................................................................391 Hydraulics..........................................................................................398 Electronics.........................................................................................398 Other operating instruments.........................................................................399 Electronic level in crane cab.......................................................................401 Toggle switch to change measuring range............................................................401 Crane cab heating system...........................................................................402 Auxiliary heater with time switch (additional equipment)............................................402 Air-conditioning system (additional equipment)......................................................404 Houselock (additional equipment)....................................................................405 Anemometer..........................................................................................405 Outrigger pressure display (additional equipment)...................................................406 11.2.2 Other operating instruments on the crane cab.....................................................407 Doors, keys, windows................................................................................407 Fire extinguisher (additional equipment)............................................................408 Crane engine diagnostics plug......................................................................409 11.3 Functional description of the safety devices...........................................................411 11.3.1 Safe load indicator (SLI)........................................................................411 11.3.2 Lowering limit switch............................................................................412 11.3.3 Lifting limit switch............................................................................413 Overriding the lifting limit switch shutdown.......................................................413 11.3.4 Dead man's switch and seat contact switch........................................................414 12 Crane engine.................................................................................................415 12.1 Starting/turning off the crane engine..................................................................417 12.1.1 CHECKLIST: Starting the crane engine.............................................................417 12.1.2 CHECKLIST: In winter.............................................................................419 12.1.3 Inspections before starting the crane engine.....................................................420 Checking the stop cock on the hydraulic system.....................................................420 Switching on the battery master switch.............................................................420 Checking coolant level..............................................................................421 Checking the hydraulic oil level....................................................................422 Checking the oil level in the crane engine........................................................422 Topping up engineoil..............................................................................423 Refuelling..........................................................................................424 12.1.4 Starting the crane engine........................................................................425 Switching on the ignition..........................................................................425 Starting the crane engine..........................................................................426 12.1.5 Inspections after starting the crane engine......................................................428 Checking instruments...............................................................................428 12.2 Switching off the crane engine.........................................................................431 12.2.1 Emergency stop via the air intake inhibitor (additional equipment)...............................432 Switching on the air intake inhibitor...............................................................432 Manually releasing the air intake lock..............................................................433 13 Crane operation..............................................................................................435 13.1 Checking the truck crane before working with thecrane...............................................437 13.1.1 CHECKLIST: When truck crane is rigged............................................................437 13.1.2 Adjusting the crane operator's seat..............................................................441 13.1.3 Checking the condition of the truck crane........................................................442 Checking the reservoir of the windscreen washing system.............................................442 Visual inspection of the entire crane...............................................................442 Checking the position of the hoist ropes............................................................443 Electrical system...................................................................................443 13.1.4 Checking the safety devices......................................................................444 Safe load indicator.................................................................................444 Lifting limit switch................................................................................444 Dead man's switch system............................................................................445 Emergency stop switch for the crane control.........................................................445 13.1.5 Preheating the hydraulic oil.....................................................................446 With an oil temperature of between –15 C and 0 C (5 F and 32 F):................................446 With an oil temperature below –15 C (5 F):........................................................446 13.1.6 Superstructure lock..............................................................................447 Removing the lock..................................................................................448 Engaging the lock..................................................................................448 13.1.7 Houselock (additional equipment).................................................................449 Switching on the houselock..........................................................................449 Switching off the houselock.........................................................................450 13.1.8 Adjusting the mirrors............................................................................451 13.2 Operating the safe load indicator (SLI)................................................................453 13.2.1 Switching on the SLI.............................................................................453 Switching on........................................................................................453 Lamp test on the SLI................................................................................455 Dimmers for the SLI status displays................................................................455 13.2.2 Setting rigging mode.............................................................................456 Setting using the SLI code..........................................................................456 Setting using individual components................................................................456 General instructions...............................................................................457 Sequence during setting.............................................................................457 Switching on entry mode............................................................................458 Entering values.....................................................................................459 Confirming entry....................................................................................461 Transferring values.................................................................................461 Switching over hoist position lights...............................................................462 13.2.3 Checks before working with the crane.............................................................463 13.2.4 During crane work................................................................................465 Continuous displays................................................................................465 Optional status displays...........................................................................466 SLI early warning...................................................................................467 SLI shutdown........................................................................................467 Error messages......................................................................................468 Error messages with additional optical displays.....................................................469 SLI override........................................................................................470 13.3 Crane work with the main boom..........................................................................471 13.3.1 External influences during crane operation.......................................................471 Horizontal alignment...............................................................................471 Safe distances......................................................................................471 Effect of wind on crane operations..................................................................472 Anemometer..........................................................................................472 Permissible wind load...............................................................................473 Earthing the load...................................................................................474 13.3.2 Slewing ranges permitted for working with the crane..............................................475 360 slewing range..................................................................................475 Working position 0 to the rear.....................................................................475 13.3.3 Hoists...........................................................................................476 Main hoist..........................................................................................476 Auxiliary hoist (additional equipment)..............................................................479 13.3.4 Derricking gear..................................................................................481 13.3.5 Slewing gear.....................................................................................483 Slewing gear permanent brake........................................................................483 Slewing.............................................................................................483 Slewing speed.......................................................................................484 Tracking the slewing gear..........................................................................484 Maximum permitted slewing speed....................................................................485 13.3.6 Telescoping gear.................................................................................487 Structure of the chapter............................................................................487 Description of functioning..........................................................................488 Main boom fixed length, intermediate length, telescoping length.....................................489 Telescope status....................................................................................490 Notes on telescope sequence.........................................................................493 Check before telescoping for the first time.........................................................493 Function of the control lever.......................................................................494 Example of procedures when telescoping..............................................................496 Check initial position.............................................................................497 Unlocking telescoping cylinder......................................................................500 Extending/ retracting telescoping cylinder and locking.............................................502 Unlock telescope section............................................................................505 Telescoping telescope section to fixed length and lock..............................................507 Telescoping telescope section to intermediate length................................................511 Locking telescope section...........................................................................512 Telescoping with fully automatic control............................................................513 Example of telescoping with teleautomatic...........................................................515 Lowering the main boom for maintenance..............................................................517 Telescoping the main boom in the horizontal position...............................................517 13.3.7 Fast speed.......................................................................................518 13.3.8 Menus on the crane control display...............................................................519 Menu Display states.................................................................................519 Menu Display telescoping status and teleautomatic..................................................523 Menu Power unit speeds/Critical load control........................................................523 Access emergency operation menu.....................................................................527 Display of an error message.........................................................................528 13.3.9 Setting a constant engine speed..................................................................530 13.3.10 Critical load control...........................................................................531 13.3.11 Incline crane cab...............................................................................532 13.3.12 Cooling the hydraulic oil.......................................................................533 Standard oil cooler.................................................................................533 Additional oil cooler...............................................................................533 13.3.13 Movements which can be carried out simultaneously...............................................534 13.4 Driving with a rigged crane............................................................................535 13.4.1 Driving route....................................................................................535 13.4.2 Rigging mode and axle loads......................................................................536 Boom positions......................................................................................536 13.4.3 Driving the rigged truck crane...................................................................538 Locking the superstructure and engaging the slewing gear permanent brake..........................538 Retracting the outriggers..........................................................................538 Switching over the suspension locking system........................................................538 Switching on separate steering......................................................................539 Driving.............................................................................................540 Extending the outriggers............................................................................540 13.5 Work break.............................................................................................541 13.5.1 Short work break.................................................................................541 13.5.2 Work breaks lasting more than 8 hours............................................................541 13.6 Crane cab heating and ventilation......................................................................543 13.6.1 Heating the crane cab............................................................................543 13.6.2 Additional water heating system (additional equipment)..........................................544 Switching on the additional heating system.........................................................544 Switching off the additional heating system........................................................545 13.6.3 Auxiliary heater with timer (additional equipment)...............................................545 Preheating crane engine............................................................................545 Preheating cranecab...............................................................................546 Switching the auxiliary heater on/off...............................................................546 Displaying and setting the current time.............................................................546 Switching on and saving the automatic heating start.................................................547 Switching off the automatic heating start...........................................................548 13.6.4 Ventilating the crane cab........................................................................549 13.7 Air-conditioning system (additional equipment).........................................................551 13.7.1 Switching on.....................................................................................551 13.7.2 Switching off....................................................................................552 13.7.3 Air conditioning.................................................................................552 How to ensure pleasant air- conditioning............................................................552 Dehumidifying crane cab air.........................................................................553 14 Rigging work.................................................................................................555 14.1 Check lists for rigging work for crane operation with main boom........................................559 14.1.1 CHECKLIST: Rigging...............................................................................559 14.1.2 CHECKLIST: Unrigging.............................................................................563 14.2 Choosing a suitable site...............................................................................567 14.2.1 Load bearing capacity of the ground and the outrigger............................................567 Enlarging the surface area of the outrigger........................................................569 14.2.2 Safe distance from banks and pits................................................................570 14.2.3 Earthing the truck crane.........................................................................571 Earthing the truck crane............................................................................571 14.2.4 Safe distance from electrical lines..............................................................572 14.3 Rigging work after driving with trailer................................................................575 14.3.1 Switching off slewing gear freewheel (additional equipment)......................................576 Before slewing......................................................................................577 14.3.2 Switching off the boom floating position (additional equipment)..................................578 14.3.3 Switching off boom pre-tensioning (additional equipment).........................................579 14.4 Outrigger..............................................................................................581 14.4.1 CHECKLIST: Extending the outriggers..............................................................581 14.4.2 CHECKLIST: Retracting outrigger..................................................................583 14.4.3 Outrigger span...................................................................................585 Outrigger span 8.70 x 8.50 m (28.5 x 27.9 ft).......................................................585 Outrigger span 8,70 x 6,00 m (28.5 x 19.7 ft).......................................................586 Outrigger span 8.50 x 2.72 m (28.5x8.8 ft)........................................................586 14.4.4 Preparing the outriggers.........................................................................588 Aligning the truck crane horizontally..............................................................588 Locking the suspension.............................................................................588 Safety for on-road driving..........................................................................588 Safety during crane operation.......................................................................589 14.4.5 Extending/retracting the outrigger beams.........................................................590 Extending the outrigger beams.......................................................................590 Retracting the outrigger beams.....................................................................594 14.4.6 Moving the outrigger pads into working/driving position..........................................595 Moving the outrigger pads into working position...................................................595 Moving the outrigger pads into driving position..................................................596 14.4.7 Extending/retracting the outrigger cylinders.....................................................597 Extending the support cylinders.....................................................................597 Retracting the outrigger cylinders.................................................................598 14.4.8 Aligning the truck crane horizontally............................................................600 Reading the status display..........................................................................600 Switching over the measuring range..................................................................601 Aligning the truck crane horizontally...............................................................601 14.4.9 Outrigger pressure display (additional equipment)...............................................602 Reading the status displays.........................................................................602 14.5 Counterweight..........................................................................................605 14.5.1 Counterweight sections and identification........................................................605 Counterweight sections..............................................................................605 Identification......................................................................................605 14.5.2 Counterweight versions...........................................................................606 14.5.3 Slinging points on the counterweight sections....................................................610 14.5.4 CHECKLIST: Rigging the counterweight.............................................................611 Rig counterweight...................................................................................611 14.5.5 CHECKLIST: Unrigging the counterweight...........................................................614 Unrig counterweight.................................................................................614 14.5.6 Placing the counterweight........................................................................616 5.4 t base plate on counterweight platform..........................................................617 Stacking counterweight sections.....................................................................617 14.5.7 Connecting/disconnecting the hydraulic connection................................................618 Establishing hydraulic connection.................................................................618 Disconnecting the hydraulic connection..............................................................619 14.5.8 Assembling the counterweight version.............................................................620 14.5.9 3.5 t counterweight section......................................................................625 Rigging with assemble rods (additional equipment)...................................................625 Locking the 3.5 t counterweight section.............................................................626 14.5.10 Extending/retracting the lifting cylinders of the 5.4 t base plate or lifting/lowering c.......627 Extend the lifting cylinders........................................................................628 Retract hoist cylinder.............................................................................629 14.5.11 Locking the counterweight on the turntable/releasing the locking pin...........................629 Hasp positions......................................................................................630 Safety cock.........................................................................................630 Locking the counterweight..........................................................................631 Unlocking the counterweight.........................................................................631 14.5.12 Rigging 3.75 t counterweight section (additional equipment).....................................632 14.5.13 Rigging 3 t counterweight blocks (additional equipment)........................................633 14.5.14 Slewing with the counterweight rigged...........................................................634 14.6 Rigging work on the main boom..........................................................................635 14.6.1 Hook block on the bumper.........................................................................635 Picking up the hook block...........................................................................635 Attaching the hook block............................................................................636 14.6.2 Hook block on a separate vehicle.................................................................637 Picking up the hook block...........................................................................637 Setting down the hook block and securing the hoist rope for on-road driving........................638 14.6.3 Reeving and unreeving the hoist rope............................................................639 Rope end clamp......................................................................................639 Installing/removing front rope grab.................................................................641 Reeving the hoist rope..............................................................................642 Lifting limit switch on the main boom...............................................................644 14.6.4 Possible reeving methods on the main boom........................................................648 14.6.5 Anemometer.......................................................................................652 Remove the anemometer..............................................................................653 14.6.6 Rigging heavy duty equipment.....................................................................654 Heavy duty equipment parts..........................................................................654 Equipment required.................................................................................654 Rigging heavy duty equipment........................................................................655 Unrigging heavy duty equipment......................................................................658 Reevings with heavy duty equipment..................................................................660 15 Malfunctions on the superstructure...........................................................................661 15.1 Superstructure emergency stop device...................................................................663 Switching off the crane engine.........................................................................663 Crane control emergency stop switch.....................................................................664 15.2 Troubleshooting for malfunctions that occur during crane operation....................................665 Load cannot be lowered..................................................................................665 15.3 Electrical system......................................................................................667 15.3.1 Plug-in modules and consoles.....................................................................668 15.3.2 Fuses............................................................................................670 Groups F1 to F9...................................................................................670 Groups F10 to F13...................................................................................674 15.3.3 SLI fuses........................................................................................675 Replacing fuses.....................................................................................675 15.4 Troubleshooting and malfunction correction.............................................................677 15.4.1 Crane engine malfunctions........................................................................677 15.4.2 Main hoist malfunctions..........................................................................678 15.4.3 Auxiliary hoist malfunctions.....................................................................680 15.4.4 Derricking gear malfunctions.....................................................................682 15.4.5 Telescoping gear malfunctions....................................................................684 15.4.6 Slewing gear malfunctions........................................................................686 15.4.7 Counterweight lifting gear/lock malfunctions.....................................................687 15.4.8 Hydraulic system/hydraulic oil cooler malfunctions...............................................688 15.4.9 Crane control malfunctions.......................................................................688 15.4.10 Malfunctions on the SLI.........................................................................689 Other malfunctions on the SLI......................................................................689 SLI error message table............................................................................690 Switch off sensor/ indicator during malfunction.....................................................697 Check that the remaining sensor/ indicator is working..............................................698 Accepting the telescope status from the crane control...............................................699 Checking SLI lines and connections.................................................................700 15.4.11 Retraction emergency operation..................................................................702 Check before all emergency operation................................................................702 Procedure for retracting...........................................................................703 Mechanical emergency operation......................................................................704 Hydraulic emergency operation.......................................................................706 15.5 Error messages crane control...........................................................................719 15.5.1 Error messages about control units...............................................................719 15.5.2 Error messages about power units.................................................................720 Determining defective part..........................................................................721 Determining error area..............................................................................722 Error causes and effects............................................................................723 15.5.3 Telescoping error messages.......................................................................725 15.5.4 Changing the connections in the control units....................................................726 Connections and control units.......................................................................726 Unrigging mobile crane with defective control unit..................................................726 Inserting and removing connections..................................................................729 15.5.5 Control lever emergency program..................................................................730 Indications on the display..........................................................................730 Carrying out emergency program.....................................................................731 15.5.6 Emergency operation submenu......................................................................732 Retracting with an error on the length indicator....................................................733 Retracting with an error on the proximity switch....................................................736 Table for approaching the locking points............................................................737 15.5.7 Entering telescope status after emergency operation menu.........................................738 15.6 Hydraulic emergency stop according to ZH1/461 (additional equipment)...................................741 15.6.1 Important instructions for hydraulic emergency operation.........................................741 15.6.2 Functioning and accessories......................................................................743 15.6.3 Connecting the transformer.......................................................................744 15.6.4 Switching emergency operation on/off.............................................................745 15.6.5 Establishing required hydraulic circuits.........................................................746 Making connections on the plug- in field............................................................746 Additional switches for hoisting gear and slewing gear.............................................747 15.6.6 Executing emergency operation....................................................................748 Driving hoisting gear emergency operation...........................................................748 Emergency operation driving derricking gear.........................................................749 Emergency operation driving the slewing gear........................................................749 15.6.7 After the emergency operation....................................................................750 16 Technical information for superstructure.....................................................................751 16.1 Technical description of the superstructure............................................................753 16.1.1 Turntable........................................................................................753 16.1.2 Crane operator’s cab.............................................................................753 16.1.3 Crane engine and hydraulic system................................................................754 16.1.4 Control system...................................................................................754 16.1.5 Main boom........................................................................................755 16.1.6 Telescoping gear.................................................................................755 16.1.7 Hoists...........................................................................................756 16.1.8 Slewing gear units...............................................................................756 16.1.9 Houselock (additional equipment).................................................................756 16.1.10 Derricking cylinder.............................................................................757 16.1.11 Electrical system..............................................................................757 16.1.12 Counterweight...................................................................................757 16.1.13 Safety equipment................................................................................758 16.2 Technical data.........................................................................................759 16.2.1 Maximum lifting capacity.........................................................................759 DIN/ISO/EN..........................................................................................759 ANSI B 30.5 (85%)...................................................................................759 16.2.2 Guaranteed value specifications..................................................................759 16.2.3 Measurements and weights of the truck crane......................................................760 Dimensions for driving on public roads.............................................................761 16.2.4 Dimensions and weights of removable parts........................................................762 Counterweight parts................................................................................762 Hook blocks and hook tackle.........................................................................763 Auxiliary hoist.....................................................................................763 Main boom...........................................................................................764 Heavy dutyequipment................................................................................764 Counterweight versions..............................................................................764 16.2.5 Technical data for superstructure................................................................768 Crane engine........................................................................................768 Crane’s electrical system...........................................................................768 Main hoist..........................................................................................768 Auxiliary hoist (additional equipment)..............................................................769 Slewing gears.......................................................................................769 Derricking gear.....................................................................................769 Main boom...........................................................................................769 Operating speeds and times without a load..........................................................770 17 Index........................................................................................................771 A...........................................................................................................775 B...........................................................................................................776 C...........................................................................................................776 D...........................................................................................................778 E...........................................................................................................779 F...........................................................................................................780 H...........................................................................................................780 I...........................................................................................................781 K...........................................................................................................781 L...........................................................................................................781 M...........................................................................................................781 O...........................................................................................................782 P...........................................................................................................783 R...........................................................................................................783 S...........................................................................................................784 T...........................................................................................................785 U...........................................................................................................787 V...........................................................................................................787 W...........................................................................................................787
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