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Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084799 – PDF DOWNLOAD
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Description
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084799 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084799 – PDF DOWNLOAD
Language : English
Pages : 810
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084799 – PDF DOWNLOAD
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 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 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. - Chapter 3 contains Information for applications engineering. It is intended pri- marily for the
truck crane operator and those responsible for applications engineering.
This chapter contains
– the required qualifications of those involved in applications engineering,
– special safety instructions,
– information that is relevant to applications engineering.
- In Chapter 4 to 6 you will find information required for Driving the truck crane: a description of
all structural and operational components, clearly de- fined checklists for rigging modes and work,
and the operating instructions for on-road and off-road driving and the removal and installation of
the aux- iliary hoist. - Rigging for on-road driving is described in Chapter 7.
- In Chapter 8, there is information on Troubleshooting on the vehicle section 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. - Chapter 11 to 13 contain the information necessary for Operating the crane section, i.e. for
working with the truck crane: a description of all components and control elements, information
about operating the crane engine as well as the crane itself. - Chapter 14 deals with rigging the truck crane. There are individual sections with information on
Selecting a suitable site, Rigging of support and counter- weight and Rigging work on the main
boom. - In Chapter 15 there is information on Troubleshooting on the crane section of the truck crane.
- Chapter 16 contains the Technical description of the individual parts and func- tional elements of
the crane section as well as its Technical data. - Chapter 17 also contains the Index. This helps you when you are looking for
certain procedures and terms in the operating instructions.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 6220 L Driving Operating Instructions Manual 2084799 – PDF DOWNLOAD
Operating instructions Part 1 Driving............................................................................... 1 1 Overview...................................................................................................... 9 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.......................................................... 29 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...................................................................... 39 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.............................................................. 45 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 4.1.5 Switch boxes for outrigger box lokking pin (additional equipment)................................. 66 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................................................................................................ 93 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.......................................................................................117 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...................................................................................193 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 locking 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 Setting up the rear outrigger box (ROB) additional equipment............................................223 7.3.1 CHECKLIST: Removing the outrigger box.............................................................224 7.3.2 CHECKLIST: Installing the outrigger box...........................................................226 7.3.3 Preparing the truck crane for dismantling/assembly................................................229 Preparing for dismantling...........................................................................229 Preparing for installation/ assembly................................................................229 7.3.4 Crane movements when installing and removing......................................................230 Prerequisites.......................................................................................230 Before installation.................................................................................230 After removal......................................................................................230 7.3.5 Slinging points on the rear outrigger box (ROB)...................................................231 7.3.6 Establishing/disconnecting the electrical connection..............................................232 7.3.7 Breaking/establishing the hydraulic connection....................................................233 Establishing the hydraulic connection...............................................................233 Breaking the hydraulic connection...................................................................233 7.3.8 Attaching/removing the outrigger box with the truck crane.........................................234 Removing spare wheel holder.........................................................................235 Attaching the outrigger box........................................................................235 7.3.9 Locking the outrigger box to the carrier, unlocking...............................................236 Locking the outrigger box..........................................................................236 Releasing the lokking pin...........................................................................236 Extending and retracting the pins...................................................................237 7.3.10 Establishing/disconnecting the pneumatic connection..............................................237 7.3.11 Slewing with the rear outrigger box (ROB) removed................................................238 Prerequisites for slewing...........................................................................238 7.3.12 Transportation on a separate vehicle.............................................................239 7.3.13 Setting down the main boom on a trailer with the rear outrigger box (ROB) removed...............240 Propping the mobile crane...........................................................................240 Setting down the main boom..........................................................................241 7.4 Rigging the main boom...................................................................................243 Additional equipment required...........................................................................243 7.4.1 CHECKLIST: Removing the main boom.................................................................245 Prerequisites.......................................................................................245 Main boom removing..................................................................................245 7.4.2 CHECKLIST: Mounting the main boom.................................................................248 Prerequisites.......................................................................................248 Installing the mainboom............................................................................248 7.4.3 Supporting the truck crane while installing/removing the mainboom................................252 7.4.4 Rigging work with the auxiliary crane.............................................................253 Lifting the main boom from the turntable............................................................253 Lifting the main boom onto the turntable............................................................254 7.4.5 Establishing/disconnecting the hydraulic connection to the lattice extension (additional eq.......255 Breaking the hydraulic connection...................................................................255 Establishing the hydraulic connection...............................................................256 7.4.6 Pulling device on the bottom axle of the boom (additional equipment)..............................257 Bottom axle pin- type keepers.......................................................................257 Hydraulic connection................................................................................258 Retracting/extending pins...........................................................................259 7.4.7 Locking pin at derricking cylinder head eyelet....................................................260 Operating the lifting equipment....................................................................260 Retracting/ extending pins.........................................................................262 7.4.8 Hydraulic connections on the main boom............................................................263 Removing/attaching the guide plates.................................................................264 Establishing hydraulic connection...................................................................264 Breaking the hydraulic connection...................................................................265 7.4.9 Electrical connections on the main boom...........................................................266 7.4.10 Checks following main jib mounting...............................................................267 Hydraulic system check.............................................................................267 Checking the electrical system.....................................................................268 7.4.11 Before road driving..............................................................................270 Securing the derricking cylinder for on-road driving................................................270 Transporting the main boom..........................................................................270 7.4.12 Derricking cylinder pressure relief..............................................................271 Activating pressure relief..........................................................................271 Deactivating pressure relief.......................................................................272 7.5 Installing/removing the auxiliary hoist (additional equipment)..........................................273 7.5.1 Slinging points and transport.....................................................................273 Slinging points.....................................................................................273 Transport...........................................................................................274 7.5.2 Mounting the auxiliary hoist......................................................................275 Removing pin- type keeper and pins..................................................................275 Attach the auxiliary hoist to the main hoist........................................................275 Locking the auxiliary hoist.........................................................................276 Establishing hydraulic and electrical connections...................................................276 7.5.3 Removing the auxiliary hoist......................................................................277 7.5.4 Permitted applications for the auxiliary hoist....................................................278 Replacement for the main hoist......................................................................278 Alternating operation with the main and auxiliary hoists............................................279 8 Malfunctions on the carrier...................................................................................283 8.1 Emergency stop device on carrier........................................................................283 Turning off the vehicle engine.........................................................................283 8.2 Breakdown in road traffic...............................................................................285 8.3 Towing the truck crane..................................................................................287 Towing with running vehicle engine.....................................................................287 Towing when the vehicle engine isoff...................................................................288 Compressed-air supply in the event of engine failure....................................................289 Power supply............................................................................................289 Gearbox.................................................................................................290 Vehicle engine..........................................................................................290 Parking brake...........................................................................................290 Mechanically releasing the parking brake..............................................................291 Towing procedure........................................................................................292 Removing the mechanical locking from all spring- loaded brake cylinders...............................292 Tow starting............................................................................................292 8.4 Wheels..................................................................................................293 8.4.1 Wheel change......................................................................................293 Removing a damaged tyre............................................................................293 Removing the wheel from the spare wheel holder.....................................................294 Mounting a damaged wheel on the spare wheel holder.................................................295 Mounting the spare wheel...........................................................................296 8.4.2 Filling the tyres yourself........................................................................297 Connecting the filling hose.........................................................................297 Filling the tyres...................................................................................298 Removing the tyre inflator hose.....................................................................298 8.5 Electrical system.......................................................................................299 8.5.1 Inserts...........................................................................................300 Front plug-in module................................................................................300 8.5.2 Fuses.............................................................................................302 Group F1 to F6....................................................................................302 Groups F7 to F9...................................................................................306 8.6 Troubleshooting and malfunction correction..............................................................307 8.6.1 Vehicle engine malfunctions.......................................................................307 8.6.2 Automatic gearbox malfunctions....................................................................309 8.6.3 Transfer case malfunctions........................................................................310 8.6.4 Differential lock malfunctions....................................................................311 8.6.5 Service brake malfunctions........................................................................312 8.6.6 Steering system malfunctions......................................................................313 8.6.7 Outrigger malfunctions............................................................................314 8.6.8 Suspension locking system malfunctions............................................................314 8.6.9 Level adjustment system malfunctions..............................................................314 8.7 Procedure in the event of malfunctions..................................................................315 8.7.1 Switching the fan thermostat to emergency operation...............................................315 8.7.2 Troubleshooting for malfunctions in the automatic gearbox.........................................316 Resetting the gearbox control......................................................................316 8.7.3 Emergency operation of the solenoid valves for the outriggers.....................................317 8.7.4 Separate steering emergency operation.............................................................320 Moving the steering into on-road driving............................................................321 9 Technical specifications carrier..............................................................................325 9.1 Technical description of the carrier....................................................................325 9.1.1 Crane carrier.....................................................................................325 9.1.2 Driver’s cab......................................................................................325 9.1.3 Drive units.......................................................................................326 9.1.4 Engine and gearbox cooling system................................................................326 9.1.5 Hydraulic system..................................................................................326 9.1.6 Steering..........................................................................................327 9.1.7 Suspension system................................................................................327 9.1.8 Outrigger.........................................................................................328 9.1.9 Compressed air system.............................................................................328 9.1.10 Service brake....................................................................................329 9.1.11 Parking brake....................................................................................329 9.1.12 Retarder.........................................................................................329 9.1.13 Secondary consumers.............................................................................329 9.1.14 Towing the crane.................................................................................329 9.1.15 Towing a trailer.................................................................................330 9.1.16 Electrical system................................................................................330 9.1.17 Slewing duct.....................................................................................330 9.2 Technical specifications................................................................................331 9.2.1 Measurements and weights of the truck crane.......................................................332 Dimensions for driving on public roads.............................................................333 9.2.2 Dimensions and weights of removable parts.........................................................334 Spare wheel (additional equipment)..................................................................334 Main boom...........................................................................................334 Outriggers..........................................................................................334 9.2.3 Carrier technical data............................................................................335 Vehicle engine......................................................................................335 Power shift gear...................................................................................335 Transfer case.......................................................................................335 Axle lines..........................................................................................335 Steering............................................................................................335 Tyres...............................................................................................336 Vehicle's electrical system.........................................................................336 Tools...............................................................................................336 Outriggers..........................................................................................337 Driving speeds......................................................................................338 Climbing ability....................................................................................338 Turning circle radiuses............................................................................339 10 Index........................................................................................................343 A...........................................................................................................345 B...........................................................................................................346 C...........................................................................................................346 D...........................................................................................................348 E...........................................................................................................349 F...........................................................................................................350 H...........................................................................................................350 I...........................................................................................................351 K...........................................................................................................351 L...........................................................................................................351 M...........................................................................................................351 O...........................................................................................................352 P...........................................................................................................353 R...........................................................................................................353 S...........................................................................................................354 T...........................................................................................................355 U...........................................................................................................357 V...........................................................................................................357 W...........................................................................................................357 Operating instructions Part 2 Crane operation.......................................................................361 11 Description of the truck crane – crane section...............................................................369 11.1 Overview of the operating and display instruments......................................................369 11.1.1 Overview of crane section........................................................................369 11.1.2 Crane cab overview...............................................................................372 11.1.3 Instrument panel.................................................................................374 Front instrument panel..............................................................................374 Fittings behind the crane driver seat...............................................................387 11.1.4 Left control console.............................................................................388 11.1.5 Right control console............................................................................389 11.1.6 Control lever configuration......................................................................390 Version 1 (standard)................................................................................390 Version 2 (additional equipment)....................................................................391 11.1.7 Control box for operating the outriggers.........................................................392 11.1.8 Counterweight hoisting gear switch unit..........................................................393 11.1.9 Switch box for electronic level..................................................................394 11.2 Functional description of the display and operating instruments.......................................395 11.2.1 Crane work.......................................................................................395 Crane engine........................................................................................395 Outrigger operation................................................................................396 Counterweight lifting gear and lock................................................................398 Crane control.......................................................................................400 Main hoist..........................................................................................402 Auxiliary hoist (additional equipment).............................................................403 Slewing gear........................................................................................404 Derricking gear.....................................................................................405 Telescoping gear....................................................................................406 Safe load indicator................................................................................411 Hydraulics..........................................................................................418 Electronics.........................................................................................418 Other operating instruments.........................................................................419 Electronic level in crane cab.......................................................................421 Toggle switch to change measuring range............................................................421 Crane cab heating system...........................................................................422 Auxiliary heater with time switch (additional equipment)............................................422 Air-conditioning system (additional equipment)......................................................424 Houselock (additional equipment)....................................................................425 Anemometer..........................................................................................425 Outrigger pressure display (additional equipment)...................................................426 11.2.2 Other operating instruments on the crane cab.....................................................427 Doors, keys, windows................................................................................427 Fire extinguisher (additional equipment)............................................................428 Crane engine diagnostics plug......................................................................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 the lifting limit switch shutdown.......................................................433 11.3.4 Dead man's switch and seat contact switch........................................................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 Checking 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........................................................442 Topping up engineoil..............................................................................443 Refuelling..........................................................................................444 12.1.4 Starting the crane engine........................................................................445 Switching on the ignition..........................................................................445 Starting the crane engine..........................................................................446 12.1.5 Inspections after starting the crane engine......................................................448 Checking instruments...............................................................................448 12.2 Switching off the crane engine.........................................................................451 12.2.1 Emergency stop via the air intake inhibitor (additional equipment)...............................452 Switching on the air intake inhibitor...............................................................452 Manually releasing the air intake lock..............................................................453 13 Crane operation..............................................................................................457 13.1 Checking the truck crane before working with thecrane...............................................457 13.1.1 CHECKLIST: When truck crane is rigged............................................................457 13.1.2 Adjusting the crane operator's seat..............................................................461 13.1.3 Checking the condition of the truck crane........................................................462 Checking the reservoir of the windscreen washing system.............................................462 Visual inspection of the entire crane...............................................................462 Checking the position of the hoist ropes............................................................463 Electrical system...................................................................................463 13.1.4 Checking the safety devices......................................................................464 Safe load indicator.................................................................................464 Lifting limit switch................................................................................464 Dead man's switch system............................................................................465 Emergency stop switch for the crane control.........................................................465 13.1.5 Preheating the hydraulic oil.....................................................................466 With an oil temperature of between –15 C and 0 C (5 F and 32 F):................................466 With an oil temperature below –15 C (5 F):........................................................466 13.1.6 Superstructure lock..............................................................................467 Removing the lock..................................................................................468 Engaging the lock..................................................................................468 13.1.7 Houselock (additional equipment).................................................................469 Switching on the houselock..........................................................................469 Switching off the houselock.........................................................................470 13.1.8 Adjusting the mirrors............................................................................471 13.2 Operating the safe load indicator (SLI)................................................................473 13.2.1 Switching on the SLI.............................................................................473 Switching on........................................................................................473 Lamp test on the SLI................................................................................475 Dimmers for the SLI status displays................................................................475 13.2.2 Setting rigging mode.............................................................................476 Setting using the SLI code..........................................................................476 Setting using individual components................................................................476 General instructions...............................................................................477 Sequence during setting.............................................................................477 Switching on entry mode............................................................................478 Entering values.....................................................................................479 Confirming entry....................................................................................481 Transferring values.................................................................................481 Switching over hoist position lights...............................................................482 13.2.3 Checks before working with the crane.............................................................483 13.2.4 During crane work................................................................................485 Continuous displays................................................................................485 Optional status displays...........................................................................486 SLI early warning...................................................................................487 SLI shutdown........................................................................................487 Error messages......................................................................................488 Error messages with additional optical displays.....................................................489 SLI override........................................................................................490 13.3 Crane work with the main boom..........................................................................491 13.3.1 External influences during crane operation.......................................................491 Horizontal alignment...............................................................................491 Safe distances......................................................................................491 Effect of wind on crane operations..................................................................492 Anemometer..........................................................................................492 Permissible wind load...............................................................................493 Earthing the load...................................................................................494 13.3.2 Slewing ranges permitted for working with the crane..............................................495 360 slewing range..................................................................................495 Working position 0 to the rear.....................................................................495 13.3.3 Hoists...........................................................................................496 Main hoist..........................................................................................496 Auxiliary hoist (additional equipment)..............................................................499 13.3.4 Derricking gear..................................................................................501 13.3.5 Slewing gear.....................................................................................503 Slewing gear permanent brake........................................................................503 Slewing.............................................................................................503 Slewing speed.......................................................................................504 Tracking the slewing gear..........................................................................504 Maximum permitted slewing speed....................................................................505 13.3.6 Telescoping gear.................................................................................507 Structure of the chapter............................................................................507 Description of functioning..........................................................................508 Main boom fixed length, intermediate length, telescoping length.....................................509 Telescope status....................................................................................510 Notes on telescope sequence.........................................................................513 Check before telescoping for the first time.........................................................513 Function of the control lever.......................................................................514 Example of procedures when telescoping..............................................................516 Check initial position.............................................................................517 Unlocking telescoping cylinder......................................................................520 Extending/ retracting telescoping cylinder and locking.............................................522 Unlock telescope section............................................................................525 Telescoping telescope section to fixed length and lock..............................................527 Telescoping telescope section to intermediate length................................................531 Locking telescope section...........................................................................532 Telescoping with fully automatic control............................................................533 Example of telescoping with teleautomatic...........................................................535 Lowering the main boom for maintenance..............................................................537 Telescoping the main boom in the horizontal position...............................................537 13.3.7 Fast speed.......................................................................................538 13.3.8 Menus on the crane control display...............................................................539 Menu Display states.................................................................................539 Menu Display telescoping status and teleautomatic..................................................543 Menu Power unit speeds/Critical load control........................................................543 Access emergency operation menu.....................................................................547 Display of an error message.........................................................................548 13.3.9 Setting a constant engine speed..................................................................550 13.3.10 Critical load control...........................................................................551 13.3.11 Incline crane cab...............................................................................552 13.3.12 Cooling the hydraulic oil.......................................................................553 Standard oil cooler.................................................................................553 Additional oil cooler...............................................................................553 13.3.13 Movements which can be carried out simultaneously...............................................554 13.4 Driving with a rigged crane............................................................................555 13.4.1 Driving route....................................................................................555 13.4.2 Rigging mode and axle loads......................................................................556 Boom positions......................................................................................556 13.4.3 Driving the rigged truck crane...................................................................558 Locking the superstructure and engaging the slewing gear permanent brake..........................558 Retracting the outriggers..........................................................................558 Switching over the suspension locking system........................................................558 Switching on separate steering......................................................................559 Driving.............................................................................................560 Extending the outriggers............................................................................560 13.5 Work break.............................................................................................561 13.5.1 Short work break.................................................................................561 13.5.2 Work breaks lasting more than 8 hours............................................................561 13.6 Crane cab heating and ventilation......................................................................563 13.6.1 Heating the crane cab............................................................................563 13.6.2 Additional water heating system (additional equipment)..........................................564 Switching on the additional heating system.........................................................564 Switching off the additional heating system........................................................565 13.6.3 Auxiliary heater with timer (additional equipment)...............................................565 Preheating crane engine............................................................................565 Preheating cranecab...............................................................................566 Switching the auxiliary heater on/off...............................................................566 Displaying and setting the current time.............................................................566 Switching on and saving the automatic heating start.................................................567 Switching off the automatic heating start...........................................................568 13.6.4 Ventilating the crane cab........................................................................569 13.7 Air-conditioning system (additional equipment).........................................................571 13.7.1 Switching on.....................................................................................571 13.7.2 Switching off....................................................................................572 13.7.3 Air conditioning.................................................................................572 How to ensure pleasant air- conditioning............................................................572 Dehumidifying crane cab air.........................................................................573 14 Rigging work.................................................................................................577 14.1 Check lists for rigging work for crane operation with main boom........................................579 14.1.1 CHECKLIST: Rigging...............................................................................579 14.1.2 CHECKLIST: Unrigging.............................................................................583 14.2 Choosing a suitable site...............................................................................587 14.2.1 Load bearing capacity of the ground and the outrigger............................................587 Enlarging the surface area of the outrigger........................................................589 14.2.2 Safe distance from banks and pits................................................................590 14.2.3 Earthing the truck crane.........................................................................591 Earthing the truck crane............................................................................591 14.2.4 Safe distance from electrical lines..............................................................592 14.3 Rigging work after driving with trailer................................................................595 14.3.1 Switching off slewing gear freewheel (additional equipment)......................................596 Before slewing......................................................................................597 14.3.2 Switching off the boom floating position (additional equipment)..................................598 14.3.3 Switching off boom pre-tensioning (additional equipment).........................................599 14.4 Outrigger..............................................................................................601 14.4.1 CHECKLIST: Extending the outriggers..............................................................601 14.4.2 CHECKLIST: Retracting outrigger..................................................................603 14.4.3 Outrigger span...................................................................................605 Outrigger span 8.70 x 8.50 m (28.5 x 27.9 ft).......................................................605 Outrigger span 8,70 x 6,00 m (28.5 x 19.7 ft).......................................................606 Outrigger span 8.50 x 2.72 m (28.5x8.8 ft)........................................................606 Outrigger span 8,70x8.50/2.4m (28.5 x 27.9/7.9 ft)...............................................607 14.4.4 Preparing the outriggers.........................................................................608 Aligning the truck crane horizontally..............................................................608 Locking the suspension.............................................................................608 Safety for on-road driving..........................................................................608 Safety during crane operation.......................................................................609 14.4.5 Extending/retracting the outrigger beams.........................................................610 Extending the outrigger beams.......................................................................610 Retracting the outrigger beams.....................................................................614 14.4.6 Moving the outrigger pads into working/driving position..........................................615 Moving the outrigger pads into working position...................................................615 Moving the outrigger pads into driving position..................................................616 14.4.7 Extending/retracting the outrigger cylinders.....................................................617 Retracting the outrigger cylinders.................................................................618 14.4.8 Aligning the truck crane horizontally............................................................620 Reading the status display..........................................................................620 Switching over the measuring range..................................................................621 Aligning the truck crane horizontally...............................................................621 14.4.9 Outrigger pressure display (additional equipment)...............................................622 Reading the status displays.........................................................................622 14.5 Counterweight..........................................................................................625 14.5.1 Counterweight sections and identification........................................................625 Counterweight sections..............................................................................625 Identification......................................................................................625 14.5.2 Counterweight versions...........................................................................626 14.5.3 Slinging points on the counterweight sections....................................................630 14.5.4 CHECKLIST: Rigging the counterweight.............................................................631 Rig counterweight...................................................................................631 14.5.5 CHECKLIST: Unrigging the counterweight...........................................................634 Unrig counterweight.................................................................................634 14.5.6 Placing the counterweight........................................................................636 5.4 t base plate on counterweight platform..........................................................637 Stacking counterweight sections.....................................................................637 14.5.7 Connecting/disconnecting the hydraulic connection................................................638 Establishing hydraulic connection.................................................................638 Disconnecting the hydraulic connection..............................................................639 14.5.8 Assembling the counterweight version.............................................................640 14.5.9 3.5 t counterweight section......................................................................645 Rigging with assemble rods (additional equipment)...................................................645 Locking the 3.5 t counterweight section.............................................................646 14.5.10 Extending/retracting the lifting cylinders of the 5.4 t base plate or lifting/lowering c.......647 Extend the lifting cylinders........................................................................648 Retract hoist cylinder.............................................................................649 14.5.11 Locking the counterweight on the turntable/releasing the locking pin...........................649 Hasp positions......................................................................................650 Safety cock.........................................................................................650 Locking the counterweight..........................................................................651 Unlocking the counterweight.........................................................................651 14.5.12 Rigging 3.75 t counterweight section (additional equipment).....................................652 14.5.13 Rigging 3 t counterweight blocks (additional equipment)........................................653 14.5.14 Slewing with the counterweight rigged...........................................................654 14.6 Rigging work on the main boom..........................................................................655 14.6.1 Hook block on the bumper.........................................................................655 Picking up the hook block...........................................................................655 Attaching the hook block............................................................................656 14.6.2 Hook block on a separate vehicle.................................................................657 Picking up the hook block...........................................................................657 Setting down the hook block and securing the hoist rope for on-road driving........................658 14.6.3 Reeving and unreeving the hoist rope............................................................659 Rope end clamp......................................................................................659 Installing/removing front rope grab.................................................................661 Reeving the hoist rope..............................................................................662 Lifting limit switch on the main boom...............................................................664 14.6.4 Possible reeving methods on the main boom........................................................667 14.6.5 Anemometer.......................................................................................671 Remove the anemometer..............................................................................672 14.6.6 Rigging heavy duty equipment.....................................................................673 Heavy duty equipment parts..........................................................................673 Equipment required.................................................................................673 Rigging heavy duty equipment........................................................................674 Unrigging heavy duty equipment......................................................................677 Reevings with heavy duty equipment..................................................................679 15 Malfunctions on the superstructure...........................................................................683 15.1 Superstructure emergency stop device...................................................................683 Switching off the crane engine.........................................................................683 Crane control emergency stop switch.....................................................................684 15.2 Troubleshooting for malfunctions that occur during crane operation....................................685 Load cannot be lowered..................................................................................685 15.3 Electrical system......................................................................................687 15.3.1 Plug-in modules and consoles.....................................................................688 15.3.2 Fuses............................................................................................690 Groups F1 to F9...................................................................................690 Groups F10 to F13...................................................................................694 15.3.3 SLI fuses........................................................................................695 Replacing fuses.....................................................................................695 15.4 Troubleshooting and malfunction correction.............................................................697 15.4.1 Crane engine malfunctions........................................................................697 15.4.2 Main hoist malfunctions..........................................................................698 15.4.3 Auxiliary hoist malfunctions.....................................................................700 15.4.4 Derricking gear malfunctions.....................................................................702 15.4.5 Telescoping gear malfunctions....................................................................704 15.4.6 Slewing gear malfunctions........................................................................706 15.4.7 Counterweight lifting gear/lock malfunctions.....................................................707 15.4.8 Hydraulic system/hydraulic oil cooler malfunctions...............................................708 15.4.9 Crane control malfunctions.......................................................................708 15.4.10 Malfunctions on the SLI.........................................................................709 Other malfunctions on the SLI......................................................................709 SLI error message table............................................................................710 Switch off sensor/ indicator during malfunction.....................................................717 Check that the remaining sensor/ indicator is working..............................................718 Accepting the telescope status from the crane control...............................................719 Checking SLI lines and connections.................................................................720 15.4.11 Retraction emergency operation..................................................................722 Check before all emergency operation................................................................722 Procedure for retracting...........................................................................723 Mechanical emergency operation......................................................................724 Hydraulic emergency operation.......................................................................726 15.5 Error messages crane control...........................................................................739 15.5.1 Error messages about control units...............................................................739 15.5.2 Error messages about power units.................................................................740 Determining defective part..........................................................................741 Determining error area..............................................................................742 Error causes and effects............................................................................743 15.5.3 Telescoping error messages.......................................................................745 15.5.4 Changing the connections in the control units....................................................746 Connections and control units.......................................................................746 Unrigging mobile crane with defective control unit..................................................746 Inserting and removing connections..................................................................749 15.5.5 Control lever emergency program..................................................................750 Indications on the display..........................................................................750 Carrying out emergency program.....................................................................751 15.5.6 Emergency operation submenu......................................................................752 Retracting with an error on the length indicator....................................................753 Retracting with an error on the proximity switch....................................................756 Table for approaching the locking points............................................................757 15.5.7 Entering telescope status after emergency operation menu.........................................758 15.6 Hydraulic emergency stop according to ZH1/461 (additional equipment)...................................761 15.6.1 Important instructions for hydraulic emergency operation.........................................761 15.6.2 Functioning and accessories......................................................................763 15.6.3 Connecting the transformer.......................................................................764 15.6.4 Switching emergency operation on/off.............................................................765 15.6.5 Establishing required hydraulic circuits.........................................................766 Making connections on the plug- in field............................................................766 Additional switches for hoisting gear and slewing gear.............................................767 15.6.6 Executing emergency operation....................................................................768 Driving hoisting gear emergency operation...........................................................768 Emergency operation driving derricking gear.........................................................769 Emergency operation driving the slewing gear........................................................769 15.6.7 After the emergency operation....................................................................770 16 Technical information for superstructure.....................................................................773 16.1 Technical description of the superstructure............................................................773 16.1.1 Turntable........................................................................................773 16.1.2 Crane operator’s cab.............................................................................773 16.1.3 Crane engine and hydraulic system................................................................774 16.1.4 Control system...................................................................................774 16.1.5 Main boom........................................................................................775 16.1.6 Telescoping gear.................................................................................775 16.1.7 Hoists...........................................................................................776 16.1.8 Slewing gear units...............................................................................776 16.1.9 Houselock (additional equipment).................................................................776 16.1.10 Derricking cylinder.............................................................................777 16.1.11 Electrical system..............................................................................777 16.1.12 Counterweight...................................................................................777 16.1.13 Safety equipment................................................................................778 16.2 Technical data.........................................................................................779 16.2.1 Maximum lifting capacity.........................................................................779 DIN/ISO/EN..........................................................................................779 ANSI B 30.5 (85%)...................................................................................779 16.2.2 Guaranteed value specifications..................................................................779 16.2.3 Measurements and weights of the truck crane......................................................780 Dimensions for driving on public roads.............................................................781 16.2.4 Dimensions and weights of removable parts........................................................782 Counterweight parts................................................................................782 Hook blocks and hook tackle.........................................................................783 Auxiliary hoist.....................................................................................783 Main boom...........................................................................................784 Heavy dutyequipment................................................................................784 Counterweight versions..............................................................................784 16.2.5 Technical data for superstructure................................................................788 Crane engine........................................................................................788 Crane’s electrical system...........................................................................788 Main hoist..........................................................................................788 Auxiliary hoist (additional equipment)..............................................................789 Slewing gears.......................................................................................789 Derricking gear.....................................................................................789 Main boom...........................................................................................789 Operating speeds and times without a load..........................................................790 17 Index........................................................................................................793 A...........................................................................................................795 B...........................................................................................................796 C...........................................................................................................796 D...........................................................................................................798 E...........................................................................................................799 F...........................................................................................................800 H...........................................................................................................800 I...........................................................................................................801 K...........................................................................................................801 L...........................................................................................................801 M...........................................................................................................801 O...........................................................................................................802 P...........................................................................................................803 R...........................................................................................................803 S...........................................................................................................804 T...........................................................................................................805 U...........................................................................................................807 V...........................................................................................................807 W...........................................................................................................807
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