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Grove Crane GMK 6220-L Driving Operating Instructions Manual 3112290 – PDF DOWNLOAD
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Description
Grove Crane GMK 6220-L Driving Operating Instructions Manual 3112290 – PDF DOWNLOAD
FILE DETAILS:
Grove Crane GMK 6220-L Driving Operating Instructions Manual 3112290 – PDF DOWNLOAD
Language : English
Pages : 876
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Grove Crane GMK 6220-L Driving Operating Instructions Manual 3112290 – PDF DOWNLOAD
Intended use:
- The truck crane GMK 6220-L is constructed in accordance with the latest technology and the
recognized safety regulations. Nevertheless, personal injury to the operator or a third party as
well as damage to the crane and other property may occur during use. - The truck crane may only be modified with the consent of the manufacturer.
- The truck crane GMK 6220-L may only be used when in excellent working condition and for its
intended purpose, and with due attention to safe oper- ation and any possible hazards.
Malfunctions that may affect safe operation are to be corrected immedi- ately. - The GMK 6220-L truck crane may only be operated at temperatures of between –25 to +40 °C unless
fitted with the appropriate special equipment. - The GMK 6220-L truck crane may only be used for the vertical lifting of loads, in the authorized
rigging modes and using a hook block that is reeved to the hoist rope. The weight and centre of
distribution of the loads must be known. Any other use of the crane is not considered to represent
intended use. - The manufacturer is not liable for damage resulting from the improper or unauthorized use of the
GMK 6220-L truck crane. The user shall take full responsibility for any such use.
Intended use also entails the following:
– Observing the complete crane documentation consisting of the operating instructions, the lifting
capacity table, the outrigger pressure table and the safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Grove Crane GMK 6220-L Driving Operating Instructions Manual 3112290 – PDF DOWNLOAD
Additional Pages SLI override................................................................................... 3 1 Overview...................................................................................................... 19 1.1 Vehicle identification.................................................................................. 19 1.2 EC Conformity Declaration............................................................................... 23 1.3 Overview and contents of the truck crane user information............................................... 25 1.3.1 Operating instructions............................................................................ 25 1.3.2 Lattice extension operating instructions.......................................................... 26 1.3.3 Maintenance manual................................................................................ 26 1.3.4 Lifting capacity tables........................................................................... 27 1.3.5 Outrigger pressure tables......................................................................... 27 1.3.6 Safety manual..................................................................................... 27 1.3.7 Circuit diagrams.................................................................................. 27 1.3.8 Spare parts list.................................................................................. 28 1.4 Instructions for using this documentation............................................................... 29 1.4.1 How are the operating instructions laid out?...................................................... 29 1.4.2 How are the pages of the operating instructions formatted?........................................ 30 1.4.3 How can I find the necessary information quickly and easily?...................................... 31 Example of cross- reference usage................................................................... 32 How to use the index................................................................................ 37 1.4.4 Definition of positional references............................................................... 37 Basic rule.......................................................................................... 37 Buttons and switches................................................................................ 37 1.4.5 Conversion table for US measurements.............................................................. 38 2 Basic safety instructions for crane operators................................................................. 41 2.1 Warnings and symbols.................................................................................... 41 2.2 Intended use............................................................................................ 43 2.3 Organizational measures................................................................................. 45 2.4 Personnel qualifications................................................................................ 47 2.5 Safety instructions that apply to truck crane driving................................................... 49 2.6 Safety instructions for truck crane work................................................................ 51 3 Information for operations planning........................................................................... 55 3.1 Safety instructions..................................................................................... 55 3.1.1 Intended use...................................................................................... 55 3.1.2 Organizational measures........................................................................... 55 3.1.3 Personnel qualifications.......................................................................... 56 3.2 Operations planning..................................................................................... 57 3.2.1 Prerequisites for operations planning............................................................. 57 3.2.2 Information for operations planning contained in the user information............................ 58 4 Description of the truck crane – Vehicle section.............................................................. 61 4.1 Overview of the operating and display elements.......................................................... 61 4.1.1 Vehicle overview.................................................................................. 61 4.1.2 Driver's cab overview............................................................................. 64 Overhead in the driver's cab........................................................................ 67 4.1.3 Front instrument panel............................................................................ 68 Left................................................................................................ 68 Middle.............................................................................................. 70 Right............................................................................................... 72 4.1.4 Side instrument panel............................................................................. 76 For the transmission............................................................................... 78 Auxiliary water heater with timer................................................................... 79 Auxiliary air heater................................................................................ 80 4.1.5 Switch boxes for outrigger box locking pin........................................................ 81 4.2 Functional description of the display and operating elements............................................ 83 4.2.1 On the instrument panels.......................................................................... 83 Vehicle engine...................................................................................... 83 Automatic transmission.............................................................................. 84 Transfer case....................................................................................... 87 Axle drive.......................................................................................... 89 Brakes.............................................................................................. 90 Suspension.......................................................................................... 91 Hydraulic system.................................................................................... 93 Steering............................................................................................ 94 Electronics......................................................................................... 95 Level adjustment system............................................................................. 97 Heating system for driver's cab..................................................................... 98 Auxiliary water heating system......................................................................100 Auxiliary air heater................................................................................101 Air-conditioning system.............................................................................102 Cab lighting........................................................................................103 Other operating elements............................................................................103 4.2.2 Other operating elements for the vehicle section..................................................105 Keys................................................................................................105 Doors...............................................................................................105 Windows.............................................................................................106 Access ladders......................................................................................108 Ladders.............................................................................................108 Vehicle engine diagnostics plug.....................................................................110 Fire extinguisher...................................................................................110 Folding berth.......................................................................................111 5 Vehicle engine................................................................................................115 5.1 Starting/turning off the vehicle engine.................................................................115 5.1.1 CHECKLIST: Starting the vehicle engine............................................................115 5.1.2 CHECKLIST: In winter..............................................................................118 5.1.3 Checks prior to starting vehicle engine...........................................................119 Checking the hydraulic system's shut-off valves.....................................................119 Switching on the battery master switch..............................................................119 Pre-checking the oil level in the automatic transmission............................................120 Checking coolant level..............................................................................121 Checking the hydraulic oil level....................................................................122 Checking the engine oil level.......................................................................122 Topping up engine oil...............................................................................123 5.1.4 Refuelling........................................................................................124 5.1.5 Starting the vehicle engine.......................................................................125 Switching on the ignition...........................................................................125 Starting the vehicle engine........................................................................127 5.1.6 Checks after the engine has been started..........................................................129 Checking instruments................................................................................129 Checking the oil level in the automatic transmission...............................................130 5.1.7 Turning off the vehicle engine....................................................................135 5.1.8 Emergency stop via the air intake inhibitor.......................................................136 Switching on the air intake inhibitor...............................................................136 Manually disconnecting the air intake inhibitor.....................................................137 6 Driving the truck crane.......................................................................................141 6.1 Checks on the truck crane before driving................................................................141 6.1.1 CHECKLIST: condition of the truck crane for on-road driving.......................................141 6.1.2 Checking the condition of the truck crane.........................................................147 Checking the reservoir of the windscreen washing system.............................................147 Warning plates for vehicle width....................................................................147 Checking the tyres..................................................................................148 Checking the electrical system.....................................................................148 Checking the mirror setting.........................................................................149 Checking the compressed air and brake systems.......................................................149 Checking the suspension............................................................................151 Checking on-road level..............................................................................151 Checking the transverse differential locks.........................................................152 Checking the drive of the second axle line/longitudinal differential locks..........................152 Checking the transfer case..........................................................................152 Checking the steering locks.........................................................................152 Checking warning lamp for Main boom not set down....................................................153 6.1.3 Adjusting the seat and the steering column........................................................154 Adjusting the driver's seat.........................................................................154 Adjusting the steering column.......................................................................154 6.1.4 Trip recorder.....................................................................................155 Inserting the 24-hour disc in the trip recorder.....................................................155 6.2 General operation.......................................................................................157 6.2.1 Operating the automatic transmission..............................................................157 Switching on........................................................................................157 Changing the driving modes.........................................................................158 Selecting the driving direction....................................................................158 Selecting highest gear/starting gear................................................................159 Starting............................................................................................160 Driving and changing gears..........................................................................160 Shifting the transmission to neutral position.......................................................162 Changing the driving direction.....................................................................163 Stopping............................................................................................163 On roller-type dynamometer..........................................................................163 6.2.2 Monitoring the control instruments while driving..................................................165 6.2.3 Driving downhill..................................................................................169 Engine retarder.....................................................................................169 Preselecting gears..................................................................................170 6.2.4 Driving uphill....................................................................................171 6.2.5 Tempomat..........................................................................................171 Switching on the Tempomat...........................................................................172 Driving with the Tempomat...........................................................................172 Switching off the Tempomat..........................................................................173 Eddy current retarder...............................................................................173 6.2.6 Parking the truck crane...........................................................................175 Applying the parking brake.........................................................................175 Automatic transmission in neutral position..........................................................175 Turning off the vehicle engine......................................................................175 Securing the truckcrane against rolling............................................................175 Switch off the battery master switch if the truck crane is idle for a longer period of time.........176 Securing the truck crane against unauthorised use...................................................176 6.3 Off-road driving........................................................................................177 6.3.1 Off-road gear.....................................................................................178 Engaging the off- road gear.........................................................................178 Deactivating the off-road gear......................................................................178 6.3.2 Drive of the second axle line/longitudinal differential locks.....................................180 Switching on drive/longitudinal differential locks..................................................180 Switching off drive/longitudinal differential locks.................................................181 6.3.3 Transverse differential locks in all driven axle lines............................................182 Switching on thetransverse differential locks.....................................................182 Switching of the transverse differential locks......................................................183 6.3.4 Level adjustment system...........................................................................184 Activating the level adjustment system..............................................................184 Raising or lowering the entire truck crane..........................................................185 Tilting the truck crane lengthwise or crosswise.....................................................186 Bringing the truck crane to On-road level...........................................................187 Deactivating the level adjustment system............................................................187 6.3.5 Freeing an immobilized truck crane................................................................188 Freeing the truck crane without external assistance.................................................188 Towing free to the rear.............................................................................189 Towing free to thefront............................................................................189 6.4 Separate steering.......................................................................................191 6.4.1 Switching to separate steering mode...............................................................193 6.4.2 Steering axle lines with separate steering........................................................194 All-wheel steering..................................................................................194 Crab travel mode....................................................................................194 6.4.3 Switching off separate steering and locking the steering..........................................195 Locking the steering in straight ahead position.....................................................195 Locking in other positions..........................................................................196 6.4.4 Matching steering angle...........................................................................197 6.5 Heating and ventilation.................................................................................199 6.5.1 Heating in the driver's cab.......................................................................199 Adjusting the air vents.............................................................................200 Ventilating the driver's cab........................................................................200 6.5.2 Auxiliary water heating system....................................................................201 Preheating the vehicle engine.......................................................................201 Preheating the driver's cab.........................................................................201 Switching on the auxiliary heater...................................................................202 Switching off the auxiliary heater..................................................................203 6.5.3 Auxiliary water heating system with timer.........................................................204 Preheating the vehicle engine.......................................................................204 Preheating the driver's cab.........................................................................204 Switching on the auxiliary heater...................................................................205 Switching off the auxiliary heater..................................................................206 Setting the time and weekday........................................................................206 Saving the automatic heating start................................................................207 Setting the automatic heating duration............................................................208 Switching the automatic heating start on/off........................................................208 Setting the remaining time..........................................................................209 6.5.4 Auxiliary air heater with timer...................................................................211 Switching on the auxiliary heater...................................................................211 Regulating the temperature..........................................................................212 Switching off the auxiliary heater..................................................................212 Setting the remaining time..........................................................................213 6.6 Air-conditioning system.................................................................................215 6.6.1 Switching on......................................................................................215 6.6.2 Switching off.....................................................................................215 6.6.3 Air conditioning..................................................................................216 How to use the air conditioning effectively.........................................................216 Dehumidifying the air in the driver's cab...........................................................217 6.7 Roof ventilator.........................................................................................217 6.8 Towing a trailer........................................................................................219 Effects on the axle loads...............................................................................219 Coupling the trailer....................................................................................220 Connecting the supply lines.............................................................................221 Removing supply lines...................................................................................222 Uncoupling the trailer..................................................................................222 Test position of the parking brake when towing a trailer................................................224 7 Driving modes and rigging for on-road driving.................................................................227 7.1 Driving modes...........................................................................................229 Information on the axle loads...........................................................................229 7.1.1 Information on how to use the tables..............................................................230 7.1.2 Tables for maximum axle load of 12 t - without ROB................................................231 For tyres 14.00R25................................................................................231 For tyres 16.00R25................................................................................232 For tyres 20.5R25.................................................................................232 7.1.3 Tables for maximum axle load of 12 t – with ROB...................................................233 For tyres 14.00R25................................................................................233 For tyres 16.00R25................................................................................234 For tyres 20.5R25.................................................................................235 7.2 Rigging work for driving with a trailer.................................................................237 7.2.1 Switching on the slewing gear freewheel...........................................................238 Prerequisites.......................................................................................238 7.2.2 Switching on boom floating position...............................................................240 Setting the main boom down on the trailer...........................................................240 7.2.3 Switching on boom pre-tensioning..................................................................242 7.3 Rigging the outrigger beams.............................................................................245 Equipment...............................................................................................245 7.3.1 CHECKLIST: Removing the outrigger beams...........................................................246 7.3.2 CHECKLIST: Installing outrigger beams.............................................................248 7.3.3 Preparing the truck crane for the removal/installation............................................251 Prerequisites for installation/ removal.............................................................251 Preparing the truck crane...........................................................................251 7.3.4 Removing/attaching outrigger pads.................................................................252 Removing outrigger pads............................................................................252 Attaching outrigger pads...........................................................................253 7.3.5 Disconnecting/establishing the hydraulic connection...............................................253 Disconnecting thehydraulic connection.............................................................254 Establishing thehydraulic connection..............................................................255 7.3.6 Disconnecting/establishing the electrical connection for the outrigger pressure display...........256 7.3.7 Transport position/operating position of the holding angle........................................257 7.3.8 Locking/releasing the extension cylinder locking pin..............................................258 Releasing the locking pin...........................................................................258 Locking the extension cylinder......................................................................259 7.3.9 Pulling out/reinserting outrigger beams...........................................................260 Pulling out outrigger beams........................................................................260 Inserting outrigger beams..........................................................................262 7.3.10 Transporting the outrigger beams/outrigger pads..................................................264 7.4 Rigging the rear outrigger box (ROB)....................................................................265 7.4.1 CHECKLIST: Removing the outrigger box.............................................................265 7.4.2 CHECKLIST: Installing the outrigger box...........................................................268 7.4.3 Preparing the truck crane for the removal/installation............................................270 Preparing for removal...............................................................................270 Preparing for installation/ assembly................................................................270 7.4.4 Crane movements when installing and removing......................................................271 Prerequisites.......................................................................................271 Before installation.................................................................................271 After removal.......................................................................................271 7.4.5 Slinging points on the rear outrigger box (ROB)...................................................272 7.4.6 Establishing/disconnecting the electrical connection..............................................273 7.4.7 Disconnecting/establishing the hydraulic connection...............................................274 Establishing thehydraulic connection..............................................................274 Disconnecting thehydraulic connection.............................................................274 7.4.8 Attaching/removing the outrigger box with the truck crane.........................................275 Removing the outrigger box.........................................................................276 Attaching the outrigger box........................................................................276 7.4.9 Locking the outrigger box to the carrier and unlocking it again...................................277 Locking the outrigger box..........................................................................277 Releasing the locking pins..........................................................................277 Extending and retracting the pins...................................................................278 7.4.10 Establishing/disconnecting the pneumatic connection..............................................278 7.4.11 Slewing with the rear outrigger box (ROB) removed................................................279 Prerequisites for slewing...........................................................................279 7.4.12 Transportation on a separate vehicle.............................................................280 7.4.13 Setting down the main boom on a trailer with the rear outrigger box (ROB) removed...............281 Bracing the truck crane.............................................................................281 Setting down the main boom..........................................................................282 7.5 Rigging the main boom...................................................................................283 Additional equipment required...........................................................................283 7.5.1 CHECKLIST: Removing the main boom.................................................................284 Prerequisites.......................................................................................284 Removing the main boom..............................................................................284 7.5.2 CHECKLIST: Installing the main boom...............................................................287 Prerequisites.......................................................................................287 Installing the main boom............................................................................287 7.5.3 Rigging work with the auxiliary crane.............................................................290 Lifting the main boom from the turntable............................................................291 Lifting the main boom to the turntable..............................................................292 7.5.4 Establishing/disconnecting the hydraulic connection to thelattice extension (additional eq.......292 Disconnecting thehydraulic connection.............................................................293 Establishing thehydraulic connection..............................................................293 7.5.5 Pulling device on the main boom pivot pin.........................................................294 Pin-type keepers on foot section....................................................................294 Hydraulic connection...............................................................................295 Retracting/ extending pins..........................................................................296 7.5.6 Locking pin on derricking cylinder head eyelet....................................................297 Operating the lifting equipment....................................................................297 Retracting/ extending pins..........................................................................299 7.5.7 Hydraulic connections on the main boom............................................................300 Removing/replacing guide plates.....................................................................301 Establishing thehydraulic connection..............................................................301 Disconnecting thehydraulic connection.............................................................302 7.5.8 Electrical connections on the main boom...........................................................303 7.5.9 Checks following main boom installation...........................................................304 Hydraulic system check..............................................................................304 Checking the electrical system......................................................................305 7.5.10 Before on-road driving...........................................................................307 Securing the derricking cylinder for on-road driving................................................307 Transporting the main boom..........................................................................307 7.5.11 Derricking cylinder pressure relief..............................................................308 Switching on pressure relief........................................................................308 Switching off pressure relief.......................................................................309 7.6 Installing/removing the auxiliary hoist.................................................................311 7.6.1 Slinging points and transport.....................................................................311 Slinging points.....................................................................................311 Transportation......................................................................................312 7.6.2 Installing the auxiliary hoist....................................................................313 Removing pin- type keeper and pins..................................................................313 Attach the auxiliary hoist to the main hoist........................................................313 Locking the auxiliary hoist........................................................................314 Establishing hydraulic and electrical connections...................................................314 7.6.3 Removing the auxiliary hoist......................................................................315 7.6.4 Permitted applications for the auxiliary hoist....................................................316 Replacement for the main hoist......................................................................316 Alternating operation with themain and auxiliary hoists..........................................317 8 Malfunctions on the carrier...................................................................................321 8.1 Emergency stop device on carrier........................................................................321 Turning off the vehicle engine..........................................................................321 8.2 What to do in the event of a breakdown in road traffic..................................................323 8.3 Towing the truck crane..................................................................................325 8.3.1 Towing in the event of engine or transmission damage..............................................326 Towing the truck crane out of the danger area.......................................................326 Compressed-air supply in the event of engine failure................................................327 Electric power supply...............................................................................327 Transmission........................................................................................328 Vehicle engine......................................................................................328 Parking brake.......................................................................................328 Mechanically releasing the parking brake...........................................................329 Towing procedure....................................................................................330 Removing mechanical locking from all spring-loaded brake cylinders.................................330 Tow starting........................................................................................330 8.4 Wheels..................................................................................................331 8.4.1 Wheel change......................................................................................331 Removing a damaged wheel...........................................................................331 Removing the wheel from thespare wheel holder......................................................332 Installing a damaged wheel on thespare wheel holder................................................333 Installing the spare wheel..........................................................................334 8.4.2 Filling the tyres yourself........................................................................335 Connecting the inflator hose........................................................................335 Filling the tyres...................................................................................336 Removing the tyre inflator hose.....................................................................336 8.5 Fuses on the carrier....................................................................................337 Information on replacing fuses..........................................................................337 8.5.1 Fuses in the driver's cab.........................................................................338 8.5.2 Fuses in the battery box..........................................................................341 8.6 Finding and eliminating malfunctions....................................................................343 8.6.1 Vehicle engine malfunctions.......................................................................343 8.6.2 Malfunctions in automatic transmission............................................................345 8.6.3 Transfer case malfunctions........................................................................346 8.6.4 Malfunctions on the differential locks............................................................347 8.6.5 Service brake malfunctions........................................................................348 8.6.6 Steering malfunctions.............................................................................349 8.6.7 Malfunctions on the outriggers....................................................................350 8.6.8 Malfunctions in the suspension locking system.....................................................350 8.6.9 Malfunctions in the level adjustment system.......................................................350 8.7 Procedure in the event of malfunctions..................................................................351 8.7.1 Switching fan thermostats to emergency operation..................................................351 8.7.2 Procedure in the event of malfunctions in the automatic transmission.............................352 Error detection.....................................................................................352 Effect of the errors................................................................................352 Reading error codes.................................................................................353 8.7.3 Emergency operation of the solenoid valves for the outriggers.....................................355 8.7.4 Emergency operation of separate steering..........................................................358 Putting the steering into on-road driving mode......................................................359 9 Technical information for the carrier.........................................................................363 9.1 Dimensions and weights of the truck crane...............................................................364 9.1.1 Dimensions of the truck crane.....................................................................364 Dimensions when driving on public roads.............................................................365 9.1.2 Dimensions and weights of removable parts.........................................................366 Spare wheel (additional equipment)..................................................................366 Main boom...........................................................................................366 Outriggers..........................................................................................366 9.2 Carrier technical data..................................................................................367 Vehicle engine..........................................................................................367 Manual transmission....................................................................................367 Transfer case...........................................................................................367 Axle lines..............................................................................................367 Steering................................................................................................367 Tyres...................................................................................................368 Vehicle's electrical system.............................................................................368 Tools...................................................................................................368 Outriggers..............................................................................................369 Driving speeds..........................................................................................370 Climbing ability........................................................................................370 Turning circle radiuses................................................................................371 10 Index........................................................................................................375 A...........................................................................................................377 B...........................................................................................................378 C...........................................................................................................378 D...........................................................................................................380 E...........................................................................................................380 F...........................................................................................................381 H...........................................................................................................382 I...........................................................................................................383 K...........................................................................................................383 L...........................................................................................................383 M...........................................................................................................384 O...........................................................................................................384 P...........................................................................................................385 R...........................................................................................................386 S...........................................................................................................386 T...........................................................................................................387 U...........................................................................................................389 V...........................................................................................................389 W...........................................................................................................389 11 Description of the crane section of the truck crane..........................................................411 11.1 Overview of the operating and display elements.........................................................411 11.1.1 Overview of the crane section....................................................................411 11.1.2 Crane cab overview...............................................................................414 11.1.3 Instrument panel.................................................................................416 Front instrumentpanel...............................................................................416 Auxiliary water heater with timer...................................................................422 Auxiliary air heater with timer.....................................................................423 Controls and fittings behind the crane operator's seat.............................................431 11.1.4 Left-hand control panel..........................................................................432 11.1.5 Right-hand control panel.........................................................................433 11.1.6 Control lever assignment.........................................................................434 Version 1 (standard)...............................................................................434 Version 2 (additional equipment)...................................................................435 11.1.7 Switch box for operating the outriggers..........................................................436 11.1.8 Counterweight hoist switch unit..................................................................437 11.1.9 Switch box for electronic level..................................................................438 11.2 Functional description of the display and operating elements...........................................439 11.2.1 Working with the crane...........................................................................439 Crane engine........................................................................................439 Outriggeroperation..................................................................................440 Counterweight hoisting gear and lock................................................................442 Crane control.......................................................................................444 Main hoist..........................................................................................446 Auxiliary hoist.....................................................................................447 Slewing gear........................................................................................448 Derricking gear.....................................................................................449 Telescoping mechanism...............................................................................450 Safe load indicator.................................................................................455 Input elements with displays........................................................................455 Display elements....................................................................................459 Hydraulic system....................................................................................462 Electrics...........................................................................................462 Other operating elements...........................................................................463 Switch box for electronic level.....................................................................465 Crane cab electronic level.........................................................................466 Crane cab heating...................................................................................467 Auxiliary water heater with timer...................................................................467 Auxiliary air heater with timer.....................................................................469 Air-conditioning system version 1...................................................................470 Air-conditioning system version 2...................................................................471 Houselock...........................................................................................471 Anemometer..........................................................................................472 11.2.2 Other operating elements in the crane cab........................................................473 Doors, keys, windows...............................................................................473 Fire extinguisher...................................................................................475 Cab lighting........................................................................................475 Crane engine diagnostics plug......................................................................476 11.3 Functional description of safety devices...............................................................477 11.3.1 Safe load indicator (SLI)........................................................................477 11.3.2 Lowering limit switch............................................................................478 11.3.3 Lifting limit switch.............................................................................479 Overriding the lifting limit switch shutdown........................................................480 11.3.4 Dead man's switch and seat contact switch........................................................481 Additional Pages SLI override...................................................................................395 12 Crane engine.................................................................................................485 12.1 Starting/turning off the crane engine..................................................................485 12.1.1 CHECKLIST: Starting the crane engine.............................................................485 12.1.2 CHECKLIST: In winter.............................................................................487 12.1.3 Inspections prior to starting the crane engine...................................................488 Checking the shut- off valve in the hydraulic system................................................488 Switching on the battery master switch..............................................................488 Checking the coolant level.........................................................................489 Checking the hydraulic oil level....................................................................490 Checking the oil level in the crane engine..........................................................490 Topping up engine oil...............................................................................491 Refuelling..........................................................................................492 12.1.4 Starting the crane engine........................................................................493 Switching on the ignition...........................................................................493 Starting the crane engine...........................................................................494 12.1.5 Inspections after starting the crane engine......................................................496 Checking instruments...............................................................................496 12.2 Turning off the crane engine...........................................................................499 12.2.1 Emergency shut-off using the air intake inhibitor................................................500 Switching on the air intake inhibitor...............................................................500 Manually disconnecting the air intake inhibitor.....................................................501 13 Crane operation..............................................................................................505 13.1 Checking the truck crane before working with thecrane.................................................505 13.1.1 CHECKLIST: With rigged truck crane...............................................................505 13.1.2 Adjusting the crane operator's seat..............................................................509 13.1.3 Checking the condition of the truck crane........................................................510 Checking the reservoir of the windscreen washing system...........................................510 Visual inspection of the entire crane...............................................................510 Checking the position of the hoist ropes............................................................511 Electrical system...................................................................................511 13.1.4 Checking the safety devices......................................................................512 Safe load indicator.................................................................................512 Lifting limit switch................................................................................512 Dead man's switch system............................................................................513 Crane control emergency stop circuit................................................................513 13.1.5 Preheating the hydraulic oil.....................................................................514 When the oil temperature is between –15 C and 0 C:...............................................514 When the oil temperature is under –15 C :.........................................................514 13.1.6 Superstructure lock..............................................................................515 Removing the lock...................................................................................516 Engaging the lock...................................................................................516 13.1.7 Houselock........................................................................................517 Switching on the houselock..........................................................................517 Switching off the houselock.........................................................................518 13.1.8 Adjusting the mirrors............................................................................519 13.2 Operating the safe load indicator (SLI)................................................................521 13.2.1 Switching on the SLI.............................................................................522 Switching on........................................................................................522 Lamp test on the SLI................................................................................524 Brightness of the displays..........................................................................524 13.2.2 Enter rigging mode...............................................................................525 Entering the SLI code...............................................................................526 Entering reeving values.............................................................................528 Entering individual components......................................................................530 13.2.3 Checks to be carried out before crane operation..................................................533 13.2.4 Displays during crane operation..................................................................535 Continuous displays................................................................................535 Optional displays...................................................................................537 13.2.5 SLI early warning................................................................................539 13.2.6 SLI shutdown.....................................................................................540 Shutdown due to overload............................................................................540 13.2.7 Error message....................................................................................541 13.2.8 SLI override.....................................................................................542 13.2.9 Displaying and entering the time and date........................................................543 Display.............................................................................................543 Input...............................................................................................544 13.3 Crane work with main boom..............................................................................545 13.3.1 External influences when working with the crane..................................................545 Horizontal alignment...............................................................................545 Safe distances......................................................................................545 Effect of wind on crane operation...................................................................546 Anemometer..........................................................................................546 Permissible wind load...............................................................................547 Earthing the load...................................................................................547 13.3.2 Slewing ranges permitted for working with the crane..............................................549 360 slewing range..................................................................................549 Working position 0 to the rear.....................................................................549 13.3.3 Hoisting gear....................................................................................550 Main hoist..........................................................................................550 Auxiliary hoist.....................................................................................553 13.3.4 Derricking gear..................................................................................555 13.3.5 Slewing gear.....................................................................................557 Slewing gear holding brake..........................................................................557 Slewing.............................................................................................557 Slewing speed.......................................................................................558 Tracking the slewing gear..........................................................................558 Maximum permitted slewing speed.....................................................................559 13.3.6 Telescoping mechanism............................................................................561 Structure of the chapter............................................................................561 Description of operating principle.................................................................562 Main boom fixed length, intermediate length, telescoping length...................................563 Telescoping.........................................................................................565 Notes on telescoping sequence.......................................................................567 Inspection before telescoping for the first time....................................................567 Control lever functions............................................................................568 Example of a telescoping procedure..................................................................570 Checking initial position...........................................................................571 Unlocking telescoping cylinder......................................................................574 Extending/retracting the telescoping cylinder and locking...........................................576 Unlocking telescopic section........................................................................579 Telescoping a telescopic section to a fixed length and locking it...................................581 Telescoping the telescopic section to an intermediate length........................................585 Locking the telescopic section......................................................................586 Automatic telescoping..............................................................................587 Example of telescoping with teleautomation..........................................................590 Lowering the main boom for maintenance..............................................................591 Telescoping main boom into horizontal position......................................................592 13.3.7 High-speed mode..................................................................................593 13.3.8 Menus on the crane control display...............................................................594 The menu Statusdisplay.............................................................................594 Menu Telescoping display and teleautomation.........................................................598 Menu Power unit speeds/Critical load control.......................................................598 Access emergency operation menu.....................................................................602 Display of an error message.........................................................................603 13.3.9 Setting a constant engine speed..................................................................605 13.3.10 Critical load control...........................................................................606 13.3.11 Inclining the crane cab.........................................................................607 13.3.12 Cooling the hydraulic oil.......................................................................608 Standard oil cooler.................................................................................608 Additional oil cooler...............................................................................608 13.3.13 Possible combinations of operations.............................................................609 13.3.14 Operation of the directional working area spotlights............................................610 Switching on/off....................................................................................610 Swivelling..........................................................................................610 13.4 Driving with a rigged crane............................................................................611 13.4.1 Route............................................................................................611 13.4.2 Rigging mode and axle loads......................................................................612 Main boom positions................................................................................612 13.4.3 Driving the rigged crane.........................................................................614 Locking the superstructure and engaging the slewing gear holding brake.............................614 Retracting the outriggers...........................................................................614 Switching over the suspension locking system........................................................614 Switching on separate steering mode................................................................615 Driving.............................................................................................616 Extending the outriggers...........................................................................616 13.5 Work interruption......................................................................................617 13.5.1 During short work interruptions..................................................................617 13.5.2 During work interruptions of more than 8 hours...................................................617 13.6 Heating and ventilation................................................................................619 13.6.1 Heating the crane cab............................................................................619 Adjusting the air vents.............................................................................620 Ventilating the crane cab...........................................................................620 13.6.2 Auxiliary water heater...........................................................................621 Preheating the crane engine.........................................................................621 Preheating the crane cab............................................................................621 Switching on the auxiliary heater...................................................................622 Switching off the auxiliary heater..................................................................623 13.6.3 Auxiliary water heater with timer................................................................624 Preheating the crane engine.........................................................................624 Preheating the crane cab............................................................................624 Switching on the auxiliary heater...................................................................625 Switching off the auxiliary heater..................................................................626 Setting the time and weekday........................................................................626 Saving the automatic heatingstart................................................................627 Setting the automatic heating duration............................................................628 Switching the automatic heating start on/off........................................................628 Setting the remaining time..........................................................................629 13.6.4 Auxiliary air heater with timer..................................................................630 Switching on the auxiliary heater...................................................................630 Regulating the temperature..........................................................................631 Switching off the auxiliary heater..................................................................631 Setting the remaining time..........................................................................632 13.7 Air-conditioning system................................................................................633 13.7.1 Version 1........................................................................................633 Switching on........................................................................................633 Switching off.......................................................................................634 13.7.2 Version 2........................................................................................634 13.7.3 Air conditioning.................................................................................635 How to use the air conditioning effectively.........................................................635 Dehumidifying the crane cab air.....................................................................635 14 Rigging work.................................................................................................639 14.1 Checklists for rigging work for crane operation with main boom.........................................639 14.1.1 CHECKLIST: Rigging...............................................................................639 14.1.2 CHECKLIST: Unrigging.............................................................................643 14.2 Choosing a suitable site...............................................................................647 14.2.1 Load bearing capacity of the ground and the outriggers...........................................647 14.2.2 Safe distance from banks and pits................................................................650 14.2.3 Earthing the truck crane.........................................................................651 Earthing the truck crane............................................................................651 14.2.4 Safe distance from electrical lines..............................................................652 14.3 Rigging work after driving with a trailer..............................................................655 14.3.1 Switch off slewing gear freewheel................................................................656 Before slewing......................................................................................657 14.3.2 Switching off the boom floating position.........................................................658 14.3.3 Switching off boom pre-tensioning................................................................658 14.4 Outriggers.............................................................................................661 14.4.1 CHECKLIST: Extending the outriggers..............................................................661 14.4.2 CHECKLIST: Retracting the outriggers.............................................................663 14.4.3 Outrigger span...................................................................................665 Outrigger span 8.70x8.50m........................................................................666 Outrigger span 8.70x6.00m........................................................................666 Outrigger span 8.70x2.68m........................................................................667 Outrigger span 8.70x8.50/2.4m....................................................................668 14.4.4 Preparing the outrigger..........................................................................669 Levelling the truck crane...........................................................................669 Locking the suspension.............................................................................669 Safety for on-road driving..........................................................................669 Safety during crane operation.......................................................................670 14.4.5 Extending/Retracting the outrigger beams.........................................................671 Extending the outrigger beams......................................................................671 Retracting the outrigger beams......................................................................675 14.4.6 Moving the outrigger pads into working/driving position..........................................676 Moving the outrigger pads into working position.....................................................676 Moving the outrigger pads into driving position....................................................677 14.4.7 Extending/retracting the outrigger cylinders....................................................678 Extending outrigger cylinders......................................................................678 Retracting outrigger cylinders......................................................................680 14.4.8 Checking the alignment of the truck crane........................................................681 On the carrier......................................................................................681 In the crane cab....................................................................................683 14.4.9 Levelling the truck crane on outriggers..........................................................685 If the main boom is on the boom rest................................................................685 If the main boom is raised..........................................................................685 14.4.10 Outrigger pressure indicator....................................................................685 On the carrier......................................................................................686 In the crane cab....................................................................................687 14.5 Counterweight..........................................................................................689 14.5.1 Counterweight sections and identification........................................................689 Counterweight parts.................................................................................689 Identification......................................................................................689 14.5.2 Counterweight combinations.......................................................................691 14.5.3 Slinging points on the counterweight parts.......................................................696 14.5.4 CHECKLIST: Rigging the counterweight.............................................................697 Unrigging counterweight............................................................................697 14.5.5 CHECKLIST: Unrigging counterweight...............................................................700 Unrigging counterweight............................................................................700 14.5.6 Setting down the counterweight sections..........................................................702 5.4 t base plate oncounterweight platform..........................................................702 Stacking counterweight sections.....................................................................703 14.5.7 Establishing/Disconnecting hydraulic connection..................................................704 Establishing the hydraulic connection...............................................................704 Disconnecting thehydraulic connection.............................................................705 14.5.8 Assembling the counterweight version.............................................................707 14.5.9 3.5 t counterweight section......................................................................712 Equipping with installation rods (additional equipment).............................................712 3.5 t counterweight section 3.5t counterweight section.............................................713 14.5.10 Extending/Retracting the lifting cylinders of the 5.4 t base plate or raising/lowering th.......714 Retracting lifting cylinders........................................................................715 Retracting lifting cylinders........................................................................716 14.5.11 Locking/unlocking the counterweight to the turntable............................................716 Hasp positions......................................................................................717 Safety valve........................................................................................717 Locking the counterweight..........................................................................718 Unlocking the counterweight.........................................................................718 14.5.12 Rigging 3.75t counterweight sections...........................................................719 14.5.13 Rigging 3t counterweight blocks................................................................720 14.5.14 Slewing with the rigged counterweight...........................................................721 14.6 Rigging work on the main boom..........................................................................723 14.6.1 Hook block on the bumper.........................................................................723 Picking up the hook block from the bumper...........................................................723 Attaching the hook block to the bumper..............................................................724 14.6.2 Hook block on a separate vehicle.................................................................725 Picking up the hook block...........................................................................725 Setting down the hook block.........................................................................726 14.6.3 Reeving and unreeving the hoist rope.............................................................729 Rope end clamp......................................................................................729 Installing/Removing front rope grab.................................................................731 Positioning the hoist rope..........................................................................732 14.6.4 Possible reeving methods on the main boom........................................................737 14.6.5 Installing/Removing the lifting limit switch.....................................................741 Installing the lifting limit switch................................................................741 Removing the lifting limit switch...................................................................745 14.6.6 Locking/Unlocking the lifting limit switch.......................................................747 Locking.............................................................................................747 Unlocking...........................................................................................748 14.6.7 Installing/Removing the anemometer...............................................................749 Installing the anemometer...........................................................................749 Removing the anemometer.............................................................................750 14.6.8 Installing/Removing the air traffic control light................................................751 Holder..............................................................................................751 Installing..........................................................................................751 Removing............................................................................................753 14.6.9 Rigging heavy duty equipment.....................................................................755 Heavy duty equipment parts.........................................................................755 Equipment required..................................................................................755 Rigging heavy duty equipment........................................................................756 Unrigging heavy duty equipment......................................................................759 Reevings with heavy duty equipment.................................................................761 15 Malfunctions on the superstructure...........................................................................765 15.1 Emergency stop devices on the superstructure...........................................................765 Switching off the crane engine..........................................................................765 Emergency stop switch for Crane control.................................................................766 15.2 Procedure in the event of a malfunction while working with the crane...................................767 Load cannot be lowered..................................................................................767 15.3 Fuses on the superstructure............................................................................769 Information on replacing fuses..........................................................................769 15.3.1 Fuses at the front of the crane cab..............................................................770 15.3.2 Fuses in the battery box.........................................................................774 15.3.3 Fuses for the SLI................................................................................775 15.4 Finding and eliminating malfunctions...................................................................777 15.4.1 Malfunctions on the crane engine.................................................................777 15.4.2 Malfunctions on the main hoist...................................................................778 15.4.3 Malfunctions on the auxiliary hoist..............................................................780 15.4.4 Malfunctions on the derricking gear..............................................................782 15.4.5 Malfunctions in the telescoping mechanism........................................................784 15.4.6 Malfunctions on the slewing gear.................................................................786 15.4.7 Malfunctions on locking pin/counterweight hoist..................................................787 15.4.8 Malfunctions in the hydraulic system/hydraulic oil cooler........................................788 15.4.9 Malfunctions on the crane control................................................................788 15.4.10 Malfunctions on the SLI.........................................................................789 General malfunctions...............................................................................789 Error messages onthe SLI control unit..............................................................790 Table – error messages..............................................................................792 15.4.11 Emergency retraction operation..................................................................794 Check prior to each emergency operation.............................................................794 Retraction procedures...............................................................................795 Mechanical emergency operation......................................................................796 Hydraulic emergency operation.......................................................................798 15.5 Crane control error messages...........................................................................811 15.5.1 Error messages concerning control units..........................................................811 15.5.2 Error messages concerning power units............................................................812 Finding a defective part............................................................................813 Determining the area of error.......................................................................814 Error causes and effects............................................................................815 15.5.3 Telescoping error messages.......................................................................817 15.5.4 Changing the connections in the control units....................................................818 Connections and control units.......................................................................818 Unrigging truck crane with defective control unit...................................................818 Inserting and removing connections.................................................................821 15.5.5 Control lever emergency program..................................................................822 Indication on thedisplay...........................................................................822 Executing emergency program.........................................................................823 15.5.6 Emergency operation submenu......................................................................824 Retracting in the event of an error on the length indicator.........................................825 Retracting in the event of an error on the proximity switch.........................................828 Table for approaching the locking points............................................................829 15.5.7 “Enter telescoping after emergency operation” menu...............................................830 15.6 Hydraulic emergency stop on the superstructure according to ZH1/461....................................833 15.6.1 Important instructions for hydraulic emergency operation.........................................833 15.6.2 Operating principle and accessories..............................................................835 15.6.3 Connecting the transformer.......................................................................836 15.6.4 Switching emergency operation on/off.............................................................838 15.6.5 Establishing the hydraulic circuits required.....................................................839 Establishing connections on the connector field.....................................................839 Additional switches for hoist and slewing gear......................................................840 15.6.6 Carrying out emergency operation.................................................................841 “Move hoist” emergency operation...................................................................841 “Move derricking gear” emergency operation..........................................................842 “Move slewing gear” emergency operation.............................................................842 15.6.7 After emergency operation........................................................................843 16 Technical information for the superstructure.................................................................847 16.1 Dimensions and weights.................................................................................847 16.1.1 Maximum lifting capacity.........................................................................847 DIN/ ISO/ EN........................................................................................847 ANSI B 30.5 (85%)...................................................................................847 16.1.2 Guaranteed value specifications..................................................................847 16.1.3 Dimensions and weights of the truck crane........................................................848 Dimensions when driving on public roads.............................................................849 16.1.4 Dimensions and weights of removable parts........................................................850 Counterweight parts.................................................................................850 Hook blocks and hook tackle.........................................................................851 Auxiliary hoist.....................................................................................851 Main boom...........................................................................................852 1) Width without add-on parts approx. 1.3 mHeavy dutyequipment.....................................852 Counterweight combinations..........................................................................852 16.2 Technical data for the superstructure..................................................................853 Crane engine............................................................................................853 Crane's electrical system...............................................................................853 Main hoist..............................................................................................853 Auxiliary hoist (additional equipment)..................................................................854 Slewing gears...........................................................................................854 Derricking gear.........................................................................................854 Main boom...............................................................................................854 Operating speeds and times without a load...............................................................855 17 Index........................................................................................................859 A...........................................................................................................861 B...........................................................................................................862 C...........................................................................................................862 D...........................................................................................................864 E...........................................................................................................864 F...........................................................................................................865 H...........................................................................................................866 I...........................................................................................................867 K...........................................................................................................867 L...........................................................................................................867 M...........................................................................................................868 O...........................................................................................................868 P...........................................................................................................869 R...........................................................................................................870 S...........................................................................................................870 T...........................................................................................................871 U...........................................................................................................873 V...........................................................................................................873 W...........................................................................................................873
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