Grove GMK 5095 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
DESCRIPTION:
Grove GMK 5095 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Serial number : 3 112 428 en
Intended use :
The GMK 5095 is a state-of-the-art truck crane, designed in accordance with approved safety regulations. Nevertheless, the operator or third parties can still be endangered and the crane or other property put at risk while using it.
The truck crane may only be modified with the consent of Manitowoc Crane Group Germany GmbH.
The GMK 5095 truck crane may only be used in a perfect technical condition as intended and with due attention paid to safe operation and possible hazards. Any malfunctions that could impair safety must be eliminated immediately.
The GMK 5095 truck crane may only be operated without the corresponding special equipment within the permitted temperature range; àTechnical Information on Carrier, p. 8 – 1.
The GMK 5095 truck crane is designed solely for lifting loads which are within the permitted GMK 5095 lifting capacities. The load must be slung as prescribed to a hook block which is positioned vertically over the load prior to lifting.
Intended use also includes
– Observing the entire crane documentation, consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual.
Improper use:
Manitowoc Crane Group Germany GmbH is not liable for damage resulting from the improper or unauthorized use of the GMK 5095 truck crane.
The user alone bears the risk. Improper use includes:
– Transporting loads on the carrier.
– Pushing, pulling or lifting loads with the level adjustment system, supports
or outrigger cylinders,
– Pushing or pulling loads or lifting them off the ground using the slewing
gear, derricking gear or telescoping mechanism,
– Pulling off fixed objects with the crane,
– Two-hook operation with the boom extension and two-hook operation on
the main boom head without additional equipment,
– Setting SLI codes that do not correspond to the actual rigging mode,
– Working with an overridden SLI or overridden lifting limit switch,
– After SLI shutdown, increasing the working radius by pulling the raised
load at an angle (e.g. with a chain hoist),
– Misuse of the outrigger pressure indicator as a safety function to prevent
the crane from overturning (outrigger pressure higher than 0 t),
– On-road driving in impermissible driving mode (axle load, dimension),
– Moving the rigged crane in an impermissible driving mode,
– Using equipment that is not permitted for the crane,
– Transporting people in any way with the lifting tackle, on the load, or in
the crane cab while driving,
– Transporting passengers outside the driver’s cab,
– Loading and unloading work, i.e. continuous operation without a sufficiently
long break,
– Usage for any kind of sport or recreation event, especially for “bungee”
jumping.
TABLE OF CONTENTS:
Grove GMK 5095 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Additional page Controls for crane cabin heating................................................ 3
Position of controls........................................................................ 3
Function.................................................................................... 4
1 Overview...................................................................................... 9
1.1 Identification.......................................................................... 9
1.2 EC Declaration of Conformity............................................................ 13
1.3 Documentation supplied.................................................................. 14
1.4 Information about the operating instructions............................................ 15
1.4.1 What do the symbols used mean?.................................................... 15
1.4.2 How are the operating instructions structured?.................................... 17
Division............................................................................ 17
Structure of the chapters........................................................... 17
Structure of the pages.............................................................. 18
1.4.3 How do I find the information I need?............................................. 19
Cross-references example............................................................ 20
1.4.4 What information is available for operations planning?............................ 22
1.5 Conversion table for US measurements.................................................... 23
2 Basic safety instructions..................................................................... 27
2.1 Intended use............................................................................ 27
2.1.1 Improper use...................................................................... 28
2.2 Organisational measures................................................................. 29
2.3 Qualifications of the personnel......................................................... 31
2.4 Safety instructions for driving the truck crane......................................... 32
2.5 Safety instructions for crane operation................................................. 32
3 Operating elements for driving................................................................ 37
3.1 Overview of the operating elements...................................................... 37
3.1.1 On the outside of the truck crane................................................. 38
3.1.2 Driver's cab...................................................................... 40
Overview............................................................................ 40
Behind the cover.................................................................... 42
3.1.3 Instrument panel.................................................................. 43
Left / right........................................................................ 43
Middle.............................................................................. 44
3.1.4 Display, driver's cab............................................................. 46
3.1.5 Steering column / steering wheel.................................................. 47
3.1.6 Transmission operating elements................................................... 48
3.1.7 Tachograph........................................................................ 49
3.1.8 ECOS control unit................................................................. 50
3.1.9 ECOS display – main menu.......................................................... 52
3.1.10 ECOS display – submenus.......................................................... 54
Level adjustment system submenu..................................................... 54
Settings submenu.................................................................... 56
Operating hours submenu............................................................. 57
Warning submenu..................................................................... 57
Transmission emergency program submenu.............................................. 58
Error submenu....................................................................... 59
3.1.11 Heating / Air-conditioning system................................................ 60
Standard heating system............................................................. 60
Auxiliary heater.................................................................... 61
3.1.12 Sockets for hand-held control.................................................... 62
3.1.13 Outrigger control units.......................................................... 63
3.2 Short description of the operating elements............................................. 65
3.2.1 Definition of information relating to directions of movement...................... 65
Basic rule.......................................................................... 65
Switches and buttons................................................................ 66
3.2.2 General information on the operating elements..................................... 66
3.2.3 General rules for buttons and symbols on the display.............................. 67
3.2.4 Engine............................................................................ 68
Steering column..................................................................... 68
Multipurpose switch................................................................. 68
Instrument panel.................................................................... 69
Main menu........................................................................... 70
3.2.5 Electrical system................................................................. 71
3.2.6 ECOS crane control................................................................ 71
Control unit........................................................................ 71
3.2.7 Transmission...................................................................... 74
Transmission display................................................................ 74
ECOS display........................................................................ 74
Operating elements.................................................................. 75
Instrument panel.................................................................... 76
3.2.8 Final drive....................................................................... 77
3.2.9 Brakes............................................................................ 78
Service brake....................................................................... 78
Parking brake....................................................................... 79
Additional brakes................................................................... 80
3.2.10 Steering / separate steering..................................................... 81
ECOS display........................................................................ 81
Driver's door....................................................................... 81
3.2.11 Suspension....................................................................... 82
3.2.12 Lighting / windscreen wipers / horn.............................................. 83
Steering column..................................................................... 83
Instrument panel.................................................................... 83
Roof................................................................................ 85
3.2.13 Level adjustment system.......................................................... 85
3.2.14 Tachograph / speedometer......................................................... 87
Tachograph.......................................................................... 87
Speedometer......................................................................... 87
3.2.15 Diagnostics...................................................................... 88
Displays / submenu.................................................................. 88
3.2.16 On-board computer................................................................ 89
3.2.17 Push-up roof..................................................................... 91
3.2.18 Windows, doors, keys............................................................. 91
Window winder....................................................................... 91
Doors............................................................................... 92
Keys................................................................................ 92
3.2.19 Front flap....................................................................... 93
4 Starting / turning off the engine for driving................................................. 97
4.1 Starting the engine from the driver's cab............................................... 97
4.1.1 CHECKLIST: Starting the engine.................................................... 97
4.1.2 CHECKLIST: At low temperatures....................................................100
4.1.3 Ladders and access ladders........................................................101
Access ladders......................................................................101
Ladders.............................................................................101
4.1.4 Refuelling........................................................................103
4.1.5 Checks before starting the engine.................................................104
On the hydraulic tank...............................................................104
Battery master switch...............................................................104
Checking the hand-held control......................................................105
4.1.6 Switch on the ignition............................................................105
4.1.7 Lamp test / equalisation of the switching states..................................106
Lamp test...........................................................................106
Equalisation of the switching states................................................107
4.1.8 Display – setting the brightness..................................................108
4.1.9 Start the engine..................................................................109
Without flame start system..........................................................110
With flame start system.............................................................111
4.1.10 Checks after starting the engine.................................................112
4.1.11 Control elements.................................................................113
Instrument panel....................................................................113
ECOS display........................................................................114
Display, driver'scab...............................................................114
4.1.12 Setting the idling speed.........................................................115
4.2 Turning off the engine..................................................................117
4.2.1 On the ignition lock / with hand-held control.....................................117
After turning off...................................................................117
4.2.2 With emergency stop switches......................................................118
Resetting the emergency stop switch.................................................118
4.3 Air intake inhibitor....................................................................119
Releasing the air intake inhibitor......................................................119
5 Driving.......................................................................................123
5.1 Before driving..........................................................................123
5.1.1 CHECKLIST: Inspections before on-road driving.....................................123
5.1.2 Checking the condition of the truck crane.........................................128
Windscreen, washing system..........................................................128
Electrical system...................................................................128
Adjusting the mirrors...............................................................129
Warning plates for vehicle width....................................................130
Displaying the vehicle height.......................................................130
Supply pressure.....................................................................131
Parking brake.......................................................................132
5.1.3 Adjusting the seat and the steering column........................................133
Driver's seat.......................................................................133
Passenger's seat....................................................................134
Adjusting the steering column.......................................................135
5.1.4 Switching the suspension on / off.................................................136
Opening the submenu.................................................................136
Switching on the suspension.........................................................137
Switching off the suspension........................................................137
5.1.5 Adjusting the tachograph..........................................................138
Prerequisites.......................................................................138
In the event of malfunctions........................................................138
Adjusting the tachograph............................................................139
Additional displays.................................................................142
5.1.6 Displaying the operating hours....................................................143
5.1.7 Settings / displays with the on-board computer....................................145
Operation...........................................................................145
Overview............................................................................146
Inspection information..............................................................146
Error information...................................................................147
Alarm clock.........................................................................147
Language............................................................................148
Settings............................................................................148
Diagnostics.........................................................................149
5.2 Operating the transmission..............................................................151
5.2.1 Switching on......................................................................151
5.2.2 Switching the transmission to neutral position....................................152
5.2.3 Changing the operating mode.......................................................152
Change-over to automatic mode.......................................................152
Change-over to manual mode..........................................................152
5.2.4 Display of the selected gears.....................................................153
5.2.5 Selecting the direction of travel and starting gear...............................153
Selecting the driving direction....................................................153
Selecting the starting gear.........................................................154
5.2.6 Starting..........................................................................155
5.2.7 Driving and changing gears........................................................156
In automatic operating mode........................................................156
In manual operating mode............................................................157
5.2.8 Changing the driving direction....................................................158
Quick change of gear................................................................158
5.2.9 Stopping..........................................................................159
Stopping for a long period of time..................................................159
5.2.10 On the roller type dynamometer...................................................159
5.3 Driving and turning off the truck crane.................................................161
5.3.1 Inspections while driving.........................................................161
Immediately after you start to move.................................................161
While driving.......................................................................162
5.3.2 Tempomat..........................................................................163
Switching on........................................................................164
Switching off.......................................................................164
5.3.3 Temposet..........................................................................165
Switching on........................................................................165
Switching off.......................................................................165
5.3.4 Driving downhill..................................................................166
Starting............................................................................166
Inspections when driving downhill...................................................166
Downshifting........................................................................167
Additional brakes...................................................................168
5.3.5 Driving uphill....................................................................169
Starting............................................................................169
Driving.............................................................................169
5.3.6 Warning submenu...................................................................170
Meaning of the symbols..............................................................170
Exiting the submenu.................................................................171
5.3.7 Error submenu.....................................................................172
5.3.8 Messages on the on-board computer display.........................................172
Warnings............................................................................173
Warning messages....................................................................174
Error messages......................................................................175
Information.........................................................................177
5.3.9 Turn off the truck crane..........................................................180
Secure against rolling away.........................................................180
When stationary for more than 8hours...............................................181
5.4 Off-road driving........................................................................183
Adjustments to the transmission.........................................................183
Connections.............................................................................183
Changing the vehicle level..............................................................183
Rocking the vehicle free and towing.....................................................183
5.4.1 Longitudinal and transverse differential locks....................................184
5.4.2 Operation of the level adjustment system..........................................186
Opening the submenu.................................................................186
Setting the on-road level...........................................................187
Pre-selecting suspension struts.....................................................187
Changing the vehicle level..........................................................188
Viewing the current inclination.....................................................188
Exiting the submenu.................................................................189
5.4.3 Freeing the truck crane stuck in terrain..........................................190
Rocking the truck crane free........................................................190
Towing free forwards................................................................191
Towing free in reverse gear.........................................................191
5.4.4 Separate steering.................................................................192
Switching to separate steering.....................................................192
Steering............................................................................193
Switching to normal steering mode...................................................194
5.5 Heating and air-conditioning system.....................................................195
5.5.1 Standard heating system...........................................................195
Switching on........................................................................195
Heating.............................................................................195
Air distribution....................................................................196
Examples............................................................................198
Switching off.......................................................................198
5.5.2 Air-conditioning system...........................................................199
Warnings............................................................................199
Switching on / off..................................................................199
Cooling.............................................................................200
Drying..............................................................................200
5.5.3 Auxiliary heater..................................................................201
Switching on........................................................................201
Temperature.........................................................................202
Setting the day and time............................................................202
Storing the heating start..........................................................203
Setting the heating period.........................................................204
Switching the heating start on and off..............................................204
Switching off.......................................................................205
Setting the remaining time..........................................................205
5.6 Towing a trailer........................................................................207
Effects on the axle loads...............................................................207
Coupling the trailer....................................................................208
Connecting the supply lines.............................................................209
Removing the supply lines...............................................................210
Uncoupling the trailer..................................................................210
Checking the braking force.............................................................212
6 Driving modes.................................................................................215
6.1 Driving modes...........................................................................215
Information about the axle loads........................................................215
6.1.1 How to use the tables............................................................216
6.1.2 Table for a maximum axle load of 10 t.............................................217
For 14.00 R25 tyres.................................................................217
For 16.00 R25 tyres.................................................................218
6.1.3 Table for a maximum axle load of 12 t.............................................219
For 14.00 R25 tyres.................................................................219
For 16.00 R25 tyres.................................................................220
For 20.5 R25 tyres..................................................................221
6.1.4 Driving mode 48 t.................................................................222
6.1.5 Maximum permitted speeds with an axle load of over 12 t...........................223
6.2 Rigging work for driving with a trailer.................................................225
6.2.1 Switching on the slewing gear freewheel...........................................226
Switching on boom floating position.................................................227
6.2.2 Switching on boom pre-tensioning..................................................228
6.2.3 Switching the superstructure driving lights on / off..............................230
Switching off.......................................................................230
Switching on........................................................................230
7 Malfunctions in driving mode..................................................................233
7.1 Emergency stop switch...................................................................233
7.2 What to do when a malfunction occurs in road traffic....................................235
7.3 Towing the truck crane..................................................................237
7.3.1 Towing in the event of engine or transmission damage..............................238
Compressed-air supply...............................................................238
Electric power supply...............................................................238
On the transmission.................................................................239
Axle drives.........................................................................240
Parking brake.......................................................................240
Towing the truck crane out of the danger area.......................................241
7.3.2 Tow starting......................................................................242
7.4 Wheels and tyres........................................................................243
7.4.1 Wheel change......................................................................243
Removing a damaged wheel............................................................244
On the spare wheel holder...........................................................244
Mounting a wheel....................................................................245
7.4.2 Filling the tyres yourself........................................................247
Connecting the filling hose.........................................................247
Filling the tyres...................................................................248
Removing the filling hose..........................................................248
7.5 Fuses...................................................................................249
Notes on changing fuses.................................................................249
7.5.1 Fuses in the driver's cab.........................................................250
F1 to F 41..........................................................................250
A1 to A3............................................................................252
7.5.2 Fuses in the battery box..........................................................254
7.6 Troubleshooting.........................................................................255
7.6.1 Malfunctions on the engine........................................................255
7.6.2 Malfunctions to the transmission..................................................257
7.6.3 Malfunctions of the service brake.................................................258
7.6.4 Malfunctions of the steering......................................................259
7.6.5 Malfunctions in the differential locks............................................260
7.6.6 Malfunctions in the hydraulic system / hydraulic oil cooler.......................260
7.6.7 Malfunctions on the suspension....................................................261
7.6.8 Malfunctions of the level adjustment system.......................................261
7.6.9 Malfunctions on the ECOS carrier..................................................262
ECOS program version................................................................262
General malfunctions................................................................262
Error messages......................................................................263
Exiting the submenu.................................................................264
On the control units................................................................265
7.7 Procedure in the event of malfunctions..................................................267
7.7.1 Switching on emergency operation in coolant circuit...............................267
7.7.2 Procedure in the event of malfunctions to the transmission and engine.............268
Engine..............................................................................268
Transmission........................................................................269
Transmission emergency program submenu..............................................270
Emergency compressed air supply.....................................................273
ID number of the transmission.......................................................275
8 Technical Information on Carrier..............................................................279
8.1 Technical data..........................................................................279
8.1.1 Dimensions and weights of the truck crane, axle loads.............................280
Dimensions..........................................................................281
Weight and axle loads...............................................................281
8.1.2 Dimensions and weights of removable parts.........................................282
Spare wheel.........................................................................282
Outriggers..........................................................................282
8.1.3 On the carrier....................................................................283
Engine..............................................................................283
Transmission........................................................................283
Transfer case.......................................................................283
Axle lines..........................................................................283
Steering............................................................................283
Tyres...............................................................................284
Outriggers..........................................................................284
Electrical system...................................................................284
Tools...............................................................................285
Towing couplings....................................................................285
Driving speeds......................................................................285
Climbing ability....................................................................285
Turning circle radiuses.............................................................285
9 Index.........................................................................................289
A...........................................................................................291
B...........................................................................................291
C...........................................................................................291
D...........................................................................................293
E...........................................................................................295
F...........................................................................................297
H...........................................................................................297
I...........................................................................................298
K...........................................................................................298
L...........................................................................................298
M...........................................................................................299
O...........................................................................................300
P...........................................................................................301
R...........................................................................................301
S...........................................................................................302
T...........................................................................................303
V...........................................................................................305
W...........................................................................................305
Additional page Controls for crane cabin heating................................................311
Position of controls........................................................................311
Function....................................................................................312
10 Operating elements for crane operation.......................................................317
10.1 Overview of the operating elements.....................................................317
10.1.1 On the outside of the truck crane................................................318
10.1.2 Crane cab........................................................................320
10.1.3 Front panel......................................................................322
10.1.4 Side panel.......................................................................323
Bottom..............................................................................323
Top.................................................................................324
Standard heating system.............................................................327
Auxiliary water heater..............................................................328
Auxiliary air heater................................................................329
10.1.5 Control panels...................................................................330
Left................................................................................330
Right...............................................................................331
10.1.6 Control lever assignment.........................................................332
Version 1...........................................................................332
Version 2...........................................................................333
10.1.7 ECOS control unit................................................................334
10.1.8 ECOS display – main menu.........................................................336
10.1.9 ECOS display – submenus..........................................................338
Counterweight submenu...............................................................338
Slewing gear / Houselock submenu....................................................339
Outriggers submenu..................................................................340
Telescoping submenu.................................................................342
Power unit speeds submenu...........................................................344
Monitoring submenu..................................................................345
Settings submenu....................................................................346
Operating hours submenu.............................................................348
Warning submenu.....................................................................349
Error submenu.......................................................................351
Working range limitation submenu....................................................352
Driving submenu.....................................................................354
10.1.10 SLI control unit................................................................356
10.1.11 Hand-held control...............................................................360
Outriggers control panel............................................................361
10.1.12 Outrigger control units.........................................................362
Outriggers..........................................................................363
Outrigger pressure display..........................................................363
Inclination display.................................................................363
10.2 Short description of the operating elements............................................365
10.2.1 Definition of information relating to directions of movement.....................365
Basic rule..........................................................................365
Switch..............................................................................365
10.2.2 General rules for buttons and symbols on the display.............................366
10.2.3 Engine for crane operation.......................................................367
Side panel..........................................................................367
ECOS display........................................................................367
10.2.4 Engine for driving...............................................................368
Side panel..........................................................................368
Main menu...........................................................................368
Outriggers submenu.................................................................369
10.2.5 Seat contact switch and dead man's switch........................................370
10.2.6 ECOS crane control...............................................................371
Control unit........................................................................371
10.2.7 Outriggers.......................................................................374
Hand-held control...................................................................374
In the Outriggers submenu...........................................................375
In the settings submenu.............................................................376
On the Outrigger control units......................................................377
10.2.8 Inclination displays.............................................................379
10.2.9 Outrigger pressure displays......................................................380
Outriggers submenu..................................................................380
Outrigger control units.............................................................380
10.2.10 Anemometer display..............................................................380
10.2.11 Counterweight submenu...........................................................381
Counterweight submenu...............................................................381
10.2.12 Main hoist......................................................................384
10.2.13 Auxiliary hoist.................................................................386
10.2.14 Slewing gear....................................................................387
Submenu.............................................................................388
10.2.15 Derricking gear.................................................................390
10.2.16 Telescoping mechanism...........................................................391
Control panels......................................................................391
Submenu.............................................................................392
In the settings submenu.............................................................396
10.2.17 Hydraulic system................................................................398
10.2.18 Houselock.......................................................................399
10.2.19 Safe load indicator (SLI).......................................................401
Input elements with displays........................................................401
Display elements....................................................................403
On the front panel..................................................................406
10.2.20 Electrical system...............................................................407
10.2.21 Lighting, windscreen wiper / washing system.....................................407
Lighting............................................................................407
Windscreen wiper / washing system...................................................409
10.2.22 Hand-held control...............................................................410
Sockets for hand- held control......................................................410
Engine control panel................................................................411
Horn................................................................................411
Outriggers control panel............................................................412
10.2.23 Windows, doors, keys............................................................414
Windows.............................................................................414
Crane cab door......................................................................414
Keys................................................................................415
10.2.24 Diagnostics.....................................................................416
10.3 Short description of the operating elements – driving from the crane cab...............417
10.3.1 Driving submenu..................................................................417
10.3.2 Engine for driving...............................................................418
10.3.3 Transmission.....................................................................419
10.3.4 Final drive......................................................................420
10.3.5 Brakes...........................................................................421
Side panel..........................................................................421
ECOS display........................................................................421
10.3.6 Steering.........................................................................422
Normal steering.....................................................................423
Separate steering...................................................................423
11 Starting / turning off the engine – for crane operation......................................427
11.1 Starting the engine – from the crane cab...............................................427
11.1.1 CHECKLIST: Starting the engine...................................................427
11.1.2 CHECKLIST: At low temperatures...................................................430
11.1.3 Refuelling.......................................................................430
11.1.4 Checks before starting the engine................................................432
On the hydraulic tank...............................................................432
Battery master switch...............................................................432
Checking the hand-held control......................................................433
11.1.5 Switch on the ignition...........................................................433
11.1.6 Lamp test / equalisation of the switching states.................................434
Lamp test...........................................................................434
Equalisation of the switching states................................................435
11.1.7 Set brightness of display........................................................436
11.1.8 Start the engine.................................................................437
Without flame start system..........................................................437
With flame start system.............................................................438
11.1.9 Checks after starting the engine.................................................439
11.1.10 Monitoring submenu..............................................................440
11.1.11 Setting the idling speed........................................................441
11.2 Starting the engine – with the hand-held control.......................................443
Prerequisites...........................................................................443
Start the engine........................................................................443
11.3 Turning off the engine.................................................................445
11.3.1 During normal operation, with the ignition lock / with the hand- held control....445
After turning off...................................................................445
11.3.2 In emergencies, with the emergency-stop switches.................................446
Resetting the emergency stop switch.................................................446
11.4 Air intake inhibitor...................................................................447
Releasing the air intake inhibitor......................................................447
12 Crane operation..............................................................................451
12.1 Before crane operation.................................................................451
12.1.1 CHECKLIST: Inspections prior to crane operation..................................451
12.1.2 Checking the condition of the truck crane........................................455
Tank for windscreen washing system..................................................455
Visual inspection...................................................................455
Checking the position of the hoist ropes............................................456
Checking the electrical system......................................................456
12.1.3 Adjusting the crane cab seat and front panel.....................................457
Crane cab seat......................................................................457
Front panel.........................................................................458
12.1.4 Checking the safety devices......................................................459
Safe load indicator.................................................................459
Lifting limit switch................................................................459
Emergency stop switch...............................................................460
Seat contact switch.................................................................461
12.1.5 Load, earthing...................................................................462
12.1.6 Preheating the hydraulic oil.....................................................463
12.1.7 Switching the houselock on / off.................................................464
Switching on the houselock..........................................................464
Switching off the houselock.........................................................466
12.2 Operation of the safe load indicator...................................................467
12.2.1 Switching on the SLI.............................................................468
Switching on........................................................................468
Lamp test on the SLI................................................................470
Brightness of the displays..........................................................470
12.2.2 Entering the rigging mode........................................................471
Entering the SLIcode...............................................................472
Entering the reeving................................................................475
Entering individual components......................................................476
12.2.3 Inspections prior to crane operation.............................................479
12.2.4 Displays during crane operation..................................................481
Continuous displays.................................................................481
Optional displays...................................................................483
12.2.5 SLI early warning................................................................485
12.2.6 SLI shutdown.....................................................................486
Shutdown due to overload............................................................486
12.2.7 Error message....................................................................487
12.2.8 SLI override.....................................................................488
12.2.9 Displaying and entering the time and date........................................489
Display.............................................................................489
Input...............................................................................490
12.3 Crane operation with main boom.........................................................491
12.3.1 Checks during crane operation....................................................491
Horizontal alignment................................................................491
Safe distances......................................................................491
Checking the wind speed.............................................................492
12.3.2 Permissible slewing ranges and working positions.................................493
360 slewing range..................................................................493
0 to the rear working position.....................................................493
180 to the front rigging position..................................................494
Free-on-wheels working position.....................................................494
12.3.3 Main hoist.......................................................................495
Switching on the main hoist.........................................................496
Lifting and lowering................................................................496
Switching off the main hoist........................................................497
12.3.4 Auxiliary hoist..................................................................498
Switching on the auxiliary hoist....................................................498
Lifting and lowering................................................................499
Switching off the auxiliary hoist...................................................500
12.3.5 Lifting limit switch and lowering limit switch...................................501
Lifting limit switch................................................................501
Lowering limit switch...............................................................503
12.3.6 Derricking gear..................................................................504
Switching on the derricking gear....................................................504
Raising and lowering the boom.......................................................505
Switching off the derricking gear...................................................506
Lowering the main boom to a horizontal position.....................................506
12.3.7 Telescoping mechanism............................................................507
Overview............................................................................508
Telescoping process.................................................................508
Assignment for display..............................................................510
Fixed length, intermediate length, telescoping length...............................512
Telescoping.........................................................................513
Telescoping sequence................................................................513
Inspections prior to starting operations............................................514
Switching on the telescoping mechanism..............................................515
Function of the control lever.......................................................515
Switching off the telescoping mechanism.............................................517
Manual telescoping..................................................................518
Checking the initial position.......................................................518
Unlocking the telescoping cylinder..................................................521
Extending / retracting the telescoping cylinder.....................................523
Lock telescoping cylinder...........................................................524
Unlocking the telescopic section....................................................525
Telescoping the telescopic section..................................................527
Locking the telescopic section......................................................528
Locking the telescopic section for on-road driving..................................529
Telescopic extension with teleautomation.........................................530
Telescoping the main boom in horizontal position....................................535
12.3.8 High-speed mode..................................................................536
Switch on function..................................................................536
Derricking gear / Telescoping mechanism.............................................536
Hoists..............................................................................537
12.3.9 Slewing gear.....................................................................538
Slewing gear brake..................................................................538
Switching on the slewing gear.......................................................539
Releasing the slewing gear brake....................................................539
Engaging the slewing gear brake.....................................................539
Slewing.............................................................................540
Slewing to 0 or 180 ...............................................................542
Braking the slewing movement........................................................543
Slewing gear freewheel..............................................................543
Switching off the slewing gear......................................................544
12.3.10 Possible movement combinations..................................................544
12.3.11 Hydraulic oil cooling...........................................................545
12.4 Settings and displays for crane operation..............................................547
12.4.1 Inclining the crane cab..........................................................547
12.4.2 Setting the idling speed.........................................................547
12.4.3 Adjusting the stroke interval of the windscreen wiper............................548
12.4.4 Limiting the power unit speeds...................................................548
12.4.5 Setting the characteristic curve for the control levers..........................550
12.4.6 Critical load control............................................................551
Function............................................................................551
Switching on and off................................................................551
12.4.7 Operation of the directional spotlights..........................................552
12.4.8 Displaying the operating hours...................................................553
12.4.9 Warning submenu..................................................................554
Meaning of the symbols..............................................................554
Exiting the submenu.................................................................557
12.4.10 Error submenu...................................................................557
12.5 Working range limiter..................................................................559
12.5.1 Opening the Working range limiter submenu........................................560
12.5.2 Viewing current settings.........................................................560
12.5.3 Entering limit values............................................................562
Overall height / Working radius.....................................................562
Slewing angle.......................................................................563
Entering objects....................................................................565
12.5.4 Entering limit values / objects manually.........................................568
Limit values........................................................................568
Objects.............................................................................569
12.5.5 Switching monitoring functions on / off..........................................570
12.5.6 Shutdown by working range limiter................................................571
12.6 Work break.............................................................................573
12.6.1 Short work breaks................................................................573
12.6.2 Work breaks of more than 8 hours.................................................574
To secure the truck crane...........................................................574
12.7 Heating and air-conditioning system....................................................575
12.7.1 Standard heating system..........................................................575
Switching on........................................................................575
Heating.............................................................................575
Air distribution....................................................................576
Switching off.......................................................................577
12.7.2 Air-conditioning system..........................................................577
Warnings............................................................................577
Switching on / off..................................................................578
Cooling.............................................................................578
Drying the air......................................................................579
12.7.3 Auxiliary water heater...........................................................579
Preheating the engine...............................................................580
Preheating the crane cab............................................................580
Switching on........................................................................581
Setting the day and time............................................................582
Storing the heating start...........................................................583
Setting the heating period..........................................................584
Switching heating start on / off....................................................584
Switching off.......................................................................585
Setting the remaining time..........................................................585
12.7.4 Auxiliary air heater.............................................................586
Switching on........................................................................586
Temperature.........................................................................587
Switching off.......................................................................587
Other functions.....................................................................587
13 Rigging work.................................................................................591
13.1 Rigging work checklists for crane operation with the main boom.........................591
13.1.1 CHECKLIST: Rigging...............................................................591
13.1.2 CHECKLIST: Unrigging.............................................................595
13.2 Choosing a suitable site...............................................................599
13.2.1 Determining the required ground bearing area.....................................599
13.2.2 Safe distance from slopes and pits...............................................602
13.2.3 Earthing the truck crane.........................................................603
13.2.4 Safe distance from electrical lines..............................................604
13.3 Rigging work after driving with a trailer..............................................607
13.3.1 Switching off the boom floating position.........................................607
13.3.2 Switching off the slewing gear freewheel.........................................608
Before slewing......................................................................608
13.3.3 Switching off boom pre-tensioning................................................609
13.4 Connecting / disconnecting the hand-held control.......................................610
13.5 Starting the engine for driving for rigging work.......................................611
13.5.1 Starting / turning off the engine with the hand-held control.....................611
Prerequisites.......................................................................611
Start the engine....................................................................612
Turning off the engine..............................................................612
13.5.2 Starting / turning off the engine from the crane cab.............................613
Prerequisites.......................................................................613
Start the engine....................................................................613
After starting the engine...........................................................614
Turning off the engine..............................................................614
13.6 Outriggers.............................................................................615
13.6.1 CHECKLIST: Extending the outriggers..............................................615
13.6.2 CHECKLIST: Retracting the outriggers.............................................617
13.6.3 Permissible outrigger spans......................................................618
13.6.4 Preparing the truck crane........................................................619
In the driver's cab.................................................................619
Outrigger control units.............................................................619
13.6.5 Setting the spans................................................................620
For on-road driving.................................................................622
13.6.6 Extending / retracting outriggers................................................623
From the control units..............................................................624
With the hand- held control.........................................................625
From the crane cab..................................................................627
13.6.7 Moving the outrigger pads into working / driving position........................629
13.6.8 Enlarging the ground bearing area................................................630
13.6.9 Extending / retracting supporting cylinders......................................631
From the control units..............................................................632
With the hand- held control.........................................................633
From the crane cab..................................................................634
13.6.10 Levelling the truck crane on outriggers.........................................636
Inclination displays................................................................636
Prerequisites.......................................................................637
Manual alignment....................................................................638
Automatic alignment.................................................................639
13.6.11 Levelling the free-standing truck crane.........................................641
13.6.12 Outrigger pressure display......................................................643
13.7 Rigging / unrigging the counterweight..................................................645
13.7.1 Counterweight parts..............................................................645
Version A...........................................................................645
Version B...........................................................................646
Version C...........................................................................646
13.7.2 Identification...................................................................647
13.7.3 Slinging points..................................................................648
13.7.4 CHECKLIST: Rigging the counterweight.............................................649
13.7.5 CHECKLIST: Unrig counterweight...................................................651
13.7.6 Assembling counterweight versions................................................652
On the turntable....................................................................652
With the base plate.................................................................653
With version A......................................................................656
With version B......................................................................658
With version C......................................................................660
13.7.7 Counterweight hoist unit.........................................................664
Counterweight submenu...............................................................664
Extending / retracting the lifting cylinders........................................665
Automatic mode, rigging.............................................................666
Automatic mode, unrigging...........................................................667
Cancel automatic mode...............................................................668
13.7.8 Removing / installing the counterweight on the turntable.........................669
7.3 t counterweight.................................................................670
9.5 t counterweight.................................................................672
13.7.9 Setting down counterweight for driving the truck crane...........................674
13.7.10 Slewing with rigged counterweight...............................................676
13.8 Rigging work on the main boom..........................................................677
13.8.1 Hook block on the bumper.........................................................677
Picking up the hook block...........................................................677
Attaching the hook block............................................................678
13.8.2 Hook block on a separate vehicle.................................................679
Picking up the hook block...........................................................680
Setting down the hook block.........................................................680
13.8.3 Reeving and unreeving the hoist rope.............................................682
Fastening the rope end clamp........................................................682
Reeving the hoist rope..............................................................684
Unreeving the hoist rope............................................................687
13.8.4 Possible reeving methods on the main boom........................................688
With 7 head sheaves.................................................................688
With 8 head sheaves.................................................................691
13.8.5 Installing / removing the lifting limit switch...................................694
Installing the lifting limit switch.................................................694
Removing the lifting limit switch...................................................697
13.8.6 Locking / Unlocking the lifting limit switch.....................................698
Locking.............................................................................698
Removing the lock...................................................................699
13.8.7 Anemometer and air traffic control light.........................................700
Mounting............................................................................700
Removing............................................................................701
13.9 Other rigging work.....................................................................703
13.9.1 Rigging in free on wheels working position.......................................703
13.9.2 Railings on the turntable........................................................705
13.9.3 Mirror for crane operation.......................................................706
14 Rigged truck crane, driving..................................................................709
14.1 Route..................................................................................711
14.2 Before driving the rigged truck crane..................................................711
14.2.1 Checking the tyre pressure and the wind speed....................................711
14.3 Permissible rigging modes and axle loads...............................................713
14.3.1 Axle loads.......................................................................713
14.3.2 To drive without a load..........................................................713
14.3.3 To drive with a load.............................................................714
14.4 Driving from the driver's cab..........................................................715
14.4.1 Preparing to drive...............................................................715
Transmission........................................................................715
Switching on separate steering......................................................715
Connections.........................................................................715
14.4.2 While driving....................................................................716
14.5 Crane cab, driving.....................................................................717
14.5.1 Preparing to drive...............................................................717
14.5.2 Opening / closing the Driving mode submenu.......................................718
Automatic...........................................................................718
Manual..............................................................................720
Closing.............................................................................720
14.5.3 Starting / turning off the engine for driving....................................721
Starting the engine.................................................................721
Turning off the engine..............................................................722
14.5.4 Steering.........................................................................722
Switching on........................................................................722
Adapt steering direction............................................................722
Displays when steering..............................................................723
Normal steering.....................................................................723
Separate steering...................................................................724
14.5.5 Operating the transmission.......................................................725
Driving direction...................................................................726
Selecting the transmission mode.....................................................726
14.5.6 Starting.........................................................................727
14.5.7 While driving....................................................................727
14.5.8 Warning messages.................................................................728
14.5.9 Possible connections.............................................................729
Longitudinal / transverse differential locks........................................730
14.5.10 After driving...................................................................731
14.6 Driving in combined operation..........................................................733
14.6.1 Switching combined operation on / off............................................733
Prerequisites.......................................................................733
Switching on........................................................................734
Switching off.......................................................................734
14.6.2 Starting / turning off the engine................................................735
14.6.3 Preparing to drive...............................................................736
Transmission........................................................................736
Switching on separate steering......................................................736
Connections.........................................................................736
14.6.4 While driving....................................................................737
Without load........................................................................737
With load...........................................................................738
15 Malfunctions during crane operation..........................................................741
15.1 Emergency stop switch..................................................................741
15.2 What to do when a malfunction occurs during crane operation............................743
Load can be lowered.....................................................................743
Load cannot be lowered..................................................................743
15.3 Fuses..................................................................................745
Notes on changing fuses.................................................................745
15.3.1 Fuses on the turntable...........................................................746
Fuse groups F1/ F2..................................................................746
Fuses on the circuit board..........................................................747
15.3.2 Fuses in the crane cab...........................................................748
15.3.3 Fuses in the battery box.........................................................750
15.3.4 SLI fuses........................................................................751
15.4 Finding and eliminating malfunctions...................................................753
15.4.1 Malfunctions on the engine.......................................................753
15.4.2 Malfunctions on the main hoist / auxiliary hoist.................................755
15.4.3 Malfunctions on the derricking gear..............................................756
15.4.4 Malfunctions in the telescoping mechanism........................................757
Telescoping mechanism error messages................................................758
15.4.5 Malfunctions on the slewing gear.................................................760
15.4.6 Malfunctions on the counterweight hoist unit.....................................761
15.4.7 Malfunctions in the hydraulic system / hydraulic oil cooler......................762
15.4.8 Malfunctions when inclining the crane cab........................................762
15.4.9 Malfunctions when operating with the hand-held control...........................762
15.4.10 Malfunctions when driving from the crane cab....................................763
15.4.11 Malfunctions of the outriggers..................................................764
15.4.12 Troubleshooting the SLI.........................................................765
General malfunctions................................................................765
Error messages......................................................................766
Table of error codes................................................................768
Switching off the sensor / tachogenerator.........................................771
15.4.13 Malfunctions ECOS – superstructure..............................................772
ECOS program version................................................................772
General malfunctions................................................................772
Error messages......................................................................773
Exiting the submenu.................................................................774
15.5 Emergency operations and programs......................................................775
15.5.1 Mechanical emergency operation for retracting....................................776
Prior to the emergency operation, check.............................................776
Procedure...........................................................................776
Mechanical emergency operation......................................................777
15.5.2 Telescoping emergency program....................................................779
Starting the emergency program......................................................779
Determining the type of error.......................................................780
If there is an error on the length indicator........................................781
If there is an error at a proximity switch..........................................785
Terminating the emergency program...................................................786
Tables for approaching the locking points...........................................787
15.5.3 Entering the current telescoping.................................................789
15.5.4 Emergency operation with the hand-held control...................................791
Preparations........................................................................791
Operating a power unit..............................................................792
Stopping movements..................................................................794
Stopping movements in emergencies...................................................794
Turning off the engine..............................................................794
15.5.5 Switching on emergency operation in coolant circuit..............................795
15.6 Hydraulic emergency operation..........................................................797
15.6.1 Operating principle..............................................................797
15.6.2 Connecting / disconnecting hoses.................................................798
15.6.3 Activating / deactivating emergency operation....................................799
15.6.4 Establishing the hydraulic circuits required.....................................800
Switching over valves...............................................................800
For lifting / lowering..............................................................802
For slewing.........................................................................803
15.6.5 Carrying out emergency operation.................................................804
Slewing.............................................................................804
Derricking..........................................................................805
Lifting / lowering..................................................................805
15.6.6 After emergency operation........................................................806
Switching off emergency operation...................................................806
Switching to crane operation........................................................806
Disconnecting the hoses.............................................................806
15.6.7 Emergency supply of another crane................................................807
For emergency supply................................................................807
After emergency supply..............................................................807
16 Technical information for the superstructure.................................................811
16.1 Technical data.........................................................................811
16.1.1 Maximum lifting capacity (DIN / ISO / EN)........................................811
16.1.2 Dimensions and weights of the truck crane, axle loads............................812
16.1.3 Dimensions and weights of removable parts........................................812
Hook blocks and hook tackle.........................................................812
Counterweight parts.................................................................813
Counterweight versions..............................................................813
16.1.4 Superstructure...................................................................814
Engine..............................................................................814
Hoists..............................................................................814
Slewing gear........................................................................814
Derricking gear.....................................................................814
Main boom...........................................................................815
Lattice extension...................................................................815
Operating speeds....................................................................815
17 Index........................................................................................819
A...........................................................................................821
B...........................................................................................821
C...........................................................................................821
D...........................................................................................823
E...........................................................................................825
F...........................................................................................827
H...........................................................................................827
I...........................................................................................828
K...........................................................................................828
L...........................................................................................828
M...........................................................................................829
O...........................................................................................830
P...........................................................................................831
R...........................................................................................831
S...........................................................................................832
T...........................................................................................833
V...........................................................................................835
W...........................................................................................835
GROVE GMK 5095 OPERATING INSTRUCTIONS MANUAL PART 1 (DRIVING) – PDF DOWNLOAD:
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