Grove GMK 5130-1 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
DESCRIPTION:
Grove GMK 5130-1 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Serial number :2 084 941 en
Operating instructions for driving and crane operation:
These operating instructions contain the information required to operate the truck crane.
- The operating instructions are divided into two parts. Part 1 with chapters 1 to 10 describes how to drive the truck crane. Part 2 with chapters11 to 17 describes how to operate the crane.
- Basic safety instructions can be found in chapter 2. Please read and observe these instructions even if you are familiar with the safety manual. These Basic safety instructions can only be found in this chapter. Special safety instructions that refer to specific hazards are can be found in the sections on the operations to which the respective hazards refer.
- Chapter 3 contains Information for operations planning. It is intended primarily for the truck crane operator and those persons responsible for planning operations. This chapter contains:
- Chapter 7 provides information on Rigging for on-road driving. Chapter 8 provides you with information on Troubleshooting in driving mode.
- Chapter 9 contains Technical descriptions of individual components and functional parts of the carrier as well as the Technical data.
Maintenance manual
The maintenance manual is intended for the maintenance personnel. The
maintenance manual does not contain any information on repair work.
The maintenance manual contains:
– Information on cleaning the truck crane
– The run-in regulations
– The maintenance intervals
– The maintenance plans
– The specifications of the required lubricants and consumables
– A description of the maintenance work on both the vehicle section and
crane section
TABLE OF CONTENTS:
Grove GMK 5130-1 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Part 1 – Driving................................................................................................ 1 1 Overview.................................................................................................. 7 1.1 Vehicle identification.............................................................................. 7 1.2 EC declaration of conformity........................................................................ 11 1.3 Overview and contents of the truck crane user information........................................... 13 1.3.1 Operating instructions for driving and crane operation........................................ 13 1.3.2 Operating instructions for the lattice extension (additional equipment)....................... 14 1.3.3 Maintenance manual............................................................................ 14 1.3.4 Lifting capacity table........................................................................ 15 1.3.5 Outrigger pressure table...................................................................... 15 1.3.6 Safety manual................................................................................. 15 1.3.7 Circuit diagrams.............................................................................. 15 1.3.8 Spare parts list.............................................................................. 16 1.4 Instructions on how to use this documentation....................................................... 17 1.4.1 How are the operating instructions structured?................................................ 17 1.4.2 How are the pages of the operating instructions structured?................................... 18 1.4.3 How can I find the information I am looking for quickly and easily?.......................... 19 Example of how to use cross-references.......................................................... 20 How to use the index............................................................................ 25 1.4.4 Definition of directional indicators.......................................................... 25 Basic rule...................................................................................... 25 Buttons and switches........................................................................... 25 1.4.5 Conversion table for US measurement units..................................................... 26 2 Basic safety instructions for the crane operator.......................................................... 29 2.1 Warnings and symbols................................................................................ 29 2.2 Intended use........................................................................................ 30 2.3 Organisational measures............................................................................. 32 2.4 Personnel qualifications............................................................................ 34 2.5 Safety instructions for driving the truck crane..................................................... 35 2.6 Safety instructions for truck crane work............................................................ 35 3 Information for operations planning....................................................................... 39 3.1 Safety instructions................................................................................. 39 3.1.1 Intended use.................................................................................. 39 3.1.2 Organisational measures....................................................................... 39 3.1.3 Personnel qualifications...................................................................... 40 3.2 Operations planning................................................................................. 41 3.2.1 Prerequisites for operations planning......................................................... 41 3.2.2 Information on operations planning which you can find in the user information................. 42 4 Description of the truck crane – vehicle section.......................................................... 45 4.1 Overview of the operating and display instruments................................................... 45 4.1.1 Overview of the vehicle....................................................................... 45 4.1.2 Overview of the driver's cab.................................................................. 48 Top view of the driver's cab.................................................................... 48 Overhead in the driver's cab.................................................................... 51 Under the front instrument panel................................................................ 52 Behind the cover............................................................................... 53 4.1.3 Front instrument panel........................................................................ 54 Left-hand insert................................................................................ 54 Tachograph insert............................................................................... 55 Speedometer insert............................................................................. 56 Right-hand insert............................................................................... 57 4.1.4 On the insert of the carrier control.......................................................... 58 4.1.5 Main menu on the driver's cab display......................................................... 60 4.1.6 Submenus on the driver's cab display.......................................................... 62 Level adjustment system submenu................................................................ 62 Settings/ Displays submenu..................................................................... 64 Carrier control instruments submenu............................................................. 65 Operating hours counter submenu............................................................... 66 Carrier warning message submenu................................................................. 66 Transmission emergency program submenu.......................................................... 67 Error menu...................................................................................... 68 4.1.7 Operating elements on the steering column..................................................... 69 4.1.8 On the side instrument panel.................................................................. 70 Transmission operating elements................................................................. 71 Heating operating elements...................................................................... 72 Auxiliary water heater........................................................................ 73 Auxiliary air heater.......................................................................... 74 4.1.9 Connections for the hand-held control......................................................... 75 4.1.10 Outrigger switch boxes....................................................................... 76 4.2 Functional description of the display and operating elements....................................... 77 4.2.1 Vehicle engine................................................................................ 77 On the steering column.......................................................................... 77 On the right-hand multipurpose switch........................................................... 77 On the instrument panels........................................................................ 79 On the driver's cab display.................................................................... 80 4.2.2 Carrier control............................................................................... 81 On the carrier control insert.................................................................. 81 On the instrument panel......................................................................... 84 4.2.3 Transmission.................................................................................. 85 On the driver's cab display.................................................................... 85 On the side instrument panel:................................................................... 88 4.2.4 Axle drive.................................................................................... 90 On the driver's cab display.................................................................... 90 4.2.5 Brakes........................................................................................ 93 Service brake................................................................................... 93 Parking brake................................................................................... 94 Engine retarder/ Eddy current retarder.......................................................... 95 4.2.6 Steering/Separate steering.................................................................... 96 On the instrument panels........................................................................ 96 In the driver's door............................................................................ 96 On the driver's cab display.................................................................... 96 4.2.7 Suspension.................................................................................... 98 4.2.8 Hydraulic system..............................................................................100 4.2.9 Electricity...................................................................................100 4.2.10 Lighting/windscreen wipers/horn..............................................................101 On the left-hand multipurpose switch............................................................101 On the instrument panels........................................................................101 Overhead in the driver's cab....................................................................103 4.2.11 Level adjustment system.....................................................................104 4.2.12 Tachograph/Speedometer.......................................................................107 Tachograph......................................................................................107 Speedometer insert..............................................................................107 4.2.13 Heating/Air-conditioning system.............................................................109 Standard heating................................................................................109 Air-conditioning system.........................................................................110 Auxiliary water heater..........................................................................110 Auxiliary airheater............................................................................112 Roof ventilator.................................................................................113 4.2.14 Other operating elements....................................................................113 4.2.15 Diagnostics plugs and displays...............................................................114 Diagnostics plug................................................................................114 Diagnostics displays............................................................................115 4.3 Other operating elements of the carrier.............................................................117 Keys................................................................................................117 Doors...............................................................................................117 Windows.............................................................................................119 Access ladders......................................................................................120 Ladders.............................................................................................120 Front flap..........................................................................................122 Fire extinguisher...................................................................................122 Folding berth.......................................................................................123 5 Vehicle engine............................................................................................127 5.1 Starting the vehicle engine from the driver's cab...................................................127 5.1.1 CHECKLIST: Starting the vehicle engine........................................................127 5.1.2 CHECKLIST: In winter..........................................................................130 5.1.3 Inspections prior to starting the vehicle engine..............................................131 Checking the shut- off valves of the hydraulic system...........................................131 Switching on the battery master switch.........................................................131 Checking the coolant level......................................................................132 Checking the hydraulic oil level................................................................133 Checking the oil level in the vehicle engine....................................................134 Topping up engine oil...........................................................................135 5.1.4 Refuelling....................................................................................136 5.1.5 Adjusting the brightness of the display.......................................................137 5.1.6 Switching on the ignition.....................................................................139 Lamp test on the display.......................................................................139 Alignment of the switching statuses.............................................................140 Lamp test, electrics............................................................................141 5.1.7 Starting the vehicle engine...................................................................141 5.1.8 Inspections after starting the engine.........................................................144 Inspections in the main menu....................................................................144 Inspections on the instrument panels............................................................145 5.1.9 Carrier control instruments submenu...........................................................146 5.1.10 Setting the idling speed.....................................................................148 5.2 Turning off the vehicle engine......................................................................149 5.2.1 Usually with the ignition lock/hand-held control..............................................149 Hand-held control not connected.................................................................149 Hand-held control connected.....................................................................149 5.2.2 With emergency stop switches in emergencies...................................................150 Resetting the emergency stop switch.............................................................150 5.3 Air intake inhibitor on the vehicle engine..........................................................151 Releasing the air intake inhibitor manually.........................................................152 6 Driving...................................................................................................155 6.1 Inspections, settings and displays prior to driving.................................................155 6.1.1 CHECKLIST: condition of the truck crane for on-road driving...................................155 6.1.2 Checking the condition of the truck crane.....................................................161 Checking the reservoir of the windscreen washing system........................................161 Warning signs for vehicle width.................................................................161 Checking the tyres.............................................................................162 Checking the electrical system..................................................................163 Checking the mirror settings....................................................................163 Boom control...................................................................................164 Checking the compressed air and brake systems..................................................165 6.1.3 Adjusting the seats and the steering column...................................................167 Adjusting the driver's seat....................................................................167 Adjusting the passenger seat...................................................................168 Adjusting the steering column..................................................................169 6.1.4 Switching the suspension on/off...............................................................170 Switching on the suspension....................................................................171 Switching off the suspension...................................................................171 6.1.5 Adjusting the tachograph......................................................................173 6.1.6 Displaying the operating hours................................................................178 6.2 Operating the transmission..........................................................................179 6.2.1 After switching on the ignition..............................................................179 6.2.2 Shifting the transmission to neutral position.................................................180 6.2.3 Selecting the operating mode of the transmission.............................................180 Changing the operating mode....................................................................180 6.2.4 Display of the selected gears.................................................................181 6.2.5 Selecting the direction of travel and starting gear...........................................181 Selecting the driving direction................................................................181 Selecting the starting gear...................................................................182 6.2.6 Starting......................................................................................183 6.2.7 Driving and changing gears....................................................................184 In automatic operating mode.....................................................................184 In manual operating mode........................................................................185 6.2.8 Changing the direction of travel..............................................................186 Quick change of gear...........................................................................186 6.2.9 Stopping......................................................................................187 Stopping for a long period of time.............................................................187 On the roller type dynamometer..................................................................187 6.3 Driving and turning off the truck crane.............................................................189 6.3.1 Monitoring the control instruments while driving..............................................189 On the instrument panels........................................................................189 On the driver's cab display....................................................................192 6.3.2 Tempomat......................................................................................193 Activating the Tempomat.........................................................................193 Driving with the Tempomat......................................................................193 Switching off the Tempomat......................................................................194 6.3.3 Temposet......................................................................................195 Switching on Temposet..........................................................................195 Driving with the Temposet......................................................................195 Switching off the Temposet......................................................................195 6.3.4 Driving downhill..............................................................................196 Starting on a slope............................................................................196 Inspections when driving downhill..............................................................196 Preselecting gears..............................................................................197 Engine retarder.................................................................................198 Eddy current retarder..........................................................................199 6.3.5 Driving uphill................................................................................200 Starting........................................................................................200 Driving.........................................................................................200 6.3.6 Carrier warning message submenu...............................................................201 Opening the submenu.............................................................................201 Meaning of the symbols..........................................................................202 Exiting the submenu.............................................................................205 6.3.7 Error menu....................................................................................207 6.3.8 Parking the truck crane.......................................................................207 Applying the parking brake......................................................................207 Activating neutral position....................................................................207 Turning off the vehicle engine.................................................................208 Securing the truck crane against rolling away...................................................208 Extended standstill.............................................................................209 6.4 Off-road driving....................................................................................211 Adjustments to the transmission.....................................................................211 Connections.........................................................................................211 Changing the vehicle level..........................................................................211 Rocking the vehicle free and towing.................................................................211 6.4.1 Operation of the longitudinal differential locks..............................................212 Switching on....................................................................................212 Switching off...................................................................................213 6.4.2 Operation of the transverse differential locks................................................214 Switching on....................................................................................214 Switching off...................................................................................215 6.4.3 Operation of the level adjustment system......................................................216 Opening the submenu.............................................................................216 Pre-selecting suspension struts................................................................217 Changing the vehicle level......................................................................218 Setting the on- road level.....................................................................219 Viewing the current inclination.................................................................219 Exiting the submenu............................................................................220 6.4.4 Freeing an immobilised truck crane............................................................221 Freeing the truckcrane by its own power.......................................................221 Towing free forwards...........................................................................222 Towing free to the rear.........................................................................222 6.5 Separate steering...................................................................................223 6.5.1 Switching on separate steering................................................................224 6.5.2 Steering with separate steering switched on...................................................225 6.5.3 Switching off separate steering...............................................................225 6.6 Heating and ventilating the driver's cab............................................................227 6.6.1 Standard heating..............................................................................227 Switching the heating on and off................................................................227 Setting the temperature........................................................................227 Setting recirculated air/fresh air..............................................................227 Setting the air distribution...................................................................228 Ventilating the driver's cab....................................................................229 6.6.2 Auxiliary water heater with timer.............................................................231 Preheating the vehicle engine..................................................................231 Preheating the driver's cab....................................................................231 Switching on the auxiliary heater...............................................................232 Switching off the auxiliary heater..............................................................233 Setting the time and weekday....................................................................233 Saving the automatic heating start..............................................................234 Setting the automatic heating duration..........................................................235 Switching the automatic heating start on/off....................................................235 Setting the remaining time.....................................................................236 6.6.3 Left auxiliary heater with timer..............................................................237 Switching on the auxiliary heater...............................................................237 Regulating the temperature......................................................................238 Switching off the auxiliary heater.............................................................238 Setting the remaining time.....................................................................239 6.6.4 Air-conditioning system.......................................................................241 Switching on....................................................................................241 Setting the air distribution...................................................................242 Switching off...................................................................................242 How to use the air conditioning effectively....................................................243 Drying the air in the driver's cab..............................................................244 6.7 Trailer mode........................................................................................245 Effects on the axle loads...........................................................................245 Coupling trailers..................................................................................246 Connecting the supply lines........................................................................247 Removing supply lines.............................................................................248 Uncoupling trailers................................................................................248 Test position of the parking brake when towing a trailer............................................250 7 Driving modes and rigging for on-road driving.............................................................253 7.1 Driving modes.......................................................................................253 Information on the axle loads.......................................................................253 7.1.1 Information on how to use the tables.........................................................254 7.1.2 Tables for maximum axle load 12t.............................................................255 For 14.00 R25 tyres.............................................................................255 For 16.00 R25 tyres.............................................................................256 For 20.5 R25 tyres..............................................................................257 7.2 Rigging work for driving with a trailer.............................................................259 7.2.1 Switching on the slewing gear freewheel.......................................................260 Prerequisites...................................................................................260 7.2.2 Switching on the boom floating position.......................................................262 Setting the main boom down on the trailer.......................................................262 7.2.3 Switching on boom pre-tensioning..............................................................264 8 Malfunctions in driving mode..............................................................................269 8.1 Emergency stop devices..............................................................................269 8.2 What to do if the truck crane breaks down in road traffic...........................................271 8.3 Towing the truck crane..............................................................................273 8.3.1 Towing the truck crane in the event of damage to the engine or transmission...................274 Towing the truck crane out of the danger area...................................................274 Switching towing mode on/off....................................................................275 Compressed-air supply for engine failures.......................................................276 Power supply....................................................................................276 Axle drives.....................................................................................277 Parking brake...................................................................................277 Releasing the parking brake mechanically........................................................278 Towing procedure................................................................................279 Unlocking all spring-loaded brake cylinders mechanically........................................279 Tow start.......................................................................................280 8.4 Wheels and tyres....................................................................................281 8.4.1 Wheel change..................................................................................281 Removing a damaged wheel........................................................................281 Removing the wheel from the spare wheel holder..................................................282 Mounting a wheel on the spare wheel holder......................................................283 Mounting sparewheels...........................................................................283 8.4.2 Filling the tyres yourself at the tyre inflator connection....................................285 Connecting the filling hose.....................................................................285 Filling tyres...................................................................................286 Removing the tyre inflator hose.................................................................286 8.5 Fuses on the carrier................................................................................287 8.5.1 Fuses in the driver's cab.....................................................................288 8.5.2 Fuses in battery box..........................................................................292 8.5.3 Fuses on input-output circuit boards..........................................................293 8.6 Finding and eliminating malfunctions................................................................295 8.6.1 Malfunctions to the vehicle engine............................................................295 8.6.2 Malfunctions to the differential locks........................................................297 8.6.3 Malfunctions to the transmission..............................................................298 8.6.4 Steering malfunctions.........................................................................299 8.6.5 Service brake malfunctions....................................................................300 8.6.6 Malfunctions to the outriggers................................................................300 8.6.7 Malfunctions to the tachograph................................................................301 8.6.8 Malfunctions to the suspension................................................................302 8.6.9 Malfunctions to the level adjustment system...................................................302 8.6.10 Malfunctions to the hydraulic system/hydraulic oil cooler....................................303 8.6.11 Finding and eliminating malfunctions to the carrier control..................................305 Program version of the carrier control..........................................................305 General malfunctions............................................................................305 Error messages on the driver's cab display......................................................306 Exiting the submenu............................................................................307 Error messages at the switch boxes..............................................................308 8.7 Procedure in the event of malfunctions..............................................................311 8.7.1 Switching to emergency mode in the coolant circuit............................................311 8.7.2 Procedure in the event of malfunctions to the transmission and vehicle engine.................312 Entries on the Transmission display.............................................................312 Transmission emergency program submenu........................................................314 Switching gears mechanically in emergency mode.................................................317 ID number of the transmission...................................................................321 8.7.3 Emergency operation of the solenoid valves for the outriggers.................................322 Pressure build-up valve.........................................................................323 Position and assignment of the solenoid valves..................................................324 9 Technical information on the carrier......................................................................329 9.1 Technical data......................................................................................329 9.1.1 Dimensions and weights of the truck crane.....................................................330 Dimensions for driving on public roads........................................................331 Total weight and axle loads.....................................................................331 9.1.2 Dimensions and weights of removable parts.....................................................332 Spare wheel.....................................................................................332 Outriggers......................................................................................332 9.1.3 Carrier.......................................................................................333 Vehicle engine..................................................................................333 Manual transmission.............................................................................333 Transfer case...................................................................................333 Axle lines......................................................................................333 Steering........................................................................................334 Tyres...........................................................................................334 Vehicle's electrical system.....................................................................334 Tools...........................................................................................334 Towing couplings...............................................................................334 Outriggers......................................................................................335 Driving speeds..................................................................................336 Climbing ability................................................................................336 Turning circle radiuses.........................................................................337 10 Index....................................................................................................341 A.......................................................................................................343 B.......................................................................................................343 C.......................................................................................................344 D.......................................................................................................347 E.......................................................................................................348 F.......................................................................................................349 H.......................................................................................................349 I.......................................................................................................350 K.......................................................................................................351 L.......................................................................................................351 M.......................................................................................................351 O.......................................................................................................352 P.......................................................................................................353 R.......................................................................................................353 S.......................................................................................................354 T.......................................................................................................355 V.......................................................................................................357 W.......................................................................................................357 Part 2 – Crane Operation........................................................................................361 11 Description of the crane section of the truck crane......................................................367 11.1 Overview of the operating and display instruments..................................................367 11.1.1 Overview of the crane section................................................................367 11.1.2 Crane cab overview...........................................................................370 11.1.3 Operating elements on the front panel........................................................372 11.1.4 Operating elements on the side panel.........................................................373 Left side of the side panel....................................................................373 At the top of the side panel...................................................................374 Operating elements for the standard heating ...................................................377 Auxiliary water heater........................................................................378 Auxiliary air heater...........................................................................379 11.1.5 At the control panels........................................................................380 Left-hand control panel.........................................................................380 Right-hand control panel........................................................................381 11.1.6 Control lever assignment.....................................................................382 Version 1 (standard)............................................................................382 Version 2 (additional equipment)................................................................383 11.1.7 On the crane control insert..................................................................384 11.1.8 Main menu on the crane control display.......................................................386 11.1.9 Submenus on the crane control display........................................................388 Counterweight submenu..........................................................................388 Superstructure lock submenu...................................................................389 Outriggers submenu.............................................................................390 Semi-automatic telescoping submenu.............................................................392 Submenu for telescoping in fully automatic mode................................................393 Power unit speeds submenu.....................................................................394 Superstructure control instruments submenu......................................................395 Settings/Displays submenu.....................................................................396 Operating hours counter submenu...............................................................398 Superstructure warning message submenu.........................................................398 Error menu......................................................................................399 Working range limitation submenu...............................................................400 11.1.10 On the SLI insert...........................................................................402 11.1.11 Hand-held control...........................................................................407 11.1.12 In the outriggers switch boxes..............................................................408 Operating elements for the outriggers...........................................................409 Display elements for the outrigger pressure indicator...........................................409 Operating and display elements for the electronic level.........................................409 11.2 Functional description of the display and operating elements.....................................411 11.2.1 Crane engine.................................................................................411 On the side panel..............................................................................411 On the crane control display...................................................................413 11.2.2 Vehicle engine...............................................................................413 11.2.3 Crane control................................................................................414 On the crane control insert.....................................................................414 On the crane control display...................................................................418 11.2.4 Outriggers, electronic level, outrigger pressure indicator...................................421 On the hand-held control........................................................................421 On the display fields on thecarrier..........................................................424 In the Settings/ Displays submenu...............................................................426 In the Outriggers submenu......................................................................427 11.2.5 Counterweight submenu........................................................................431 Counterweight submenu..........................................................................431 11.2.6 Superstructure lock submenu..................................................................434 Turntable locking..............................................................................434 Houselock.......................................................................................436 11.2.7 Hoists.......................................................................................437 Main hoist......................................................................................437 Auxiliary hoist.................................................................................439 11.2.8 Derricking gear..............................................................................440 Derricking the lattice extension................................................................442 11.2.9 Slewing gear.................................................................................442 11.2.10 Telescoping mechanism.......................................................................444 On the control panels..........................................................................444 Control lever for telescoping...................................................................445 Telescoping submenu............................................................................446 11.2.11 Hydraulic system............................................................................455 On the control panels...........................................................................455 In the Settings/ Displays submenu..............................................................455 In the Superstructure control instruments submenu...........................................456 In the Superstructure warning message submenu...............................................456 11.2.12 Safe load indicator (SLI)...................................................................457 Input elements with displays....................................................................457 Display elements................................................................................461 Information displays...........................................................................465 On the front panel..............................................................................468 11.2.13 Electricity, lighting, windscreen wiper/washing system......................................469 Electricity.....................................................................................469 Lighting........................................................................................469 Windscreen wiper/Washing system................................................................470 11.2.14 Heating.....................................................................................472 Standard heating................................................................................472 Auxiliary water heater..........................................................................473 Auxiliary air heater............................................................................475 Air-conditioning system.........................................................................475 11.2.15 On the hand-held control....................................................................477 Connections on the truck crane..................................................................477 Crane engine control panel......................................................................478 Horn button.....................................................................................478 Outriggers/Electronic level control panel......................................................478 Emergency operation pre-selection button........................................................479 Two-hand control panel..........................................................................480 11.2.16 Other operating elements of the crane cab...................................................483 Keys............................................................................................483 Crane cab door..................................................................................483 Windows.........................................................................................484 Cab lighting....................................................................................485 Diagnostics plug................................................................................485 Fire extinguisher...............................................................................486 11.3 Functional description of the safety devices.......................................................487 11.3.1 Safe load indicator (SLI)....................................................................487 11.3.2 Lowering limit switch........................................................................489 11.3.3 Lifting limit switch.........................................................................490 Overriding the lifting limit switch shutdown...................................................490 12 Crane engine.............................................................................................495 12.1 Starting the crane engine..........................................................................495 12.1.1 CHECKLIST: Starting the crane engine.........................................................495 12.1.2 CHECKLIST: In winter.........................................................................498 12.1.3 Inspections prior to starting the crane engine...............................................499 Checking the shut- off valves in the hydraulic system..........................................499 Switching on thebattery master switch.........................................................499 Checking the coolant level......................................................................500 Checking the hydraulic oil level................................................................501 Checking the oil level in the crane engine......................................................502 Topping up engine oil..........................................................................503 12.1.4 Refuelling...................................................................................504 12.1.5 Adjusting the brightness of the display......................................................505 12.1.6 Turning on the ignition......................................................................507 Crane control lamp test........................................................................507 Electricity lamp test..........................................................................509 12.1.7 Starting the crane engine....................................................................510 Starting the crane engine without the flame start system........................................511 Starting the crane engine with the flame start system...........................................512 12.1.8 Inspections after starting the crane engine..................................................513 Inspections to thecrane control insert........................................................513 Inspections on the side panel...................................................................513 Inspections on the Crane control display.......................................................514 12.2 Turning off the crane engine.......................................................................517 12.2.1 Usually with the ignition lock/with the hand-held control....................................517 Hand-held control not connected.................................................................517 Hand-held control connected.....................................................................517 12.2.2 In emergencies, with the emergency-stop switches.............................................518 Resetting the emergency stop switch.............................................................519 12.3 Air intake inhibitor on the crane engine...........................................................520 Manually disconnecting the air intake inhibitor.....................................................521 13 Crane operation..........................................................................................525 13.1 Inspections and adjustments prior to crane operation...............................................525 13.1.1 CHECKLIST: With rigged truck crane...........................................................525 13.1.2 Adjusting the front panel and crane cab seat.................................................532 Adjusting the front panel......................................................................532 Adjusting the crane cab seat....................................................................533 13.1.3 Checking the condition of the truck crane....................................................534 Checking the windscreen washing system.........................................................534 Visual inspection of the entire crane...........................................................534 Checking the electrical system..................................................................535 Checking the position of the hoist ropes.......................................................535 13.1.4 Checking the safety devices..................................................................537 Checking the safe load indicator................................................................537 Inspection of the lifting limit switch.........................................................538 Checking the seat contact switch and dead man's switch system...................................538 Crane control emergency stop circuit............................................................539 13.1.5 Prewarming hydraulic oil.....................................................................540 At an oil temperature between 0C and –15C...................................................540 At an oil temperature of below –15C:.......................................................540 13.1.6 Locking/Unlocking the turntable..............................................................541 Opening the submenu.............................................................................542 Slewing to the locking point ..................................................................543 Locking the turntable..........................................................................544 Unlocking the turntable....................................................................544 Error display when locking the turntable.......................................................545 13.1.7 Switching the houselock on/off...............................................................546 Opening the submenu.............................................................................546 Switching on the houselock.....................................................................547 Switching off the houselock....................................................................549 13.2 Operation of the safe load indicator (SLI).........................................................551 13.2.1 Switching on the SLI.........................................................................551 Activation......................................................................................551 Lamp test on the SLI............................................................................553 Brightness of the displays......................................................................553 13.2.2 Entering the rigging mode....................................................................555 Entering the SLI code..........................................................................556 Entering reeving values........................................................................559 Entering individual components..................................................................560 13.2.3 Inspections prior to working with the crane..................................................563 13.2.4 During crane work............................................................................567 Continuous displays............................................................................567 Optional displays..............................................................................569 13.2.5 SLI pre-warning and SLI shutdown.............................................................570 SLI early warning...............................................................................570 SLI shutdown................................................................................571 Error message...................................................................................573 Error messages with additional visual display...................................................574 SLI override...................................................................................575 13.2.6 Displaying and entering the time and date....................................................576 Display.........................................................................................576 Input...........................................................................................576 13.3 Crane work with the main boom......................................................................579 13.3.1 External influences when working with the crane..............................................579 Horizontal alignment...........................................................................579 Safe distances.................................................................................579 Monitoring the wind speed.......................................................................580 If the maximum permitted wind speed is exceeded.................................................582 Permissible wind load..........................................................................583 Earthing the load...............................................................................583 13.3.2 Permissible slewing ranges and working positions for crane work..............................585 360 slewing range..............................................................................585 0 to the rear working position.................................................................585 180 to the front rigging position..............................................................586 With the truck crane free on wheels.............................................................586 13.3.3 Main hoist...................................................................................587 Switching on the main hoist.....................................................................587 Lifting and lowering...........................................................................588 Switching off the main hoist...................................................................591 13.3.4 Auxiliary hoist..............................................................................592 Switching on the auxiliary hoist...............................................................592 Lifting and lowering...........................................................................593 Switching off the auxiliary hoist..............................................................593 13.3.5 Derricking gear..............................................................................594 Switching on the derricking gear...............................................................594 Raising and lowering the beam...................................................................595 Switching off the derricking gear..............................................................596 Automatic speed limitation.....................................................................596 Lowering the main boom to a horizontal position.................................................596 13.3.6 Slewing gear.................................................................................599 Switching on the slewing gear..................................................................599 Prerequisites...................................................................................600 Slewing.........................................................................................600 Braking the slewing movement....................................................................603 Tracking the slewing gear......................................................................604 Switching off the slewing gear.................................................................605 Automatic speed limitation.....................................................................605 13.3.7 Telescoping mechanism........................................................................607 Structure of this section......................................................................607 Description of theoperating principle..........................................................608 Fixed, intermediate and telescoping lengths of the main boom..................................609 Telescoping.....................................................................................611 Notes on the telescoping sequence.............................................................613 Inspection before telescoping for the first time................................................613 Switching on the telescoping mechanism..........................................................614 Control lever functions........................................................................614 Switching off the telescoping mechanism.....................................................616 Example of a telescoping procedure..............................................................617 Checking the initial position..................................................................618 Unlocking the telescoping cylinder.............................................................623 Extending/ Retracting the telescoping cylinder.................................................626 Locking the telescoping cylinder................................................................627 Unlocking the telescopic section...............................................................631 Telescoping the telescopic section.............................................................633 Locking telescopic sections....................................................................635 Telescoping telescopic sections to an intermediate length......................................639 Locking the telescopic section for on-road driving.............................................639 Telescoping in fully automatic mode.............................................................640 Telescoping the main boom into ahorizontal position............................................646 13.3.8 Possible combinations of operations..........................................................647 13.3.9 High speed...................................................................................648 Derricking gear/ Telescoping mechanism..........................................................648 Hoists..........................................................................................649 13.3.10 Hydraulic oil cooling.......................................................................650 Standard oil cooler............................................................................650 Additional oil cooler..........................................................................650 13.4 Adjustments and displays whilst operating the crane................................................651 13.4.1 Adjusting power unit speeds..................................................................651 13.4.2 Setting characteristic curves for the control lever.........................................653 13.4.3 Setting a constant engine speed..............................................................655 Increasing the constant engine speed............................................................656 Reducing the constant engine speed.............................................................656 Exceeding the constant engine speed.............................................................656 13.4.4 Critical load control........................................................................657 Function........................................................................................657 Switching on and off...........................................................................657 13.4.5 Tilting the crane cab........................................................................659 13.4.6 Adjusting the stroke interval of the windscreen wiper........................................660 13.4.7 Operation of the directional working area spotlights.........................................661 Switching on/off................................................................................661 Changing the direction..........................................................................661 13.4.8 Displaying the operating hours...............................................................662 13.4.9 Superstructure warning message submenu.......................................................664 Opening the submenu.............................................................................664 Meaning of the symbols..........................................................................665 Exiting the submenu............................................................................669 13.4.10 Error menu..................................................................................669 13.5 Working range limitation...........................................................................671 13.5.1 Opening the Working range limitation submenu.................................................672 13.5.2 Viewing the current settings.................................................................673 Monitoring on/ offdisplay......................................................................673 Viewing the limit values entered...............................................................673 13.5.3 Entering a limit value for the maximum overall height........................................675 13.5.4 Entering a limit value for the maximum working radius........................................676 13.5.5 Entering limit values for maximum slewing angles.............................................677 Displays in the Working range limitation submenu................................................677 Display of slewing angles.......................................................................678 Entering the slewing angle.....................................................................679 13.5.6 Entering point data for objects..............................................................680 Display of the defined objects.................................................................680 Selecting and deleting point data.............................................................681 Entering point data............................................................................682 13.5.7 Entering limit values manually...............................................................684 Limit values for the overall height, working radius or slewing angle............................684 Manual input of point data......................................................................685 13.5.8 Switching monitoring functions on and off....................................................687 Switching monitoring functions on...............................................................687 Switching off monitoring........................................................................688 13.5.9 Shutdown due to working range limitation.....................................................689 Deactivated crane operations....................................................................689 Overriding shutdown procedures.................................................................690 Error messages in the event of a shutdown.......................................................690 13.6 Driving the rigged truck crane.....................................................................691 13.6.1 Permissible rigging modes and axle loads of to 6 t counterweight.............................692 To drive crane without a load...................................................................692 To drive with a load............................................................................692 13.6.2 Permissible rigging modes and axle loads over 6 t counterweight..............................693 Axle load table................................................................................694 13.6.3 Route........................................................................................696 13.6.4 Before driving the rigged truck crane........................................................697 Locking the turntable..........................................................................697 Putting the truck crane on the wheels...........................................................697 Switching on separate steering.................................................................699 13.6.5 Driving the rigged truck crane...............................................................699 After driving...................................................................................700 13.7 Work break.........................................................................................701 13.7.1 During short work breaks.....................................................................701 13.7.2 During work breaks of more than 8 hours......................................................701 Securing the truck crane against unauthorised use...............................................702 13.8 Heating and ventilating the crane cab..............................................................703 13.8.1 Standard heating.............................................................................703 Switching the heating on and off................................................................703 Setting the temperature........................................................................704 Setting recirculated/fresh air..................................................................704 Setting the air distribution..................................................................704 13.8.2 Auxiliary water heater.......................................................................706 Preheating the crane engine....................................................................706 Preheating the crane cab.......................................................................706 Switching on the auxiliary heater...............................................................707 Switching off the auxiliary heater..............................................................708 Setting the time and weekday....................................................................709 Saving the automatic heating start.............................................................709 Setting the automatic heating duration.........................................................711 Switching the automatic heating start on/off....................................................711 Setting the remaining time.....................................................................712 13.8.3 Auxiliary air heater.........................................................................713 Switching on the auxiliary heater...............................................................713 Regulating the temperature......................................................................714 Switching off the auxiliary heater.............................................................714 13.8.4 Air-conditioning system......................................................................715 Activation......................................................................................715 Setting the air distribution..................................................................716 Deactivation....................................................................................716 Information on how to benefit ideally from the air conditioning...............................717 Drying the air in the crane cab.................................................................718 14 Rigging work.............................................................................................721 14.1 Checklists for rigging work for crane operation with the main boom.................................721 14.1.1 CHECKLIST: Rigging...........................................................................721 14.1.2 CHECKLIST: Unrigging.........................................................................725 14.2 Choosing a suitable site...........................................................................729 14.2.1 Load bearing capacity of the ground and the outriggers.......................................729 Enlarging the ground bearing area..............................................................731 14.2.2 Safe distance from banks and pits............................................................732 14.2.3 Earthing of the truck crane..................................................................733 Earthing the truck crane........................................................................733 14.2.4 Safe distance from electrical lines..........................................................734 14.3 Rigging work after driving with a trailer..........................................................737 14.3.1 Switching off the boom floating position.....................................................738 14.3.2 Switching off boom pre-tensioning............................................................739 14.3.3 Switching off the slewing gear freewheel.....................................................740 Prerequisites...................................................................................740 Before slewing..................................................................................742 14.4 Rigging add-on parts into positions for crane operation/driving...................................743 14.4.1 Folding mirrors in and out and adjusting them................................................744 Main hoist mirrors..............................................................................744 Mirrors on the turntable........................................................................745 14.5 Connecting/Disconnecting the hand-held control.....................................................747 14.5.1 Connecting the hand-held control.............................................................747 14.5.2 Disconnecting the hand-held control..........................................................748 14.6 Starting the vehicle engine for rigging work.......................................................749 14.6.1 Starting/Turning off the vehicle engine with the hand-held control..........................749 Prerequisites...................................................................................749 Starting the vehicle engine....................................................................750 Turning off the vehicle engine.................................................................751 14.6.2 Starting/Turning off the vehicle engine from the crane cab...................................751 Prerequisites...................................................................................751 Starting the vehicle engine.....................................................................751 After starting the engine.......................................................................752 Turning off the vehicle engine.................................................................752 14.7 Outriggers.........................................................................................753 14.7.1 CHECKLIST: Extending the outriggers..........................................................753 14.7.2 CHECKLIST: Retracting the outriggers.........................................................755 14.7.3 Permissible outrigger spans..................................................................757 Outrigger span of 7.80x7.50 m.................................................................758 Outrigger span of 7.80x5.10 m.................................................................758 Outrigger span of 7.80x2.50 m.................................................................759 Free on wheels..................................................................................760 14.7.4 Preparing the truck crane....................................................................761 Levelling the truck crane......................................................................761 Locking the suspension.........................................................................761 Switching on/off the display fields on the carrier.............................................762 14.7.5 Extending/Retracting the outrigger beams.....................................................763 With the hand- held control.....................................................................763 From the switch boxes...........................................................................766 From the crane cab..............................................................................768 Setting outrigger spans.........................................................................771 14.7.6 Securing the outrigger beams for on-road driving.............................................773 14.7.7 Moving the outrigger pads into working/driving position......................................774 14.7.8 Extending/Retracting outrigger cylinders.....................................................775 With the hand- held control.....................................................................776 From the switch boxes...........................................................................779 From the crane cab..............................................................................783 14.7.9 Checking the alignment of the truck crane....................................................787 On the hand-held control........................................................................787 On the switch boxes............................................................................789 On the crane control display...................................................................791 14.7.10 Levelling the truck crane on outriggers.....................................................793 If the boom is on the boom rest...............................................................793 If the boom is raised.........................................................................793 Automatic alignment............................................................................793 14.7.11 Levelling the truck crane free on wheels....................................................796 When rigging....................................................................................796 During crane work...............................................................................796 14.7.12 Outrigger pressure indicator................................................................798 Outrigger pressure indicator in the crane cab...................................................798 Outrigger pressure indicator on the carrier.....................................................799 14.8 Rigging/Unrigging the counterweight................................................................801 14.8.1 Counterweight parts..........................................................................801 Basic version...................................................................................801 Additional version1...........................................................................802 Additional version2...........................................................................802 Additional version3...........................................................................803 Additional version4...........................................................................803 14.8.2 Identification...............................................................................804 14.8.3 Counterweight combinations...................................................................805 14.8.4 Slinging points on the counterweight parts...................................................810 14.8.5 CHECKLIST: Rigging the counterweight.........................................................812 14.8.6 CHECKLIST: Unrigging the counterweight.......................................................814 14.8.7 Assembling counterweight combinations........................................................817 Combinations which can be installed on the turntable...........................................818 Setting down the 2.5t base plate...............................................................819 Combinations that can be varied...............................................................820 Combinations with additional equipment..........................................................824 14.8.8 Counterweight hoist unit.....................................................................835 Selecting the Counterweight submenu............................................................835 Checking the current hoist unit status........................................................836 Display of faulty statuses....................................................................837 Extending/ Retracting the lifting cylinders.....................................................838 Locking/ Unlocking counterweights..............................................................840 14.8.9 Removing/Installing the counterweight sections on theturntable..............................842 Installing......................................................................................842 Removing........................................................................................844 14.8.10 Assembling counterweight sections for driving the truck crane...............................846 14.8.11 Slewing with the rigged counterweight.......................................................848 14.9 Rigging work on the main boom......................................................................851 14.9.1 Hook block on the bumper.....................................................................851 Picking up the hook block from the bumper.......................................................851 Attaching the hook block to the bumper..........................................................852 14.9.2 Hook block on a separate vehicle.............................................................853 Picking up the hook block......................................................................854 Setting down the hook block....................................................................854 14.9.3 Reeving and unreeving the hoist rope.........................................................856 Rope end clamp..................................................................................856 Positioning the hoist rope.....................................................................858 14.9.4 Possible reeving methods on the main boom....................................................862 14.9.5 Installing/Removing the lifting limit switch.................................................867 Installing lifting limit switches...............................................................867 Removing lifting limit switches.................................................................871 14.9.6 Locking/Unlocking the lifting limit switch...................................................873 Locking.........................................................................................873 Unlocking......................................................................................874 14.9.7 Installing/Removing the anemometer...........................................................875 Installing the anemometer.....................................................................875 Removing the anemometer........................................................................876 14.9.8 Installing/Removing the air traffic control light............................................877 Installing......................................................................................877 Removing........................................................................................878 15 Malfunctions during crane operation......................................................................881 15.1 Emergency-stop devices.............................................................................881 15.2 Procedure in the event of a malfunction during crane operation....................................883 If it is possible to lower the load.................................................................883 If it is not possible to lower the load.............................................................884 15.3 Fuses on the superstructure........................................................................885 Information on replacing fuses....................................................................885 15.3.1 Fuses on the turntable.......................................................................886 Fuse group F1.................................................................................887 Fuse group F2.................................................................................887 Fuses on the circuit board.....................................................................888 Fuses on the input/output circuit boards........................................................888 15.3.2 Fuses in the crane cab.......................................................................889 15.3.3 Fuses in the battery box.....................................................................891 15.3.4 Fuses of the SLI.............................................................................893 15.4 Finding and eliminating malfunctions to the power units............................................895 15.4.1 Malfunctions to the crane engine.............................................................895 15.4.2 Malfunctions when operating with the hand-held control.......................................897 15.4.3 Malfunctions to the main hoist...............................................................898 15.4.4 Malfunctions to the auxiliary hoist..........................................................900 15.4.5 Malfunctions to the derricking gear..........................................................902 15.4.6 Malfunctions to the slewing gear.............................................................904 15.4.7 Malfunctions to the counterweight hoist unit.................................................906 15.4.8 Malfunctions to the hydraulic system/hydraulic oil cooler....................................907 15.4.9 Malfunctions to the turntable lock...........................................................907 15.4.10 Malfunctions during the inclination of the crane cab........................................907 15.4.11 Malfunctions to the telescoping mechanism...................................................908 Telescoping mechanism error messages............................................................910 15.4.12 Malfunctions to the outriggers..............................................................913 15.5 Finding and eliminating malfunctions to the SLI....................................................915 15.5.1 General malfunctions.........................................................................915 15.5.2 Error messages on the SLI insert.............................................................916 Error messages table............................................................................916 15.6 Finding and eliminating malfunctions on the crane control.........................................919 Program version of the crane control................................................................919 15.6.1 General malfunctions.........................................................................919 15.6.2 Error messages on the crane control display..................................................920 Exiting the submenu............................................................................921 15.7 Emergency operations and programs..................................................................923 15.7.1 Mechanical emergency activation for retraction operations....................................924 Check prior to theemergency activation.........................................................924 Retraction procedures..........................................................................925 Mechanical emergency operation.................................................................925 15.7.2 Telescoping emergency program submenu........................................................928 Starting the emergency program................................................................928 Display and operating elements of the emergency program.........................................930 Retracting in theevent of an error to the length indicator.....................................932 Retracting in the event of an error to the proximity switch.....................................935 Terminating theemergency program..............................................................937 Tables for approaching the locking points.......................................................938 15.7.3 Entering telescoping statuses after emergency operations.....................................940 15.7.4 Emergency operation in the event of a failure to the operating elements in the crane cab.....943 Connecting the hand-held control................................................................943 Starting the crane engine with the hand-held control............................................944 Pre-selecting power units......................................................................944 Operating power units...........................................................................945 Stopping operations............................................................................947 Stopping operations in emergencies.............................................................947 Turning off the crane engine...................................................................948 15.8 Hydraulic emergency operation according to German employers liability association guidelines.......949 15.8.1 Important instructions for hydraulic emergency operation.....................................949 15.8.2 Operating principle and accessories..........................................................951 For emergency operation.........................................................................951 For the emergency supply........................................................................952 15.8.3 Connecting/Disconnecting hoses...............................................................952 Establishing connections.......................................................................953 Disconnecting..................................................................................954 15.8.4 Activating/Deactivating emergency mode.......................................................955 15.8.5 Establishing the hydraulic circuits required.................................................956 Switching positions of the valves...............................................................956 Additional switching operations for the main hoist..............................................958 Additional switching operations for the slewing gear............................................959 15.8.6 Operating in emergency mode..................................................................960 Operating the main hoist in emergency mode......................................................961 Operating the slewing gear in emergency mode....................................................961 Operating the derricking gear in emergency mode................................................962 15.8.7 After operating in emergency mode............................................................963 Switching off emergency mode....................................................................963 Establishing hydraulic circuits for crane operation...........................................963 Disconnecting hose connections..................................................................963 15.8.8 Emergency supply of another crane............................................................964 Connecting/Disconnecting hoses..................................................................964 Switching the emergency supply on/off..........................................................965 16 Technical information on the superstructure..............................................................969 16.1 Technical data.....................................................................................969 16.1.1 Maximum lifting capacity (DIN/ ISO/ EN)......................................................969 16.1.2 Maximum lifting capacity (ANSI B 30.5).......................................................969 16.1.3 Dimensions, weights and axle loads...........................................................970 Dimensions for driving on public roads........................................................971 Total weight and axle loads.....................................................................971 16.1.4 Dimensions and weights of removable parts....................................................972 Hook blocks and hook tackle.....................................................................972 Counterweight parts............................................................................973 Counterweight combinations......................................................................973 16.1.5 Technical data of the superstructure.........................................................974 Crane engine....................................................................................974 Main hoist......................................................................................974 Auxiliary hoist (additional equipment)..........................................................974 Slewing gears...................................................................................975 Derricking gear.................................................................................975 Main boom.......................................................................................975 Lattice extension...............................................................................975 Operating speeds and times without a load......................................................976 17 Index....................................................................................................979 A.......................................................................................................981 B.......................................................................................................981 C.......................................................................................................982 D.......................................................................................................985 E.......................................................................................................986 F.......................................................................................................987 H.......................................................................................................987 I.......................................................................................................988 K.......................................................................................................989 L.......................................................................................................989 M.......................................................................................................989 O.......................................................................................................990 P.......................................................................................................991 R.......................................................................................................991 S.......................................................................................................992 T.......................................................................................................993 V.......................................................................................................995 W.......................................................................................................995
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