Grove GMK 5200 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
DESCRIPTION:
Grove GMK 5200 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Vehicle serial number: 2 084 829 en
Overview and contents of the truck crane user information
1.3.1 Operating instructions:
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 contains the Description of the vehicle section of the truck crane; Part 2 with chapters 11 to 18 contains the Description of the crane section.
In Chapter 2 you will find Basic safety instructions. Please read and observe these instructions, even if you are familiar with the safety manual. The Basic safety instructions are contained in this chapter only. Special safety instructions that relate to specific hazards are described in the section containing the operation with which the hazard is associated.
Chapter 3 contains Information for operations planning. It is intended primarily for the truck crane operator and those responsible for operations planning. This chapter contains
– the qualifications required for those involved in operations planning for the truck crane
– special safety instructions
– information that is relevant to operations planning
In Chapter 4 to 6 you will find information required for Driving the truck crane: a description of all structural and operational components, clearly defined check lists for rigging modes and work, and the operating instructions for on-road and off-road driving and the removal and installation of the auxiliary hoist.
Rigging for on-road driving is described in Chapter 7.
In Chapter 8 , there is information on Troubleshooting on the vehicle section of the truck crane.
Chapter 9 contains the Technical description of the individual parts and functional elements of the vehicle parts as well as the Technical data.
Chapter 10 contains the Index. This helps you when you are looking for certain procedures and terms in the operating instructions.
TABLE OF CONTENTS:
Grove GMK 5200 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Operating instructions Part 1 – Driving............................................................................. 1
Correction sheets – Drives...................................................................................... 3
Important information....................................................................................... 5
Validity................................................................................................ 5
Reason for these correction sheets...................................................................... 5
Information............................................................................................. 5
Correction.................................................................................................. 6
9.1.3 Drive units....................................................................................... 6
Axle lines.......................................................................................... 6
Additional pages - Emergency operation/Emergency program telescoping ........................................... 9
1 Overview...................................................................................................... 13
1.1 Vehicle identification.................................................................................. 15
1.2 EC Conformity Declaration............................................................................... 18
1.3 Overview and contents of the truck crane user information............................................... 19
1.3.1 Operating instructions............................................................................ 19
1.3.2 Operating instructions for the lattice extension (additional equipment)........................... 20
1.3.3 Maintenance manual................................................................................ 20
1.3.4 Lifting capacity tables........................................................................... 21
1.3.5 Outrigger pressure tables......................................................................... 21
1.3.6 Safety manual..................................................................................... 21
1.3.7 Circuit diagrams.................................................................................. 21
1.3.8 Spare parts list.................................................................................. 22
1.4 Instructions for using this documentation............................................................... 22
1.4.1 How are the operating instructions laid out?...................................................... 22
1.4.2 How are the pages of the operating instructions formatted?........................................ 23
1.4.3 How can I find the necessary information quickly and easily?...................................... 24
Example of cross- reference usage................................................................... 25
How to use the index............................................................................... 30
1.4.4 Definition of positional references............................................................... 30
Basic rule.......................................................................................... 30
Buttons and switches............................................................................... 30
1.4.5 Conversion table for US measurements.............................................................. 31
2 Basic safety instructions for crane operators................................................................. 33
2.1 Warnings and symbols.................................................................................... 35
2.2 Intended use............................................................................................ 36
2.3 Organizational measures................................................................................. 38
2.4 Personnel qualifications................................................................................ 40
2.5 Safety instructions that apply to truck crane driving................................................... 41
2.6 Safety instructions for truck crane work................................................................ 41
3 Information for operations planning........................................................................... 45
3.1 Safety instructions..................................................................................... 47
3.1.1 Intended use...................................................................................... 47
3.1.2 Organizational measures........................................................................... 47
3.1.3 Personnel qualifications.......................................................................... 48
3.2 Operations planning..................................................................................... 49
3.2.1 Prerequisites for operations planning............................................................. 49
3.2.2 Information for operations planning contained in the user information ........................... 50
4 Description of the truck crane – Vehicle section.............................................................. 51
4.1 Overview of the operating and display instruments....................................................... 53
4.1.1 Vehicle overview.................................................................................. 53
4.1.2 Driver's cab overview............................................................................. 56
Above the windscreen................................................................................ 58
4.1.3 Front instrument panel............................................................................ 60
4.1.4 Side instrument panel............................................................................. 68
4.2 Functional description of the display and operating elements........................................... 75
4.2.1 On the instrument panels.......................................................................... 75
Vehicle engine...................................................................................... 75
Automatic transmission............................................................................. 77
Axle drive.......................................................................................... 79
Brakes.............................................................................................. 80
Suspension.......................................................................................... 81
Hydraulic system.................................................................................... 82
Steering............................................................................................ 82
Electricity......................................................................................... 83
Level adjustment system............................................................................ 85
Heating system for driver's cab..................................................................... 87
Auxiliary heater with timer (additional equipment).................................................. 89
Air-conditioning system (additional equipment)...................................................... 90
Cab lighting........................................................................................ 92
Other operating elements........................................................................... 92
4.2.2 Other operating elements for the vehicle section.................................................. 94
Keys, doors, windows................................................................................ 94
Access ladders...................................................................................... 95
Ladders............................................................................................. 96
Vehicle engine diagnostics plug..................................................................... 97
Fire extinguisher (additional equipment)............................................................ 98
Folding berth (additional equipment)................................................................ 98
5 Vehicle engine................................................................................................ 99
5.1 Starting/turning off the vehicle engine.................................................................101
5.1.1 CHECKLIST: Starting the vehicle engine............................................................101
5.1.2 CHECKLIST: In winter..............................................................................104
5.1.3 Checks prior to starting vehicle engine...........................................................105
Checking the hydraulic unit's shut-off valves.......................................................105
Switching on the battery master switch.............................................................105
Pre-checking the oil level in the automatic transmission............................................106
Checking coolant level..............................................................................107
Checking the hydraulic oil level....................................................................108
Draining off water from the fuel filter.............................................................108
Visual inspection of the drive belts................................................................110
Visual inspection of the combustion air system......................................................111
Checking the overall condition of the vehicle engine................................................112
Checking the engine oil level.......................................................................113
Topping up engine oil...............................................................................114
5.1.4 Refuelling........................................................................................115
5.1.5 Starting the vehicle engine.......................................................................116
Switching on the ignition..........................................................................116
Starting the vehicle engine........................................................................118
5.1.6 Checks after the engine has been started..........................................................121
Checking instruments...............................................................................121
Checking the oil level in the automatic transmission...............................................123
5.1.7 Turning off the vehicle engine....................................................................128
5.1.8 Emergency stop via the air intake inhibitor (additional equipment)................................129
Switching on the air intake inhibitor...............................................................129
Releasing the air intake inhibitor manually.........................................................130
6 Driving the truck crane.......................................................................................131
6.1 Checks on the truck crane before driving................................................................133
6.1.1 CHECKLIST: Condition of the truck crane for on-road driving.......................................133
6.1.2 On-road driving mode table........................................................................137
Axle loads in driving mode..........................................................................138
6.1.3 Checking the condition of the truck crane.........................................................139
Checking the reservoir of the windscreen washing system............................................139
Warning plates for vehicle width....................................................................139
Checking the tyres.................................................................................140
Checking the electrical system......................................................................140
Checking the mirror settings........................................................................141
Checking the compressed-air and braking system.....................................................141
Checking suspension................................................................................142
Checking on-road level.............................................................................142
Checking the transverse differential locks..........................................................143
Checking the drive of the 1st axle line/longitudinal differential locks.............................143
Checking the steering locks.......................................................................143
Checking the Boom not set down warning lamp.........................................................144
6.1.4 Adjusting the seat and the steering column........................................................145
Adjusting the driver's seat........................................................................145
Adjusting the steering column......................................................................145
6.1.5 Trip recorder.....................................................................................146
Inserting the 24- hour disc in the trip recorder....................................................146
6.2 General operation.......................................................................................149
6.2.1 Operating the automatic transmission..............................................................149
Switching on........................................................................................149
Automatic transmission driving modes...............................................................150
Selecting the driving direction....................................................................151
Starting............................................................................................152
Driving and changing gears..........................................................................152
Switching transmission to neutral position..........................................................153
Changing the direction of travel....................................................................154
Stopping the truck crane............................................................................155
Cold start program.................................................................................155
On the roller type dynamometer......................................................................155
6.2.2 Monitoring the control instruments while driving..................................................156
6.2.3 Driving downhill..................................................................................160
Engine retarder.....................................................................................160
Preselecting gears..................................................................................161
Eddy current retarder (additional equipment)........................................................162
6.2.4 Driving uphill....................................................................................163
6.2.5 Tempomat..........................................................................................164
Activating the Tempomat...........................................................................164
Driving with the Tempomat..........................................................................164
Switching off the Tempomat.........................................................................165
6.2.6 Temposet..........................................................................................166
Switching Temposet on...............................................................................166
Switching Temposet off..............................................................................166
6.2.7 Shutting down the truck crane.....................................................................167
Applying the parking brake..........................................................................167
Automatic gear- box in neutral position...........................................................167
Turning off the vehicle engine.....................................................................167
Securing the truck crane against rolling............................................................167
Switch off the battery master switch if the truck crane is idle for a longer period of time.........168
Securing the truck crane against unauthorized use...................................................168
6.3 Off-road driving........................................................................................169
6.3.1 Drive of the 1st axle line / longitudinal differential locks......................................170
Switching on drive / longitudinal differential locks................................................170
Switching off drive / longitudinal differential locks...............................................171
6.3.2 Transverse differential locks in all driven axle lines............................................172
Activating the transverse differential locks........................................................172
Deactivating the transverse differential locks......................................................173
6.3.3 Level adjustment system...........................................................................174
Activating the level adjustment system..............................................................174
Raising or lowering the entire truck crane..........................................................175
Tilting the truck crane lengthwise or crosswise.....................................................176
Bring the truck crane into On- road level...........................................................177
Deactivating the level adjustment system............................................................177
6.3.4 Freeing an immobilized truck crane................................................................178
Freeing the truck crane by its own power..........................................................178
Towing free to the front...........................................................................179
Towing free to the rear............................................................................179
6.4 Separate steering.......................................................................................181
6.4.1 Switching on separate steering....................................................................182
6.4.2 Steering axle lines with separate steering........................................................183
All-wheel steering..................................................................................183
Crab travel mode....................................................................................183
6.4.3 Switching off separate steering and locking the steering..........................................184
Locking the steering................................................................................184
6.5 Heating and ventilation.................................................................................187
6.5.1 Heating in the driver's cab.......................................................................187
Ventilating the driver's cab........................................................................189
6.5.2 Auxiliary water heating system (additional equipment).............................................190
Preheating the vehicle engine......................................................................190
Preheating the driver's cab........................................................................190
Switching on the auxiliary heating system...........................................................190
Switching off the auxiliary heater..................................................................191
6.5.3 Auxiliary heater with timer (additional equipment)................................................192
Preheating the vehicle engine......................................................................192
Preheating the driver's cab........................................................................192
Switching the auxiliary heater on/off...............................................................192
Displaying and setting the current time.............................................................193
Switching on and saving the automatic heating start.................................................193
Switching off the level adjustment system...........................................................194
6.5.4 Roof ventilator (additional equipment)............................................................195
6.6 Air-conditioning system (additional equipment)..........................................................197
6.6.1 Switching on......................................................................................197
6.6.2 Switching off.....................................................................................197
6.6.3 Air conditioning..................................................................................198
How to use the air conditioning effectively.........................................................198
Dehumidifying the air in the driver's cab...........................................................199
6.7 Towing a trailer (additional equipment).................................................................201
Effects on the axle loads...............................................................................201
Coupling the trailer...................................................................................202
Connecting the supply lines............................................................................203
Removing supplylines..................................................................................204
Uncoupling the trailer.................................................................................204
Test position of the parking brake when towing a trailer................................................206
7 Rigging for on-road driving...................................................................................207
7.1 Rigging work for driving with a trailer.................................................................209
7.1.1 Switch on slewing gear freewheel..................................................................210
7.1.2 Switching on boom floating position...............................................................212
Setting the main boom down on the trailer...........................................................212
7.1.3 Switching on boom pretensioning...................................................................214
7.2 Rigging the outrigger beam..............................................................................217
Equipment...............................................................................................217
7.2.1 CHECKLIST: Removing the outrigger beams...........................................................218
7.2.2 CHECKLIST: Mounting outrigger beams...............................................................220
7.2.3 Preparing the truck crane for removal/installation................................................222
Prerequisites for installation/removal..............................................................222
Preparing the truck crane..........................................................................222
7.2.4 Removing/attaching outrigger pads.................................................................223
Removing outrigger pads............................................................................223
Attaching the outrigger pads.......................................................................224
7.2.5 Disconnecting/establishing the hydraulic connection...............................................225
Disconnecting the hydraulic connection............................................................225
Establishing the hydraulic connection............................................................226
7.2.6 Disconnecting/establishing the electrical connection for the outrigger pressure indicator.........227
7.2.7 Screwing in/unscrewing and setting spacers........................................................228
Screwing in spacers................................................................................228
Unscrewing and setting spacers......................................................................228
7.2.8 Transport position/operating position of the holding angle........................................229
7.2.9 Locking/releasing the extension cylinder locking pin..............................................230
Releasing the locking pin...........................................................................230
Locking the extension cylinder......................................................................231
7.2.10 Extending/reinserting outrigger beams............................................................231
Extending the outrigger beam.......................................................................231
Reinserting the outrigger beams....................................................................234
7.2.11 Transporting the outrigger beams/outrigger pads..................................................236
7.3 Rigging the main boom...................................................................................237
Additional equipment required...........................................................................237
7.3.1 CHECKLIST: Removing the main boom.................................................................239
Prerequisites.......................................................................................239
Removing the main boom..............................................................................239
7.3.2 CHECKLIST: Mounting the main boom.................................................................242
Prerequisites.......................................................................................242
Installing the main boom............................................................................242
7.3.3 Supporting the truck crane while installing/removing the main boom................................246
7.3.4 Rigging work with the auxiliary crane.............................................................247
Lifting the main boom from the turntable............................................................247
Lifting the main boom onto the turntable............................................................248
7.3.5 Establishing/disconnecting the hydraulic connection to the lattice extension (additional eq.......249
Breaking the hydraulic connection...................................................................249
Establishing the hydraulic connection...............................................................250
7.3.6 Pulling device on the boom pivot pin (additional equipment).......................................251
Bottom axle pin- type keepers.......................................................................251
Hydraulic connection................................................................................252
Retracting/extending pins...........................................................................253
7.3.7 Locking pin at derricking cylinder head eyelet....................................................254
Operating the lifting equipment.....................................................................254
Retracting/extending pins...........................................................................256
7.3.8 Hydraulic connections on the main boom............................................................257
Removing/ attaching the guide plates................................................................258
Establishing hydraulic connection...................................................................258
Breaking the hydraulic connection...................................................................258
7.3.9 Electrical connections on the main boom...........................................................260
7.3.10 Checks following main boom installation..........................................................261
Hydraulic system check.............................................................................261
Checking the electrical system.....................................................................262
7.3.11 Before road driving..............................................................................264
Securing the derricking cylinder for on-road driving................................................264
Transporting the main boom..........................................................................264
7.3.12 Derricking cylinder pressure relief..............................................................265
Activating pressure relief..........................................................................265
Deactivating pressure relief........................................................................266
7.4 Installing/removing the auxiliary hoist (additional equipment)..........................................267
7.4.1 Slinging points and transport.....................................................................267
Slinging points.....................................................................................267
Transport...........................................................................................268
7.4.2 Mounting the auxiliary hoist......................................................................269
Removing pin- type keeper and pins..................................................................269
Attach the auxiliary hoist to the main hoist........................................................269
Locking the auxiliary hoist.........................................................................270
Establishing hydraulic and electrical connections...................................................270
7.4.3 Removing the auxiliary hoist......................................................................271
7.4.4 Permitted applications for the auxiliary hoist....................................................272
Replacement for the main hoist......................................................................272
Alternating operation with the main and auxiliary hoists............................................273
8 Malfunctions on the carrier...................................................................................275
8.1 Emergency stop device on carrier........................................................................277
Turning off the vehicle engine.........................................................................277
8.2 What to do in the event of a breakdown in road traffic..................................................279
8.3 Towing the truck crane..................................................................................281
8.3.1 Towing in the case of engine or transmission damage...............................................281
Towing the truck crane out of the danger area.......................................................282
Longer distances....................................................................................282
Compressed-air supply in the event of engine failure................................................284
Electric power supply...............................................................................284
Gears...............................................................................................285
Vehicle engine......................................................................................285
Holding brake.......................................................................................285
Mechanically releasing the parking brake............................................................286
Towing procedure....................................................................................286
Removing mechanical locking from all spring- loaded brake cylinders.................................287
Tow starting........................................................................................287
8.4 Wheels..................................................................................................289
8.4.1 Wheel change......................................................................................289
Removing a damaged wheel............................................................................289
Removing the wheel from the spare wheel holder....................................................290
Mounting a damaged wheel on the spare wheel holder..................................................291
Mounting the spare wheel...........................................................................292
8.4.2 Filling the tyres yourself........................................................................293
Connecting the filling hose.........................................................................293
Filling the tyres...................................................................................294
Removing the tyre inflator hose.....................................................................294
8.5 Cold start device – changing the cartridge containing the cold start agent..............................295
8.6 Electrical system.......................................................................................297
8.6.1 Inserts...........................................................................................298
Front plug-in module................................................................................298
8.6.2 Fuses.............................................................................................300
Groups F1 to F6...................................................................................300
Groups F7 to F10..................................................................................303
8.7 Troubleshooting.........................................................................................305
8.7.1 Vehicle engine malfunctions.......................................................................305
8.7.2 Automatic transmission malfunctions...............................................................307
8.7.3 Differential lock malfunctions....................................................................308
8.7.4 Service brake malfunctions........................................................................309
8.7.5 Steering malfunctions.............................................................................310
8.7.6 Outrigger malfunctions............................................................................310
8.7.7 Suspension locking system malfunctions............................................................311
8.7.8 Level adjustment system malfunctions..............................................................311
8.8 Procedure in the event of malfunctions..................................................................313
8.8.1 Switch the fan thermostat to emergency operation..................................................313
8.8.2 Troubleshooting for malfunctions in the automatic transmission....................................315
troubleshooting.....................................................................................315
Effect of error.....................................................................................315
Reading error codes...............................................................................316
Error messages while checking oil level.............................................................318
8.8.3 Emergency operation of the solenoid valves for the outriggers.....................................319
9 Technical information for the carrier.........................................................................323
9.1 Technical description of the carrier....................................................................325
9.1.1 Crane carrier.....................................................................................325
9.1.2 Driver's cab......................................................................................325
9.1.3 Drive units.......................................................................................326
9.1.4 Engine and transmission cooling system............................................................326
9.1.5 Hydraulic system..................................................................................326
9.1.6 Steering..........................................................................................327
9.1.7 Suspension system.................................................................................327
9.1.8 Outriggers........................................................................................328
9.1.9 Compressed air system.............................................................................328
9.1.10 Service brake....................................................................................329
9.1.11 Holding brake....................................................................................329
9.1.12 Engine retarder..................................................................................329
9.1.13 Secondary consumers..............................................................................330
9.1.14 Towing the crane.................................................................................330
9.1.15 Towing a trailer.................................................................................330
9.1.16 Electrical system................................................................................330
9.1.17 Rotary transmission..............................................................................330
9.2 Technical data..........................................................................................331
9.2.1 Measurements and weights of the truck crane.......................................................332
Dimensions for driving on public roads.............................................................333
9.2.2 Dimensions and weights of removable parts.........................................................334
Spare wheel (additional equipment)..................................................................334
Main boom...........................................................................................334
Outriggers..........................................................................................334
9.2.3 Carrier technical data............................................................................335
Vehicle engine......................................................................................335
On-load shift gearbox..............................................................................335
Transfer case.......................................................................................335
Axle lines..........................................................................................335
Steering............................................................................................335
Tyres...............................................................................................336
Vehicle's electrical system.........................................................................336
Tools...............................................................................................336
Outriggers..........................................................................................337
Driving speeds......................................................................................338
Climbing ability....................................................................................338
Turning circle radiuses.............................................................................339
10 Index........................................................................................................341
A...........................................................................................................345
B...........................................................................................................346
C...........................................................................................................346
D...........................................................................................................348
E...........................................................................................................349
F...........................................................................................................349
G...........................................................................................................350
H...........................................................................................................350
I...........................................................................................................350
K...........................................................................................................351
L...........................................................................................................351
M...........................................................................................................351
O...........................................................................................................352
P...........................................................................................................353
R...........................................................................................................353
S...........................................................................................................354
T...........................................................................................................355
V...........................................................................................................356
W...........................................................................................................357
Operating instructions Part 2 – Crane operation.....................................................................361
Additional pages - Emergency operation/Emergency program telescoping ...........................................363
11 Description of the crane section of the truck crane..........................................................367
11.1 Overview of the operating and display instruments......................................................369
11.1.1 Crane section overview...........................................................................369
11.1.2 Overview of crane cab............................................................................372
11.1.3 Instrument panel.................................................................................374
Front instrument panel..............................................................................374
Controls and fittings behind the crane driver's seat................................................387
11.1.4 Left-hand control console........................................................................388
11.1.5 Right-hand control console.......................................................................389
11.1.6 Control lever configuration......................................................................390
Version 1 (standard)................................................................................390
Version 2 (additional equipment)....................................................................391
11.1.7 Switch box for operating the outriggers..........................................................392
11.1.8 Counterweight hoist switch unit..................................................................393
11.1.9 Switch box for electronic level..................................................................394
11.2 Functional description of the display and operating elements..........................................395
11.2.1 Working with the crane...........................................................................395
Crane engine........................................................................................395
Outriggeroperation.................................................................................396
Counterweight hoisting gear and lock................................................................398
Crane control.......................................................................................400
Main hoist..........................................................................................402
Auxiliary hoist (additional equipment)..............................................................403
Slewing gear........................................................................................404
Derricking gear.....................................................................................405
Telescoping mechanism...............................................................................406
Safe load indicator................................................................................411
Hydraulic system....................................................................................418
Electricity.........................................................................................418
Other operating elements...........................................................................419
Electronic level in the crane cab...................................................................421
Changeover switch Change over measuring range.......................................................421
Crane cab heating..................................................................................422
Auxiliary heater with timer (additional equipment)..................................................422
Air-conditioning system (additional equipment)......................................................424
Houselock (additional equipment)....................................................................425
Anemometer..........................................................................................425
Outrigger pressure indicator (additional equipment).................................................426
11.2.2 Other operating elements in the crane cab........................................................427
Doors, keys, windows................................................................................427
Fire extinguisher (additional equipment)............................................................429
VDO electronics crane engine........................................................................429
11.3 Functional description of the safety devices...........................................................431
11.3.1 Safe load indicator (SLI)........................................................................431
11.3.2 Lowering limit switch............................................................................432
11.3.3 Lifting limit switch.............................................................................433
Overriding the lifting limit switch shutdown........................................................433
11.3.4 Dead man's and seat contact switches.............................................................434
12 Crane engine.................................................................................................435
12.1 Starting / turning off the crane engine................................................................437
12.1.1 CHECKLIST: Starting the crane engine.............................................................437
12.1.2 CHECKLIST: in winter.............................................................................440
12.1.3 Checks before starting the crane engine..........................................................441
Checking the shut- off valve in the hydraulic system...............................................441
Switching on the battery master switch.............................................................441
Checking coolant level..............................................................................442
Checking the hydraulic oil level....................................................................443
Checking the oil level in the crane engine........................................................443
Topping up engine oil..............................................................................444
Draining off water from the fuel filter.............................................................445
Checking the overall condition of the crane engine..................................................446
Refuelling..........................................................................................447
12.1.4 Starting the crane engine........................................................................448
Switching on the ignition..........................................................................448
Starting the crane engine..........................................................................449
12.1.5 Checks after starting the crane engine...........................................................452
Checking instruments...............................................................................452
12.1.6 Switching off the crane engine...................................................................454
12.1.7 Emergency stop via the air intake inhibitor (additional equipment)...............................455
Switching on the air intake inhibitor...............................................................455
Releasing the air intake inhibitor manually.........................................................456
13 Crane operation..............................................................................................457
13.1 Checking the truck crane before working with the crane.................................................459
13.1.1 CHECKLIST: When truck crane is rigged............................................................459
13.1.2 Adjusting the crane operator's seat..............................................................463
13.1.3 Checking the condition of the truck crane........................................................464
Checking the reservoir of the windscreen washing system.............................................464
Visual inspection of the entire crane...............................................................464
Checking the position of the hoist ropes............................................................465
Electrical system...................................................................................465
13.1.4 Checking the safety devices......................................................................466
Safe load indicator.................................................................................466
Lifting limit switch................................................................................466
Dead man's switch system............................................................................467
Emergency stop switch for the Crane control.........................................................467
13.1.5 Preheating the hydraulic oil.....................................................................468
When the oil temperature is between –15 C and 0 C (5 F und 32 F):...............................468
At oil temperatures below -15 C (5 F):............................................................468
13.1.6 Superstructure lock..............................................................................469
Removing the lock.................................................................................470
Engaging the lock..................................................................................470
13.1.7 Houselock (additional equipment).................................................................471
Switching on the houselock..........................................................................471
Switching off the houselock.........................................................................472
13.1.8 Adjusting the mirrors............................................................................473
13.2 Operating the safe load indicator (SLI)................................................................475
13.2.1 Switching on the SLI.............................................................................475
Switching on........................................................................................475
Lamp test on the SLI................................................................................477
Dimmers for the SLI displays........................................................................477
13.2.2 Setting the rigging mode.........................................................................478
Setting via the SLI code............................................................................478
Setting using individual components.................................................................478
General instructions................................................................................479
Sequence during setting.............................................................................479
Switching on input mode.............................................................................480
Entering values.....................................................................................481
Confirming input....................................................................................483
Accepting values....................................................................................483
Switching over the Hoists indicator lamps...........................................................484
13.2.3 Checks before working with the crane.............................................................485
13.2.4 During crane work................................................................................487
Continuous displays...............................................................................487
Optional displays..................................................................................488
SLI early warning...................................................................................489
SLI shutdown........................................................................................489
Error message.......................................................................................490
Error messages with additional optical displays.....................................................491
SLI override.......................................................................................492
13.3 Crane work with main boom..............................................................................493
13.3.1 External influences during crane operation.......................................................493
Horizontal alignment................................................................................493
Safe distances.....................................................................................493
Effect of wind on crane operations..................................................................494
Anemometer..........................................................................................494
Permissible wind load..............................................................................495
Earthing the load...................................................................................496
13.3.2 Slewing ranges permitted for working with the crane..............................................497
360 slewing range..................................................................................497
Working position 0 to the rear.....................................................................497
13.3.3 Hoists...........................................................................................498
Main hoist..........................................................................................498
Auxiliary hoist (additional equipment)..............................................................501
13.3.4 Derricking gear..................................................................................503
13.3.5 Slewing gear.....................................................................................505
Slewing gear holding brake..........................................................................505
Slewing.............................................................................................505
Slewing speed.......................................................................................506
Tracking the slewing gear...........................................................................506
Maximum permitted slewing speed.....................................................................507
13.3.6 Telescoping mechanism............................................................................509
Structure of the chapter............................................................................509
Description of functioning..........................................................................510
Main boom fixed length, intermediate length, telescoping length.....................................511
Telescoping.........................................................................................512
Notes on the telescoping sequence...................................................................515
Check before telescoping for the first time.........................................................515
Function of the control lever.......................................................................516
Example of the procedure for telescoping............................................................518
Checking initial position...........................................................................519
Unlocking the telescoping cylinder..................................................................522
Extending/retracting the telescoping cylinder and locking...........................................524
Unlocking a telescopic section......................................................................527
Telescoping a telescopic section to a fixed length and locking it...................................529
Telescoping the telescopic section to an intermediate length........................................533
Locking the telescopic section......................................................................534
Automatic telescoping...............................................................................535
Example of telescoping with teleautomation.........................................................537
Lowering the main boom for maintenance.............................................................539
Telescoping the main boom into a horizontal position................................................539
13.3.7 High-speed mode..................................................................................540
13.3.8 Menus on the crane control display...............................................................541
The menu Display states.............................................................................541
Menu Telescoping display and teleautomation.........................................................545
Menu Power unit speeds/Critical load control........................................................545
Menu Access Emergency operation.....................................................................549
Display of an error message.........................................................................550
13.3.9 Setting a constant engine speed..................................................................552
13.3.10 Critical load control...........................................................................553
13.3.11 Inclining the crane cab.........................................................................554
13.3.12 Cooling the hydraulic oil.......................................................................555
Standard oil cooler................................................................................555
Additional oil cooler..............................................................................555
13.3.13 Possible movement combinations..................................................................556
13.4 Driving with a rigged crane............................................................................557
13.4.1 Driving route....................................................................................557
13.4.2 Rigging mode and axle loads......................................................................558
Boom positions......................................................................................558
13.4.3 Driving the rigged crane.........................................................................560
Locking the superstructure and engaging the slewing gear holding brake..............................560
Retracting the outriggers..........................................................................560
Switching over the suspension locking system........................................................560
Switching on separate steering......................................................................561
Driving.............................................................................................562
Extending the outriggers...........................................................................562
13.5 Work breaks............................................................................................563
13.5.1 Short work breaks................................................................................563
13.5.2 Work breaks lasting more than 8 hours............................................................563
13.6 Crane cab heating and ventilation......................................................................565
13.6.1 Heating the crane cab............................................................................565
13.6.2 Auxiliary water heating system (additional equipment)............................................566
Switching on the auxiliary heating system...........................................................566
Switching off the auxiliary heater..................................................................567
13.6.3 Auxiliary heater with timer (additional equipment)...............................................567
Preheating crane engine............................................................................567
Preheating crane cab...............................................................................568
Switching the auxiliary heater on/off...............................................................568
Displaying and setting the current time.............................................................568
Switching off the automatic heating start...........................................................569
Switching off the automatic heating start...........................................................570
13.6.4 Ventilating the crane cab........................................................................571
13.7 Air-conditioning system (additional equipment).........................................................573
13.7.1 Switching on.....................................................................................573
13.7.2 Switching off....................................................................................574
13.7.3 Air conditioning.................................................................................574
How to use the air conditioning effectively.........................................................574
Dehumidifying the crane cab air.....................................................................575
14 Rigging work.................................................................................................577
14.1 Checklists for rigging work for crane operation with main boom.........................................581
14.1.1 CHECKLIST: Rigging...............................................................................581
14.1.2 CHECKLIST: Unrigging.............................................................................585
14.2 Choosing a suitable site...............................................................................587
14.2.1 Load bearing capacity of the ground and the outriggers...........................................587
Enlarging the ground bearing area...................................................................589
14.2.2 Safe distance from slopes and pits...............................................................590
14.2.3 Earthing the truck crane.........................................................................591
Earthing the truck crane............................................................................591
14.2.4 Safe distance from electrical lines..............................................................592
14.3 Rigging work after driving with trailer................................................................595
14.3.1 Switch off slewing gear freewheel (additional equipment).........................................596
Before slewing......................................................................................597
14.3.2 Switching off the boom floating position (additional equipment)..................................598
14.3.3 Switching off boom pre-tensioning (additional equipment).........................................599
14.4 Outriggers.............................................................................................601
14.4.1 CHECKLIST: Extending the outriggers..............................................................601
14.4.2 CHECKLIST: Retracting the outriggers.............................................................603
14.4.3 Permissible outrigger spans......................................................................605
Outrigger span 8.50x8.30m (27,9 x 27,2 ft).......................................................605
Outrigger span 8.50x5.70m (27,9 x 18,7 ft).......................................................606
Outrigger span 8.50x2.72m (27,9x8,9 ft)........................................................606
14.4.4 Preparing the truck crane........................................................................607
Aligning the truck crane horizontally...............................................................607
Locking the suspension.............................................................................607
14.4.5 Securing / releasing the outrigger beams.........................................................608
Securing the outrigger beams........................................................................608
Releasing the outrigger beams.......................................................................609
14.4.6 Extending / retracting the outrigger beams.......................................................610
Extending the outrigger beams.......................................................................610
Retracting the outrigger beams.....................................................................612
Setting outrigger spans.............................................................................613
14.4.7 Moving the outrigger pads into working / driving position........................................616
Moving the outrigger pads into working position.....................................................616
Moving the outrigger pads into driving position ...................................................617
14.4.8 Extending/retracting the outrigger cylinders....................................................618
Extending the outrigger cylinders...................................................................618
Retracting the outrigger cylinders.................................................................619
14.4.9 Aligning the truck crane horizontally............................................................621
Reading the status display..........................................................................621
Switching over the measuring range..................................................................622
Aligning the truck crane horizontally...............................................................622
14.4.10 Outrigger pressure indicator (additional equipment).............................................623
Reading the status displays.........................................................................623
14.5 Counterweight..........................................................................................625
14.5.1 Counterweight parts and identification...........................................................625
Counterweight parts.................................................................................625
Identification......................................................................................625
14.5.2 Counterweight versions...........................................................................626
14.5.3 Slinging points on the counterweight sections....................................................629
14.5.4 CHECKLIST: Rigging the counterweight.............................................................630
Rigging the counterweight...........................................................................630
14.5.5 CHECKLIST: Unrigging the counterweight...........................................................633
Unrigging the counterweight.........................................................................633
14.5.6 Set down the counterweight sections..............................................................635
5.4 t base plate on counterweight platform..........................................................635
Stackingcounterweight sections.....................................................................636
14.5.7 Establishing / releasing hydraulic connection....................................................637
Establishing the hydraulic connection...........................................................637
Disconnecting the hydraulic connection..............................................................638
14.5.8 Assembling the counterweight version.............................................................639
14.5.9 3.5 t counterweight section......................................................................644
Equipping with installation rods (additional equipment)............................................644
Locking the 3.5 t counterweight section.............................................................645
14.5.10 Extending / retracting the 5.4 t base plate or raising / lowering the counterweight.............646
Lifting cylinders: extending........................................................................647
Lifting cylinders: retracting.......................................................................648
14.5.11 Locking/unlocking the counterweight to the turntable............................................648
Hasp positions......................................................................................649
Safety cock.........................................................................................649
Locking the counterweight...........................................................................650
Unlocking the counterweight.........................................................................650
14.5.12 Rigging 3 t counterweight blocks (additional equipment)........................................651
14.5.13 Slewing with the rigged counterweight...........................................................652
14.6 Rigging work on the main boom..........................................................................653
14.6.1 Hook block on the bumper.........................................................................653
Picking up the hook block...........................................................................653
Attaching the hook block............................................................................654
14.6.2 Hook block on a separate vehicle.................................................................655
Picking up the hook block...........................................................................655
Setting down the hook block and securing the hoist rope for on-road driving.........................656
14.6.3 Reeving and unreeving the hoist rope.............................................................657
Cable end clamp.....................................................................................657
Reeving the hoist rope.............................................................................659
Lifting limit switch on the main boom...............................................................661
14.6.4 Possible reeving methods on the main boom........................................................665
14.6.5 Anemometer.......................................................................................669
Installing the anemometer...........................................................................669
Remove the anemometer..............................................................................670
14.6.6 Rigging heavy duty equipment.....................................................................671
Heavy duty equipment parts..........................................................................671
Equipment required.................................................................................671
Rigging heavy duty equipment........................................................................672
Unrigging heavy duty equipment......................................................................675
Reevings with heavy duty equipment..................................................................677
15 Malfunctions on the superstructure...........................................................................679
15.1 Superstructure emergency stop device...................................................................681
Switching off the crane engine.........................................................................681
Crane control emergency stop switch.....................................................................682
15.2 What to do in the event of a malfunction when working with the crane.................................683
Load cannot be lowered..................................................................................683
15.3 Cold start device - changing the cartridge containing the cold start agent.............................685
15.4 Electrical system......................................................................................687
15.4.1 Plug-in modules and consoles.....................................................................688
15.4.2 Fuses............................................................................................690
Groups F1 to F9...................................................................................690
Groups F10 to F13.................................................................................694
15.4.3 SLI fuses........................................................................................695
Replacing fuses.....................................................................................695
15.5 Troubleshooting........................................................................................697
15.5.1 Crane engine malfunctions........................................................................697
15.5.2 Main hoist malfunctions..........................................................................698
15.5.3 Auxiliary hoist malfunctions.....................................................................700
15.5.4 Derricking gear malfunctions.....................................................................702
15.5.5 Telescoping mechanism malfunctions...............................................................704
15.5.6 Slewing gear malfunctions........................................................................706
15.5.7 Locking pin / counterweight lifting gear malfunctions............................................707
15.5.8 Hydraulic system / hydraulic oil cooler malfunctions.............................................708
15.5.9 Crane control malfunctions.......................................................................708
15.5.10 Malfunctions on the SLI.........................................................................709
Other malfunctions on the SLI.......................................................................709
SLI error message table.............................................................................710
Switch off sensor / indicator during malfunction....................................................717
Check that the remaining sensor/ indicator is working..............................................718
Accept telescoping from the crane control...........................................................719
Checking SLI lines and connections..................................................................720
15.5.11 Emergency retract operation.....................................................................722
Checks before each emergency operation..............................................................722
Retraction procedure................................................................................723
Mechanical emergency operation......................................................................724
Hydraulic emergency operation.......................................................................726
15.6 Crane control error messages...........................................................................739
15.6.1 Error messages concerning control units..........................................................739
15.6.2 Error messages concerning power units............................................................740
Finding a defective part...........................................................................741
Determining the area of error.......................................................................742
Error causes and effects............................................................................743
15.6.3 Telescoping error messages.......................................................................745
15.6.4 Changing the connections in the control units....................................................746
Connections and control units.......................................................................746
Unrigging truck crane with defective control unit...................................................746
Disconnecting and removing connections..............................................................749
15.6.5 Control lever emergency program..................................................................750
Indication on the display...........................................................................750
Executing emergency program.........................................................................751
15.6.6 Emergency operation submenu......................................................................752
Retracting with an error on the length indicator....................................................753
Retracting with an error on the proximity switch....................................................756
Table for approaching the locking points............................................................757
15.6.7 "Entering telescoping after emergency operation" menu............................................758
15.7 Hydraulic emergency stop on the superstructure according to ZH1/461 (additional equipment).............761
15.7.1 Important instructions for hydraulic emergency operation.........................................761
15.7.2 Functioning and accessories......................................................................763
15.7.3 Connecting the transformer.......................................................................764
15.7.4 Switching emergency operation on/off.............................................................765
15.7.5 Establishing required hydraulic circuits.........................................................766
Making connections at the connector field...........................................................766
Additional switches for hoist and slewing gear.....................................................767
15.7.6 Carrying out emergency operation.................................................................768
"Move hoist" emergency operation....................................................................768
Hoist emergency operation...........................................................................769
Slewing gear emergency operation....................................................................769
15.7.7 After emergency operation........................................................................770
16 Technical information for superstructure.....................................................................771
16.1 Technical description of the superstructure............................................................773
16.1.1 Turntable........................................................................................773
16.1.2 Crane operator's cab.............................................................................773
16.1.3 Crane engine and hydraulic system................................................................774
16.1.4 Control system...................................................................................774
16.1.5 Main boom........................................................................................775
16.1.6 Telescoping mechanism............................................................................775
16.1.7 Hoists...........................................................................................776
16.1.8 Slewing gears....................................................................................776
16.1.9 Houselock (additional equipment).................................................................776
16.1.10 Derricking cylinder.............................................................................777
16.1.11 Electrical system...............................................................................777
16.1.12 Counterweight...................................................................................777
16.1.13 Safety devices..................................................................................778
16.2 Technical data.........................................................................................779
16.2.1 Maximum lifting capacity.........................................................................779
DIN/ ISO/ EN........................................................................................779
ANSI B 30.5 (85%)...................................................................................779
16.2.2 Guaranteed value specifications..................................................................779
16.2.3 Dimensions and weights of the truck crane........................................................780
Dimensions for driving on public roads.............................................................781
16.2.4 Dimensions and weights of removable parts........................................................782
Counterweightparts.................................................................................782
Hook blocks and hook tackle.........................................................................783
Auxiliary hoist.....................................................................................783
Main boom...........................................................................................784
Heavy dutyequipment................................................................................784
Counterweight versions..............................................................................784
16.2.5 Technical data for superstructure................................................................787
Crane engine........................................................................................787
Crane's electrical system...........................................................................787
Main hoist..........................................................................................787
Auxiliary hoist (additional equipment)..............................................................788
Slewing gears.......................................................................................788
Derricking gear.....................................................................................788
Main boom...........................................................................................788
Operating speeds and times without a load..........................................................789
17 Index........................................................................................................791
A...........................................................................................................795
B...........................................................................................................796
C...........................................................................................................796
D...........................................................................................................798
E...........................................................................................................799
F...........................................................................................................799
G...........................................................................................................800
H...........................................................................................................800
I...........................................................................................................800
K...........................................................................................................801
L...........................................................................................................801
M...........................................................................................................801
O...........................................................................................................802
P...........................................................................................................803
R...........................................................................................................803
S...........................................................................................................804
T...........................................................................................................805
V...........................................................................................................806
W...........................................................................................................807
GROVE GMK 5200 OPERATING INSTRUCTIONS MANUAL PART 1 (DRIVING) – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
Grove GMK 5200 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOADGrove GMK 5200 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
PLEASE NOTE:
This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
s.v
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
