Grove GMK 5220 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
DESCRIPTION:
Grove GMK 5220 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Intended use:
The GMK 5220 is a state-of-the-art truck crane, designed in accordance with approved safety regulations. Nevertheless, the operator or third parties can still be endangered and the crane or other property put at risk while using it.
Modifications may only be made to the truck crane following the approval of Deutsche GROVE GmbH.
The GMK 5220 truck crane may only be used in a perfect technical condition as intended and with due attention paid to safe operation and possible hazards. Any malfunctions that could impair safety must be eliminated immediately.
The GMK 5220 truck crane may only be operated without the corresponding special equipment within the permitted temperature range; àTechnical information on the carrier, p. 8 – 1.
The GMK 5220 truck crane is designed solely for lifting loads which are within the permitted GMK 5220 lifting capacities. The load must be slung as prescribed to a hook block which is positioned vertically over the load prior to lifting.
Intended use also entails
– Observing the entire crane documentation, consisting of the operating instructions,
the lifting capacity table, the outrigger pressure table and the
safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual
Improper use
Deutsche GROVE GmbH is not liable for any damage caused by improper or
unauthorized use of the GMK 5220 truck crane. The user alone bears the
risk.
Improper use includes:
– Transporting loads on the carrier
– Pushing, pulling or lifting loads with the level adjustment system, beams
or outrigger cylinders
– Pushing or pulling loads or lifting them off the ground using the slewing
gear, derricking gear or telescoping mechanism
– Pulling off fixed objects with the crane
– Two-hook operation with the boom extension and two-hook operation on
the main boom head without additional equipment
– Setting SLI codes that do not correspond to the actual rigging mode
– Working with an overridden SLI or overridden lifting limit switch
– After SLI deactivation, increasing the radius by pulling the raised load at
an angle (e.g. with a chain hoist)
– Misuse of the outrigger pressure indicator as a safety function to prevent
the crane from overturning after an SLI shutdown (outrigger pressure
higher than 0 t)
– On-road driving in an unauthorised driving mode (axle load, dimension)
– Moving the rigged crane in an unauthorized driving mode
– Using parts of equipment that are not authorised for the crane
TABLE OF CONTENTS:
Grove GMK 5220 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
1 Overview................................................................................................. 7
1.1 Identification..................................................................................... 7
1.2 EC Declaration of Conformity....................................................................... 11
1.3 Documentation supplied............................................................................. 12
1.4 Information about the operating instructions....................................................... 13
1.4.1 What do the symbols used mean?............................................................... 13
1.4.2 How are the operating instructions structured?............................................... 15
Division....................................................................................... 15
Structure of the chapters...................................................................... 15
Structure of the pages......................................................................... 16
1.4.3 How do I find the information I need?........................................................ 17
Cross-references example....................................................................... 18
1.4.4 What information is available for operations planning?....................................... 20
1.5 Conversion table for US measurements............................................................... 21
2 Basic safety instructions................................................................................ 25
2.1 Intended use....................................................................................... 25
2.1.1 Improper use................................................................................. 26
2.2 Organisational measures............................................................................ 27
2.3 Personnel qualification............................................................................ 29
2.4 Safety instructions for driving the truck crane.................................................... 30
2.5 Safety instructions for crane operation............................................................ 31
3 Operating elements when driving.......................................................................... 35
3.1 Overview of the operating elements................................................................. 35
3.1.1 On the outside of the truck crane............................................................ 36
3.1.2 In the driver's cab.......................................................................... 38
Top view of driver's cab...................................................................... 38
Below in the driver's cab..................................................................... 40
Above in the driver's cab..................................................................... 41
Behind the cover.............................................................................. 42
3.1.3 Front instrument panel....................................................................... 43
Left........................................................................................... 43
Tachograph version 1.......................................................................... 44
Middle......................................................................................... 45
Right.......................................................................................... 47
3.1.4 ECOS control unit............................................................................ 48
3.1.5 ECOS display – main menu..................................................................... 50
3.1.6 ECOS display – submenus...................................................................... 52
Level adjustment system submenu............................................................... 52
Settings submenu............................................................................... 54
Submenu Monitoring............................................................................. 55
Operating hours submenu....................................................................... 56
Warning submenu................................................................................ 56
Error submenu.................................................................................. 57
3.1.7 Side instrument panel........................................................................ 58
Standard heating............................................................................... 59
Auxiliary water heater....................................................................... 60
Auxiliary air heater........................................................................ 61
3.1.8 Transmission................................................................................. 62
3.1.9 Steering column.............................................................................. 63
3.1.10 Sockets for hand-held control............................................................... 64
3.1.11 Outrigger control units..................................................................... 65
3.2 Short description of the operating elements........................................................ 67
3.2.1 Definition of positional references.......................................................... 67
Basic rule..................................................................................... 67
Switches and buttons.......................................................................... 68
3.2.2 General information on the operating elements................................................ 68
3.2.3 General rules for buttons and symbols on the display......................................... 69
3.2.4 Engine....................................................................................... 70
Steering column................................................................................ 70
Multipurpose switch............................................................................ 70
Instrument panels.............................................................................. 71
3.2.5 Electrical system/electronics................................................................ 72
Electrical system.............................................................................. 72
3.2.6 ECOS crane control........................................................................... 73
Control unit................................................................................... 73
Instrument panel............................................................................... 76
3.2.7 Transmission................................................................................. 77
ECOS display................................................................................... 77
Side instrument panel.......................................................................... 78
3.2.8 Transfer case................................................................................ 81
3.2.9 Final drive.................................................................................. 82
3.2.10 Brakes...................................................................................... 84
Service brake.................................................................................. 84
Parking brake.................................................................................. 85
Additional brakes.............................................................................. 86
3.2.11 Normal steering mode/separate steering...................................................... 87
Instrument panels.............................................................................. 87
ECOS display................................................................................... 88
Driver's door.................................................................................. 89
3.2.12 Suspension.................................................................................. 90
3.2.13 Lighting/windscreen wipers/horn............................................................. 91
Steering column................................................................................ 91
Instrument panels.............................................................................. 91
Overhead in the driver's cab................................................................... 93
3.2.14 Level adjustment system..................................................................... 94
3.2.15 Tachograph/Speedometer...................................................................... 96
Tachograph..................................................................................... 96
Speedometer................................................................................... 96
3.2.16 Roof ventilator............................................................................. 97
3.2.17 Diagnostics................................................................................. 98
Connections.................................................................................... 98
Display/submenu................................................................................ 98
3.2.18 Windows, doors, keys........................................................................ 99
Windows........................................................................................ 99
Doors..........................................................................................100
Keys...........................................................................................101
3.2.19 Front flap..................................................................................101
4 Starting/turning off the engine for driving..............................................................105
4.1 Starting the engine from the driver's cab..........................................................105
4.1.1 CHECKLIST: Starting the engine...............................................................105
4.1.2 CHECKLIST: In low temperatures...............................................................108
4.1.3 Access ladders and ladders...................................................................108
Access ladders.................................................................................108
Ladders........................................................................................109
4.1.4 Refuelling...................................................................................111
4.1.5 Checks before starting the engine............................................................112
On the hydraulic tank..........................................................................112
Battery master switch..........................................................................113
Checking the hand-held control.................................................................113
4.1.6 Ignition, switching on.......................................................................113
4.1.7 Lamp test/equalisation of the switching states...............................................114
Lamp test......................................................................................114
Equalisation of the switching states...........................................................115
4.1.8 Adjusting the brightness of the display......................................................117
4.1.9 Starting the engine..........................................................................118
Without flame start system.....................................................................119
With flame start system.......................................................................120
4.1.10 Checks after starting the engine............................................................121
Checks in the main menu........................................................................121
Kontrollen im Hauptmenü........................................................................121
Checks on the instrument panels................................................................121
4.1.11 Monitoring submenu..........................................................................123
4.1.12 Setting the idling speed....................................................................124
4.2 Turning off the engine.............................................................................125
4.2.1 Usually with the ignition lock/with the hand-held control....................................125
Hand-held control not connected................................................................125
Hand-held control connected....................................................................125
After parking.................................................................................125
4.2.2 With emergency stop switches in emergencies..................................................126
Resetting the emergency stop switch............................................................126
4.3 Air intake inhibitor...............................................................................127
Removing the air intake inhibitor..................................................................127
5 Driving..................................................................................................131
5.1 Before driving.....................................................................................131
5.1.1 CHECKLIST: Checks before on-road driving.....................................................131
5.1.2 Checking the condition of the truck crane....................................................137
Windscreen washing system......................................................................137
Warning signs for vehicle width................................................................137
Electrical system..............................................................................138
Mirror setting.................................................................................138
Checking the vehicle height....................................................................139
Checking the compressed air and brake systems.................................................140
5.1.3 Adjusting the seats and steering column......................................................142
Adjusting the driver's seat..................................................................142
Adjusting the passenger seat.................................................................143
Adjusting the steering column.................................................................144
5.1.4 Switching the suspension on/off..............................................................145
Opening the submenu...........................................................................145
Switching on the suspension...................................................................146
Switching off the suspension..................................................................146
5.1.5 Setting the tachograph – version 1...........................................................147
Prerequisites..................................................................................147
Display of error messages.....................................................................147
Adjusting the tachograph......................................................................148
5.1.6 Displaying the operating hours...............................................................152
5.2 Operating the transmission.........................................................................153
5.2.1 Switching on.................................................................................153
5.2.2 Switching the transmission to neutral position...............................................154
While driving..................................................................................154
5.2.3 Changing the driving mode....................................................................155
5.2.4 Selecting the driving direction..............................................................156
5.2.5 Selecting highest gear/starting gear.........................................................157
5.2.6 Starting.....................................................................................157
5.2.7 Driving and changing gears...................................................................158
5.2.8 Changing the driving direction...............................................................159
5.2.9 Stopping.....................................................................................160
Stopping for a long period of time............................................................160
5.2.10 On the roller type dynamometer..............................................................160
5.2.11 Oil level gauge.............................................................................161
5.3 Driving and turning off the truck crane............................................................163
5.3.1 Checks while driving.........................................................................163
Directly after you start to move...............................................................163
While driving..................................................................................164
5.3.2 Tempomat.....................................................................................167
Activating the Tempomat.......................................................................167
Driving with the Tempomat.....................................................................168
Switching off the Tempomat....................................................................168
5.3.3 Driving downhill.............................................................................169
Starting.......................................................................................169
Checks when driving downhill..................................................................169
Shifting down from the highest gear............................................................170
Sustained action brake.........................................................................171
Retarder.......................................................................................172
5.3.4 Driving uphill...............................................................................173
Starting.......................................................................................173
Driving........................................................................................173
5.3.5 Warning submenu..............................................................................175
Opening the submenu...........................................................................175
Meaning of the symbols.........................................................................176
Exiting the submenu...........................................................................178
5.3.6 Error submenu................................................................................178
5.3.7 Parking the truck crane......................................................................179
Securing the truck crane against rolling away..................................................179
When standing still for more than 8 hours......................................................180
5.3.8 Folding berth................................................................................181
5.4 Off-road driving...................................................................................183
Adjustments to the transmission....................................................................183
Connections........................................................................................183
Changing the vehicle level........................................................................183
Rocking the vehicle free and towing...............................................................183
5.4.1 Transfer case – off-road gear on/off.........................................................184
Prerequisites..................................................................................184
Switching on...................................................................................184
Switching off..................................................................................185
Neutral position...............................................................................185
5.4.2 Operation of the longitudinal differential locks.............................................186
Switching on...................................................................................186
Switching off..................................................................................187
5.4.3 Operation of the transverse differential locks...............................................188
Switching on...................................................................................188
Switching off..................................................................................189
5.4.4 Operation of the level adjustment system.....................................................190
Opening the submenu...........................................................................190
Setting the on- road level....................................................................191
Pre-selecting suspension struts..............................................................191
Changing the vehicle level.....................................................................192
Viewing the current inclination................................................................192
Exiting the submenu...........................................................................193
5.4.5 Freeing the immobilised truck crane..........................................................194
Rocking the truck crane free..................................................................194
Towing free to the front......................................................................195
Towing free backwards.........................................................................195
5.5 Separate steering..................................................................................197
5.5.1 Switching on separate steering...............................................................198
5.5.2 Steering with separate steering..............................................................198
Manually.......................................................................................198
Automatically..................................................................................199
5.5.3 Switching off separate steering..............................................................200
5.6 Heating and ventilating the driver's cab...........................................................201
5.6.1 Standard heating.............................................................................201
Switching the heating on and off...............................................................201
Setting the temperature.......................................................................201
Setting recirculated/fresh air.................................................................202
Setting the air distribution.................................................................202
Ventilating the driver's cab...................................................................203
5.6.2 Auxiliary water heating system...............................................................204
Preheating the engine.........................................................................204
Preheating the driver's cab...................................................................204
Switching on the auxiliary heater..............................................................205
Switching off the auxiliary heater.............................................................206
Setting the time and weekday...................................................................206
Saving the automatic heating start............................................................207
Setting the heating period....................................................................208
Switching the automatic heating start on and off...............................................208
Setting the remaining time....................................................................209
5.6.3 Auxiliary air heater with timer..............................................................210
Switching on the auxiliary heater..............................................................210
Setting the temperature........................................................................211
Switching off the auxiliary heater............................................................211
Further functions..............................................................................211
5.6.4 Air-conditioning system......................................................................212
Switching on...................................................................................212
Setting the air distribution.................................................................212
Switching off..................................................................................213
Information on how to get the maximum benefit from the air conditioning .....................213
Dry air in the driver's cab...................................................................214
5.7 Towing a trailer...................................................................................215
Effects on the axle loads..........................................................................215
Coupling the trailer..............................................................................216
Connecting the supply lines.......................................................................217
Removing supply lines............................................................................218
Uncoupling the trailer............................................................................218
Checking the braking force........................................................................220
6 Driving modes and rigging for on-road driving............................................................223
6.1 Driving modes......................................................................................223
6.2 Rigging work for driving with a trailer............................................................225
6.2.1 Switching on the slewing gear freewheel......................................................225
Prerequisites..................................................................................225
6.2.2 Switching on boom floating position..........................................................227
6.2.3 Switching on boom pre-tensioning.............................................................228
6.2.4 Switching the superstructure driving lights on/off...........................................230
Switching off..................................................................................230
Switching on...................................................................................230
6.3 Rigging the main boom..............................................................................231
Additional equipment required......................................................................231
6.3.1 CHECKLIST: Removing the main boom............................................................232
Prerequisites..................................................................................232
Checklist......................................................................................232
6.3.2 CHECKLIST: Mounting the main boom............................................................235
Prerequisites..................................................................................235
Checklist......................................................................................235
6.3.3 Fitting slings to the main boom..............................................................239
6.3.4 Removing/attaching the clamp.................................................................240
6.3.5 Switching the pressure relief on/off.........................................................241
6.3.6 Retracting/fitting the derricking cylinder head pin..........................................242
Derricking cylinder...........................................................................242
Operation of the lifting device................................................................242
Retracting the derricking cylinder head axle...................................................243
Fitting the derricking cylinder head axle......................................................244
6.3.7 Retracting/extending the boom pivot pin......................................................245
Before retracting..............................................................................245
After extension................................................................................245
Retracting/extending the pivot pin.............................................................246
6.3.8 Separate the hydraulic/electrical connection.................................................247
Lifting in front of the turntable..............................................................247
Breaking.......................................................................................248
6.3.9 Establishing the hydraulic/electrical connection.............................................249
Lifting onto the turntable.....................................................................249
Establishing...................................................................................250
6.3.10 Aligning the connecting points..............................................................251
6.3.11 Securing/releasing derricking cylinder......................................................251
6.3.12 Transporting the main boom..................................................................252
6.3.13 Checks after main boom installation.........................................................253
6.4 Rigging the outrigger beam.........................................................................255
6.4.1 CHECKLIST: Removing the outrigger beams......................................................256
6.4.2 CHECKLIST: Mounting the outrigger beams......................................................258
6.4.3 Preparing the truck crane....................................................................261
Prerequisites..................................................................................261
For removal....................................................................................261
6.4.4 Removing/attaching outrigger pads............................................................262
Removing the outrigger pad.....................................................................262
Applying the outrigger pads....................................................................263
6.4.5 Disconnecting/establishing the hydraulic connection..........................................264
6.4.6 Establishing/disconnecting the electrical connection.........................................265
6.4.7 Unscrewing/screwing in the spacers...........................................................266
Unscrewing.....................................................................................266
Screwing in....................................................................................267
6.4.8 Disconnecting/establishing the connections to the outrigger box..............................268
6.4.9 Pulling out/Inserting the outrigger beam.....................................................268
Pulling out the outrigger beam.................................................................268
Inserting the outrigger beam...................................................................270
6.4.10 Transporting the outrigger beams............................................................272
6.5 Rig the auxiliary hoist............................................................................273
6.5.1 Slinging the auxiliary hoist.................................................................273
6.5.2 CHECKLIST: Installing the auxiliary hoist....................................................274
6.5.3 CHECKLIST: Removing the auxiliary hoist......................................................275
6.5.4 Creating/loosening the connection to the turntable...........................................276
6.5.5 Establishing/disconnecting the hydraulic connection..........................................277
6.5.6 Making/breaking the electrical connection....................................................278
6.5.7 Securing the hoist rope......................................................................279
6.5.8 Transporting the auxiliary hoist.............................................................280
6.5.9 Check that the auxiliary hoist is functioning properly.......................................281
Slewing direction..............................................................................281
Slewing indicator..............................................................................281
7 Malfunctions in driving mode.............................................................................285
7.1 Emergency stop devices.............................................................................285
7.2 What to do when a malfunction occurs in road traffic...............................................287
7.3 Towing the truck crane.............................................................................289
7.3.1 Towing in the event of engine or transmission damage.........................................289
Compressed-air supply..........................................................................290
Electric power supply..........................................................................290
Axle drives....................................................................................290
Transmission...................................................................................290
Transfer case..................................................................................291
Parking brake..................................................................................291
Towing the truck crane out of the danger area..................................................292
7.3.2 Starting to tow..............................................................................292
7.4 Wheels and tyres...................................................................................293
7.4.1 Wheel change.................................................................................293
Removing a damaged wheel.......................................................................294
On the spare wheel holder......................................................................294
Wheel, installing..............................................................................295
7.4.2 Filling the tyres yourself...................................................................297
Connecting the filling hose....................................................................297
Filling the tyres..............................................................................298
Remove the filling hose........................................................................298
7.5 Fuses on the carrier...............................................................................299
Information on replacing fuses...................................................................299
7.5.1 Fuses in the driver's cab....................................................................300
7.5.2 Fuses in the battery box.....................................................................304
7.5.3 Fuses on I/O boards..........................................................................305
7.6 Finding and eliminating malfunctions...............................................................307
7.6.1 Malfunctions on the engine for driving.......................................................307
7.6.2 Differential lock malfunctions...............................................................309
7.6.3 Malfunctions on the transmission.............................................................310
7.6.4 Malfunctions of the transfer case............................................................311
7.6.5 Service brake malfunctions...................................................................311
7.6.6 Steering malfunctions........................................................................312
7.6.7 Malfunctions to the suspension...............................................................313
7.6.8 Level adjustment system malfunctions.........................................................313
7.6.9 Malfunctions in the hydraulic system/hydraulic oil cooler....................................314
7.6.10 Malfunctions on the ECOS carrier............................................................315
ECOS program version...........................................................................315
General malfunctions..........................................................................315
Error messages.................................................................................316
Exiting the submenu...........................................................................317
Error display on the control units.............................................................318
7.7 Procedure in the event of malfunctions.............................................................319
7.7.1 Switching on emergency operation in coolant circuit..........................................319
7.7.2 Malfunctions on the engine...................................................................320
7.7.3 Malfunctions to the transmission.............................................................321
General malfunctions...........................................................................321
Display E......................................................................................321
Transmission malfunction.......................................................................322
Reading error codes...........................................................................323
8 Technical information on the carrier.....................................................................327
8.1 Technical data.....................................................................................327
8.1.1 Dimensions and weights of the truck crane, axle loads........................................328
Dimensions.....................................................................................329
Weight and axle loads..........................................................................329
8.1.2 Dimensions and weights of removable parts....................................................330
Spare wheel....................................................................................330
Outriggers.....................................................................................330
Main boom......................................................................................331
Auxiliary hoist................................................................................331
8.1.3 Carrier......................................................................................331
Engine.........................................................................................331
Transmission...................................................................................331
Transfer case..................................................................................331
Axle lines.....................................................................................332
Steering.......................................................................................332
Tyres..........................................................................................332
Vehicle's electrical system....................................................................333
Tools..........................................................................................333
Towing coupling...............................................................................333
Outriggers.....................................................................................333
Driving speeds.................................................................................334
Climbing ability...............................................................................334
Turning circle radiuses........................................................................334
9 Index....................................................................................................337
A......................................................................................................339
B......................................................................................................339
C......................................................................................................340
D......................................................................................................342
E......................................................................................................343
F......................................................................................................345
H......................................................................................................345
I......................................................................................................346
K......................................................................................................346
L......................................................................................................346
M......................................................................................................347
O......................................................................................................348
P......................................................................................................349
R......................................................................................................349
S......................................................................................................350
T......................................................................................................352
V......................................................................................................354
W......................................................................................................354
10 Operating elements for crane operation..................................................................363
10.1 Overview of the operating elements................................................................363
10.1.1 On the outside of the truck crane...........................................................364
10.1.2 Crane cab...................................................................................366
10.1.3 Front panel.................................................................................368
10.1.4 Side panel..................................................................................369
Bottom.........................................................................................369
Top............................................................................................370
Standard heating system........................................................................373
Auxiliary water heating system.................................................................374
Auxiliary air heater.........................................................................375
10.1.5 Control panels..............................................................................376
Left-hand controlpanel........................................................................376
Right-hand controlpanel.......................................................................377
10.1.6 Control lever assignment....................................................................378
Version 1......................................................................................378
Version 2......................................................................................379
10.1.7 ECOS control unit...........................................................................380
10.1.8 ECOS display – main menu....................................................................382
10.1.9 ECOS display – submenus.....................................................................384
Counterweight submenu..........................................................................384
Submenu slewing gear/Houselock.................................................................385
Outriggers submenu.............................................................................386
Telescoping submenu............................................................................388
Power unit speeds submenu......................................................................390
Monitoring submenu.............................................................................391
Settings submenu...............................................................................392
Operating hours submenu........................................................................394
Warning submenu................................................................................394
Error submenu..................................................................................395
Working range limitation submenu..............................................................396
10.1.10 SLI control unit...........................................................................398
10.1.11 SLI display – main menu....................................................................400
10.1.12 SLI display – submenus.....................................................................401
Enter rigging mode submenu...................................................................401
Monitoring submenu............................................................................402
Rigging mode monitoring submenu................................................................404
Lifting capacity tablesubmenu.................................................................405
Working range submenu..........................................................................406
Error submenu..................................................................................407
Settings submenu...............................................................................409
10.1.13 Hand-held control..........................................................................410
Outriggers control panel.......................................................................411
10.1.14 On the outrigger control units.............................................................412
Outriggers.....................................................................................413
Outrigger pressure display.....................................................................413
Inclination display............................................................................413
10.2 Short description of the operating elements.......................................................415
10.2.1 Definition of positional references.........................................................415
Basic rule.....................................................................................415
Switch.........................................................................................416
10.2.2 General rules for buttons and symbols on the display........................................416
10.2.3 Engine for crane operation..................................................................417
Side panel.....................................................................................417
ECOS display...................................................................................418
10.2.4 Engine for driving..........................................................................419
Side panel.....................................................................................419
Outriggers submenu.............................................................................419
10.2.5 Seat contact switch and dead man's switch...................................................420
10.2.6 ECOS crane control..........................................................................421
Control unit...................................................................................421
10.2.7 Outriggers..................................................................................425
Hand-held control..............................................................................425
In the Outriggers submenu......................................................................426
In the Settings submenu........................................................................427
On the outrigger control units.................................................................428
10.2.8 Inclination displays........................................................................430
10.2.9 Outrigger pressure displays.................................................................431
Outriggers submenu............................................................................431
Outrigger control units........................................................................431
10.2.10 Anemometer displays........................................................................431
10.2.11 Counterweight submenu......................................................................432
Counterweight submenu..........................................................................432
10.2.12 Main hoist.................................................................................435
10.2.13 Auxiliary hoist............................................................................437
10.2.14 Slewing gear...............................................................................438
Control panels.................................................................................438
Submenu........................................................................................439
10.2.15 Derricking gear............................................................................441
10.2.16 Telescoping mechanism......................................................................442
Control panels.................................................................................442
Submenu........................................................................................443
In the Settings submenu........................................................................447
10.2.17 Hydraulic system...........................................................................449
10.2.18 Houselock..................................................................................450
10.2.19 Safe load indicator (SLI)..................................................................451
Control unit...................................................................................451
Main menu......................................................................................453
Enter rigging mode submenu.....................................................................454
Monitoring submenu.............................................................................457
Lifting capacity table submenu................................................................460
Working range submenu..........................................................................461
Other..........................................................................................462
10.2.20 Electrical system..........................................................................463
10.2.21 Lighting, windscreen wiper/washing system..................................................463
Lighting.......................................................................................463
Windscreen wiper/washing system...............................................................465
10.2.22 Hand-held control..........................................................................466
Sockets on truck crane.........................................................................466
Engine control panel...........................................................................467
Horn...........................................................................................467
Outriggers control panel.......................................................................468
10.2.23 Diagnostics................................................................................470
10.2.24 Windows, doors, keys.......................................................................471
Windows........................................................................................471
Crane cab door.................................................................................471
Keys...........................................................................................472
11 Starting/turning off the engine – for crane operation..................................................475
11.1 Starting the engine – from the crane cab..........................................................475
11.1.1 CHECKLIST: Starting the engine..............................................................475
11.1.2 CHECKLIST: for low temperatures.............................................................478
11.1.3 Refuelling..................................................................................479
11.1.4 Checks before starting the engine...........................................................481
On the hydraulic tank..........................................................................481
Battery master switch..........................................................................481
Checking the hand-held control.................................................................482
11.1.5 Switching on the ignition...................................................................482
11.1.6 Lamp test...................................................................................483
Lamp test......................................................................................483
11.1.7 Adjusting the brightness of the display.....................................................485
11.1.8 Starting the engine.........................................................................486
Without flame start system.....................................................................486
With flame start system........................................................................487
11.1.9 Checks after starting the engine............................................................488
11.1.10 Monitoring submenu.........................................................................489
11.1.11 Setting the idling speed...................................................................490
11.2 Starting the engine – with the hand-held control..................................................491
Prerequisites......................................................................................491
Starting the engine................................................................................491
11.3 Turning off the engine............................................................................493
11.3.1 During normal operation, with the ignition lock/with the hand- held control.................493
Hand-held control not connected................................................................493
Hand-held control connected....................................................................493
After parking..................................................................................493
11.3.2 In emergencies, with the emergency-stop switches............................................494
Resetting the emergency stop switch............................................................494
11.4 Air intake inhibitor..............................................................................495
Releasing the air intake inhibitor.................................................................495
12 Crane operation.........................................................................................499
12.1 Before crane operation............................................................................499
12.1.1 CHECKLIST: Inspections before operating the crane...........................................499
12.1.2 Checking the condition of the truck crane...................................................503
Windscreen washing system......................................................................503
Visual inspection..............................................................................503
Checking the position of the hoist ropes.......................................................504
Checking the electrical system.................................................................504
12.1.3 Adjusting the crane cab seat and front panel................................................505
Adjusting the crane cab seat...................................................................505
Adjusting the front panel......................................................................505
12.1.4 Checking the safety devices.................................................................506
Safe load indicator............................................................................506
Lifting limit switch...........................................................................506
Emergency stop switch..........................................................................507
Seat contact switch and dead man's switch......................................................508
12.1.5 Earthing the load...........................................................................509
12.1.6 Preheating the hydraulic oil................................................................511
12.1.7 Switching the houselock on/off..............................................................512
Switching on the houselock.....................................................................512
Switching off the houselock....................................................................514
12.2 Operation of the safe load indicator..............................................................515
12.2.1 Switching on the SLI........................................................................516
Switching on...................................................................................516
Brightness of the displays.....................................................................518
12.2.2 Entering the rigging mode...................................................................519
Entering individual components.................................................................520
Entering the SLI code..........................................................................523
Entering the reeving...........................................................................524
Accept rigging mode............................................................................524
12.2.3 Checks prior to crane operation.............................................................526
Open the submenu...............................................................................526
Checks.........................................................................................527
12.2.4 Displays during crane operation.............................................................529
12.2.5 SLI early warning...........................................................................532
12.2.6 SLI shutdown................................................................................532
Shutdown due to overload.......................................................................532
12.2.7 Display in the event of errors..............................................................534
12.2.8 SLI override................................................................................535
12.2.9 Displaying the lifting capacity tables......................................................536
12.2.10 Entering the time/date.....................................................................538
12.3 Crane operation with main boom....................................................................539
12.3.1 Checks during crane operation...............................................................539
Horizontal alignment...........................................................................539
Safe distances.................................................................................539
Checking the wind speed........................................................................540
12.3.2 Permissible slewing ranges and working positions for crane operation.......................541
360 slewing range.............................................................................541
0 to the rear working position................................................................541
180 to the front rigging position.............................................................541
12.3.3 Main hoist..................................................................................543
Switching on the main hoist....................................................................544
Lifting and lowering...........................................................................544
Switching off the main hoist...................................................................545
12.3.4 Auxiliary hoist.............................................................................546
Switching on the auxiliary hoist...............................................................546
Lifting and lowering...........................................................................547
Switching off the auxiliary hoist..............................................................548
12.3.5 Lifting limit switch and lowering limit switch..............................................549
Lifting limit switch...........................................................................549
Lowering limit switch..........................................................................551
12.3.6 Derricking gear.............................................................................552
Switching on the derricking gear...............................................................552
Raising and lowering the boom..................................................................552
Switching off the derricking gear..............................................................553
Lowering the main boom to a horizontal position................................................554
12.3.7 Telescoping mechanism.......................................................................555
Overview.......................................................................................556
Telescoping process...........................................................................556
Assignment to display..........................................................................558
Fixed length, intermediate length, telescoping length..........................................560
Telescoping....................................................................................561
Telescoping sequence..........................................................................561
Checks prior to starting operations............................................................562
Switching on the telescoping mechanism.........................................................563
Function of the control lever..................................................................563
Switching off the telescoping mechanism........................................................565
Manual telescoping.............................................................................566
Checking the initial position..................................................................566
Unlocking the telescoping cylinder............................................................569
Extending/Retracting the telescoping cylinder..................................................571
Locking the telescoping cylinder...............................................................572
Unlocking a telescopic section.................................................................573
Telescope telescopic section...................................................................575
Locking the telescopic section.................................................................576
Locking the telescopic section for on-road driving.............................................577
Telescopic extension with teleautomation.......................................................578
Telescoping the main boom in horizontal position...............................................583
12.3.8 High speed..................................................................................584
Derricking gear/ Telescoping mechanism.........................................................584
Hoisting gears.................................................................................585
12.3.9 Slewing gear................................................................................586
Slewing gear brake.............................................................................586
Switching on the slewing gear..................................................................587
Releasing the slewing gear brake...............................................................587
Engaging the slewing gear brake................................................................587
Slewing........................................................................................588
Slewing to 0 or 180 ..........................................................................590
Braking the slewing movement...................................................................591
Slewing gear freewheel.........................................................................591
Switching off the slewing gear.................................................................592
12.3.10 Possible movement combinations.............................................................593
12.3.11 Hydraulic oil cooling......................................................................594
12.4 Settings and displays for crane operation.........................................................595
12.4.1 Limiting the power unit speeds..............................................................595
12.4.2 Setting the characteristic curve for the control levers.....................................597
12.4.3 Inclining the crane cab.....................................................................598
12.4.4 Setting the idling speed....................................................................598
12.4.5 Critical load control.......................................................................599
Function.......................................................................................599
Switching on and off...........................................................................599
12.4.6 Adjusting the stroke interval of the windscreen wiper.......................................600
12.4.7 Operation of the directional spotlights.....................................................601
Switching on/off...............................................................................601
Directing......................................................................................601
12.4.8 Displaying the operating hours..............................................................602
12.4.9 Warning submenu.............................................................................603
Opening the submenu............................................................................603
Meaning of the symbols.........................................................................603
Exiting the submenu............................................................................605
12.4.10 Error submenu..............................................................................606
12.5 Working range limiter.............................................................................607
12.5.1 Opening the Working range limiter submenu...................................................608
12.5.2 Viewing current settings....................................................................608
12.5.3 Entering limit values.......................................................................610
Overall height/ Working radius.................................................................610
Slewing angle..................................................................................611
Entering objects...............................................................................613
12.5.4 Entering limit values/objects manually......................................................616
Limit values...................................................................................616
Objects........................................................................................617
12.5.5 Switching monitoring functions on/off.......................................................618
12.5.6 Shutdown by working range limiter...........................................................619
12.6 Work break........................................................................................621
12.6.1 Short work breaks...........................................................................621
12.6.2 Work breaks of more than 8 hours............................................................622
Securing the truck crane against unauthorised use..............................................622
12.7 Heating and ventilating the crane cab.............................................................623
12.7.1 Standard heating system.....................................................................623
Switch heating system on/off...................................................................623
Setting the temperature........................................................................624
Setting recirculated/fresh air................................................................624
Setting the air distribution...................................................................624
12.7.2 Auxiliary water heating system..............................................................626
Preheating the engine.........................................................................626
Preheating the crane cab.......................................................................627
Switching on the heating system................................................................627
Switching off the heater.......................................................................628
Setting the time and weekday...................................................................629
Saving the automatic heating start.............................................................630
Setting the heating period.....................................................................631
Switching the automatic heating start on and off...............................................631
Setting the remaining time.....................................................................632
12.7.3 Auxiliary air heater........................................................................633
Switching on the heater........................................................................633
Setting the temperature........................................................................634
Switching off the heater.......................................................................634
Additional functions...........................................................................634
12.7.4 Air-conditioning system.....................................................................635
To switch on...................................................................................635
Setting the air distribution...................................................................635
Switching off..................................................................................636
For pleasant air conditioning in the crane cab.................................................636
Drying the air.................................................................................637
13 Rigging work............................................................................................641
13.1 Rigging work checklists for crane operation with the main boom....................................641
13.1.1 CHECKLIST: Rigging..........................................................................641
13.1.2 CHECKLIST: Unrigging........................................................................645
13.2 Choosing a suitable site..........................................................................649
13.2.1 Determining the required ground bearing area................................................649
13.2.2 Safe distance from slopes and pits..........................................................652
13.2.3 Earthing the truck crane....................................................................653
13.2.4 Safe distance from electrical lines.........................................................654
13.3 Rigging work after driving with a trailer.........................................................657
13.3.1 Switching off the slewing gear freewheel....................................................658
Prerequisites..................................................................................658
Before slewing.................................................................................658
13.3.2 Switching off the boom floating position....................................................659
13.3.3 Switching off boom pre-tensioning...........................................................660
13.4 Connecting/Disconnecting the hand-held control....................................................661
13.5 Starting the engine for driving for rigging work..................................................663
13.5.1 Starting/Turning off the engine with the hand-held control..................................663
Prerequisites..................................................................................663
Starting theengine............................................................................664
Turning off theengine.........................................................................664
13.5.2 Starting/Turning off the engine from the crane cab..........................................665
Prerequisites..................................................................................665
Starting theengine............................................................................665
After starting theengine......................................................................666
Turning off theengine.........................................................................666
13.6 Outriggers........................................................................................667
13.6.1 CHECKLIST: Extending the outriggers.........................................................667
13.6.2 CHECKLIST: Retract outriggers...............................................................669
13.6.3 Permissible outrigger spans.................................................................670
13.6.4 Preparing the truck crane...................................................................671
In the driver's cab............................................................................671
Outrigger control units........................................................................671
13.6.5 Setting the outrigger spans.................................................................672
For on-road driving...........................................................................674
13.6.6 Extending/Retracting the outrigger beams....................................................675
From the control units.........................................................................675
With the hand- held control....................................................................677
From the crane cab.............................................................................679
13.6.7 Moving the outrigger pads into working/driving position.....................................681
13.6.8 Enlarging the ground bearing area...........................................................682
13.6.9 Extending/Retracting outrigger cylinders....................................................683
From the control units.........................................................................684
With the hand- held control....................................................................685
From the crane cab.............................................................................686
13.6.10 Levelling the truck crane on outriggers....................................................688
Inclination displays..........................................................................688
Prerequisites..................................................................................689
Manual alignment...............................................................................690
Automatic alignment...........................................................................691
13.6.11 Outrigger pressure display.................................................................693
13.7 Rigging/Unrigging the counterweight...............................................................695
13.7.1 Counterweight parts.........................................................................695
13.7.2 Identification..............................................................................697
13.7.3 Slinging points.............................................................................699
13.7.4 CHECKLIST: Rigging counterweight............................................................700
13.7.5 CHECKLIST: Unrigging counterweight..........................................................701
13.7.6 Assemble counterweight versions.............................................................702
With Version A.................................................................................704
With Version B.................................................................................706
13.7.7 Counterweight hoist unit....................................................................708
Counterweight submenu..........................................................................708
Extending/ retracting the lifting cylinders..................................................709
Automatic mode, rigging........................................................................710
Automatic mode, unrigging......................................................................712
Cancel automatic mode..........................................................................714
13.7.8 Screwing the counterweight section to the turntable.........................................715
13.7.9 Slewing with rigged counterweight...........................................................716
13.7.10 Assembling counterweight parts for driving the truck crane.................................718
13.8 Rigging work on the main boom.....................................................................719
13.8.1 Hook block on the bumper....................................................................719
Picking up the hook block......................................................................719
Attaching the hook block.......................................................................720
13.8.2 Hook block on a separate vehicle............................................................721
Picking up the hook block......................................................................722
Setting down the hook block....................................................................722
13.8.3 Reeving and unreeving the hoist rope........................................................724
Fastening the rope end clamp...................................................................724
Reeving the hoist rope.........................................................................726
Unreeving the hoist rope.......................................................................730
13.8.4 Possible reevings with 8 head sheaves.......................................................731
13.8.5 Possible reevings with 9 head sheaves.......................................................735
13.8.6 Installing/Removing the lifting limit switch................................................739
Installing the lifting limit switch............................................................739
Removing the lifting limit switch.............................................................743
13.8.7 Locking/Unlocking the lifting limit switch..................................................745
Locking........................................................................................745
Removing the lock..............................................................................746
13.8.8 Anemometer and air traffic control light....................................................747
Installing.....................................................................................747
Removing.......................................................................................748
13.9 Other rigging work................................................................................749
13.9.1 Folding mirrors in and out and adjusting them...............................................749
13.9.2 Installing/removing the heavy duty equipment................................................751
Additional equipment required..................................................................751
Equipment required............................................................................751
Installing.....................................................................................752
Maximum reeving................................................................................753
Removing.......................................................................................754
14 Driving the rigged truck crane..........................................................................757
14.1 Route.............................................................................................757
14.2 Permissible rigging modes and axle loads..........................................................758
Axle load table....................................................................................758
14.3 Before driving....................................................................................760
14.3.1 Secure superstructure so it cannot slew.....................................................760
14.3.2 Checking the tyre pressure and the wind speed...............................................760
14.3.3 Putting the truck crane on the wheels.......................................................761
14.3.4 Transmission/Connections....................................................................763
Transmission...................................................................................763
Connections....................................................................................763
14.4 While driving.....................................................................................763
14.5 After driving.....................................................................................764
15 Malfunctions during crane operation.....................................................................767
15.1 Emergency stop devices............................................................................767
15.2 What to do when a malfunction occurs during crane operation.......................................769
Load can be lowered................................................................................769
Load cannot be lowered.............................................................................769
15.3 Fuses on the superstructure.......................................................................771
Notes on changing fuses............................................................................771
15.3.1 Fuses on the turntable......................................................................772
Fuse groups F1/F2..............................................................................772
Fuses on the circuit board.....................................................................774
Fuses on I/O circuit boards....................................................................774
15.3.2 Fuses in the crane cab......................................................................775
15.3.3 Fuses in the battery box....................................................................777
15.3.4 SLI fuses...................................................................................778
15.4 Finding and eliminating malfunctions..............................................................781
15.4.1 Malfunctions on the engine for crane operation..............................................781
15.4.2 Malfunctions when operating with the hand-held control......................................783
15.4.3 Malfunctions on the main hoist/auxiliary hoist..............................................784
15.4.4 Malfunctions on the derricking gear.........................................................785
15.4.5 Malfunctions on the slewing gear............................................................786
15.4.6 Malfunctions on the counterweight hoist unit................................................787
15.4.7 Malfunctions in the hydraulic system/hydraulic oil cooler...................................788
15.4.8 Malfunctions during the inclination of the crane cab........................................788
15.4.9 Malfunctions in the telescoping mechanism...................................................789
Telescoping mechanism error messages...........................................................791
15.4.10 Malfunctions on the outriggers.............................................................792
15.4.11 Troubleshooting on the SLI.................................................................793
General malfunctions...........................................................................793
Error messages in the Monitoring submenu.......................................................794
Displays in the Errors submenu................................................................796
Table of error codes...........................................................................798
Switch off sensor/ tachogenerator..............................................................801
15.4.12 Malfunctions ECOS – superstructure.........................................................802
ECOS program version...........................................................................802
General malfunctions...........................................................................802
Error messages.................................................................................803
Exiting the submenu............................................................................804
15.5 Emergency operations and programs.................................................................805
15.5.1 Mechanical emergency operation for retracting...............................................806
Check prior to the emergency operation.........................................................806
Procedure......................................................................................806
Mechanical emergency operation.................................................................807
15.5.2 Telescoping emergency program...............................................................809
Starting the emergency program.................................................................809
Determining the type of error..................................................................810
If there is an error on the length indicator...................................................811
If there is an error on a proximity switch.....................................................815
Terminating the emergency program..............................................................816
Tables for approaching the locking points......................................................817
15.5.3 Entering the current telescoping............................................................819
15.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....821
Preparations...................................................................................821
Operating a power unit.........................................................................822
Stopping movements.............................................................................824
Stopping movements in emergencies..............................................................824
Turning off the engine........................................................................824
15.6 Hydraulic emergency operation.....................................................................825
15.6.1 Important instructions for hydraulic emergency operation....................................825
15.6.2 Operating principle and accessories.........................................................827
For emergency operation.......................................................................827
For the emergency supply.......................................................................828
15.6.3 Connecting/Disconnecting hoses..............................................................829
Establishing connections.......................................................................829
Disconnecting..................................................................................830
15.6.4 Activating/Deactivating emergency mode......................................................831
15.6.5 Establishing the required hydraulic circuits................................................832
Switching over valves..........................................................................832
For lifting/lowering...........................................................................834
For slewing....................................................................................835
15.6.6 Carrying out emergency operation............................................................836
Lifting/Lowering in emergency mode.............................................................836
Slewing in emergency mode......................................................................837
Raising/Lowering in emergency mode.............................................................838
15.6.7 After emergency operation...................................................................839
Switching off emergency operation..............................................................839
Switching over the crane operation.............................................................839
Disconnecting the hoses........................................................................839
15.6.8 Emergency supply of another crane...........................................................840
For emergency supply...........................................................................840
After emergency supply.........................................................................840
16 Technical information for the superstructure............................................................843
16.1 Technical data....................................................................................843
16.1.1 Maximum lifting capacity (DIN/ISO/EN).......................................................843
16.1.2 Maximum lifting capacity (ASME B 30.5)......................................................843
16.1.3 Dimensions and weights of the truck crane, axle loads.......................................844
16.1.4 Dimensions and weights of removable parts...................................................844
Hook blocks and hook tackle....................................................................844
Counterweight parts............................................................................845
Heavy duty equipment..........................................................................845
Auxiliary hoist................................................................................845
16.1.5 Superstructure..............................................................................846
Engine.........................................................................................846
Main hoist.....................................................................................846
Auxiliary hoist................................................................................846
Slewing gears..................................................................................847
Derricking gear................................................................................847
Main boom......................................................................................847
Lattice extension..............................................................................847
Operating speeds...............................................................................848
17 Index...................................................................................................851
A......................................................................................................853
B......................................................................................................853
C......................................................................................................854
D......................................................................................................856
E......................................................................................................857
F......................................................................................................859
H......................................................................................................859
I......................................................................................................860
K......................................................................................................860
L......................................................................................................860
M......................................................................................................861
O......................................................................................................862
P......................................................................................................863
R......................................................................................................863
S......................................................................................................864
T......................................................................................................866
V......................................................................................................868
W......................................................................................................868
GROVE GMK 5220 OPERATING INSTRUCTIONS MANUAL PART 1 (DRIVING) – PDF DOWNLOAD:
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Grove GMK 5220 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOADGrove GMK 5220 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
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