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