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
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