Grove GMK 5130-1 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
DESCRIPTION:
Grove GMK 5130-1 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Serial number : 3 112 278 en
Intended use:
The GMK 5130-1 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 5130-1 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.
- Without the corresponding special equipment, the GMK 5130-1 truck crane may only be operated within the permitted temperature range; àTechnical information on the carrier, p. 8 – 1.
- The GMK 5130-1 truck crane is designed solely for lifting loads which are within the permitted GMK 5130-1 lifting capacities. The load must be slung as prescribed to a hook block which is positioned vertically over the load prior to lifting.
Intended use also includes
– Observing the entire crane documentation, consisting of the operating
instructions, the lifting capacity table, the outrigger pressure table and the
safety manual
– Adhering to the inspection and maintenance requirements specified in
the maintenance manual
Improper use
Deutsche GROVE GmbH is not liable for any damage caused by improper or unauthorized use of the GMK 5130-1 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 shutdown, increasing the working radius by pulling the raised
load at an angle (e.g. with a chain hoist)
– Misuse of the outrigger pressure indicator as a safety function to prevent
the crane from overturning after an SLI shutdown (outrigger pressure
greater than 0 t)
– On-road driving in impermissible driving mode (axle load, dimension)
– Moving the rigged crane in an impermissible driving mode
– Using equipment that is not permitted for the crane
TABLE OF CONTENTS:
Grove GMK 5130-1 Operating Instructions Manual Part 1 (Driving) – PDF DOWNLOAD
Part 1......................................................................................................... 1 Additional pageWind surface of the load.................................................................... 3 1 Overview................................................................................................. 9 1.1 Identification..................................................................................... 9 1.2 EC Declaration of Conformity....................................................................... 13 1.3 Documentation supplied............................................................................. 14 1.4 Information about the operating instructions....................................................... 15 1.4.1 What do the symbols used mean?............................................................... 15 1.4.2 How are the operating instructions structured?............................................... 17 Division....................................................................................... 17 Structure of the chapters...................................................................... 17 Structure of the pages......................................................................... 18 1.4.3 How do I find the information I need?........................................................ 19 Cross-references example....................................................................... 20 1.4.4 What information is available for operations planning?....................................... 22 1.5 Conversion table for US measurements............................................................... 23 2 Basic safety instructions................................................................................ 27 2.1 Intended use....................................................................................... 27 2.1.1 Improper use................................................................................. 28 2.2 Organisational measures............................................................................ 29 2.3 Qualifications of the personnel.................................................................... 31 2.4 Safety instructions for driving the truck crane.................................................... 32 2.5 Safety instructions for crane operation............................................................ 33 3 Operating elements for driving........................................................................... 37 3.1 Overview of the operating elements................................................................. 37 3.1.1 On the outside of the truck crane............................................................ 38 3.1.2 In the driver's cab.......................................................................... 40 Top view of driver's cab....................................................................... 40 Below in the driver's cab...................................................................... 42 Overhead in the driver's cab................................................................... 43 Behind the cover............................................................................... 44 3.1.3 Front instrument panel....................................................................... 45 Left........................................................................................... 45 Tachograph..................................................................................... 46 Middle......................................................................................... 47 Right.......................................................................................... 49 3.1.4 ECOS control unit............................................................................ 50 3.1.5 ECOS display – main menu..................................................................... 52 3.1.6 ECOS display – submenus...................................................................... 54 Level adjustment system submenu................................................................ 54 Settings submenu............................................................................... 56 Submenu Inspection............................................................................. 57 Operating hours submenu........................................................................ 58 Warning submenu................................................................................ 58 Transmission emergency program submenu......................................................... 59 Error submenu.................................................................................. 60 3.1.7 Side instrument panel........................................................................ 61 Standard heating............................................................................... 62 Auxiliary water heating system................................................................. 63 Auxiliary airheater........................................................................... 64 3.1.8 Transmission................................................................................. 65 3.1.9 Steering column.............................................................................. 66 3.1.10 Sockets for hand-held control............................................................... 67 3.1.11 Outrigger control units..................................................................... 68 3.2 Short description of the operating elements........................................................ 69 3.2.1 Definition of positional references.......................................................... 69 Basic rule..................................................................................... 69 Switches and buttons.......................................................................... 70 3.2.2 General information on the operating elements................................................ 70 3.2.3 General rules for buttons and symbols on the display......................................... 71 3.2.4 Engine....................................................................................... 72 Steering column................................................................................ 72 Multipurpose switch............................................................................ 72 Instrument panels.............................................................................. 73 3.2.5 Electrical system / electronics.............................................................. 74 Electrical system.............................................................................. 74 3.2.6 ECOS crane control........................................................................... 74 Control unit................................................................................... 74 Instrument panel............................................................................... 77 3.2.7 Transmission................................................................................. 78 ECOS display................................................................................... 78 Side instrument panel.......................................................................... 79 3.2.8 Final drive.................................................................................. 82 3.2.9 Brakes....................................................................................... 84 Service brake.................................................................................. 84 Parking brake.................................................................................. 85 Additional brakes.............................................................................. 86 3.2.10 Steering / Separate steering................................................................ 87 Instrument panels.............................................................................. 87 ECOS display................................................................................... 87 Driver's door.................................................................................. 88 3.2.11 Suspension.................................................................................. 88 3.2.12 Lighting / windscreen wipers / horn......................................................... 89 Steering column................................................................................ 89 Instrument panels.............................................................................. 89 Overhead in the driver's cab................................................................... 91 3.2.13 Level adjustment system..................................................................... 92 3.2.14 Tachograph / Speedometer.................................................................... 94 Tachograph..................................................................................... 94 Speedometer.................................................................................... 94 3.2.15 Roof ventilator............................................................................. 95 3.2.16 Diagnostics................................................................................. 95 Connections / buttons......................................................................... 95 Displays / submenu............................................................................ 96 3.2.17 Windows, doors, keys........................................................................ 97 Windows........................................................................................ 97 Doors.......................................................................................... 98 Keys........................................................................................... 99 3.2.18 Front flap.................................................................................. 99 4 Starting / turning off the engine for driving............................................................103 4.1 Starting the engine from the driver's cab..........................................................103 4.1.1 CHECKLIST: Starting the engine...............................................................103 4.1.2 CHECKLIST: If the temperature is low.........................................................106 4.1.3 Access ladders and ladders...................................................................106 Access ladders.................................................................................106 Ladders........................................................................................107 4.1.4 Refuelling...................................................................................109 4.1.5 Inspections before starting the engine.......................................................110 On the hydraulictank..........................................................................110 Battery master switch..........................................................................111 Checking the hand-held control.................................................................111 4.1.6 Switching on the ignition....................................................................111 4.1.7 Lamp test / equalisation of the switching states.............................................112 Lamp test......................................................................................112 Equalisation of the switching states...........................................................113 4.1.8 Adjusting the brightness of the display......................................................114 4.1.9 Starting the engine..........................................................................115 Without flame start system.....................................................................116 With flame start system........................................................................117 4.1.10 Checking after starting the engine..........................................................118 Checking in the main menu......................................................................118 Checking the instrument panels.................................................................119 4.1.11 Monitoring submenu..........................................................................119 4.1.12 Setting the idling speed....................................................................120 4.2 Turning off the engine.............................................................................121 4.2.1 During normal operation, with the ignition lock / with the hand- held control................121 Hand-held control not connected................................................................121 Hand-held control connected....................................................................121 After parking..................................................................................121 4.2.2 With emergency stop switches in emergencies..................................................122 Resetting the emergency stop switch............................................................122 4.3 Air intake inhibitor...............................................................................123 Releasing the air intake inhibitor.................................................................123 5 Driving..................................................................................................127 5.1 Before driving.....................................................................................127 5.1.1 CHECKLIST: Inspections before on-road driving................................................127 5.1.2 Checking the condition of the truck crane....................................................133 Windscreen washing system.....................................................................133 Warning signs for vehicle width................................................................133 Electrical system..............................................................................134 Adjusting the mirrors.........................................................................134 Checking the vehicle height...................................................................135 Supply pressure................................................................................136 Parking brake..................................................................................137 5.1.3 Adjusting the seats and steering column......................................................138 Adjusting the driver's seat....................................................................138 Adjusting the passenger seat..................................................................139 Adjusting the steering column..................................................................140 5.1.4 Switching the suspension on / off............................................................141 Opening the submenu...........................................................................141 Switching on the suspension....................................................................142 Switching off the suspension...................................................................142 5.1.5 Adjusting the tachograph.....................................................................143 Prerequisites..................................................................................143 Display of error messages......................................................................143 Adjusting the tachograph.......................................................................144 5.1.6 Displaying the operating hours...............................................................148 5.2 Operating the transmission.........................................................................149 5.2.1 To switch on.................................................................................149 5.2.2 Switching the transmission to neutral position...............................................150 5.2.3 Changing the operating mode..................................................................150 Change-over to automatic mode..................................................................150 Change-over to manual mode.....................................................................150 5.2.4 Display of the selected gears................................................................151 5.2.5 Selecting the direction of travel and starting gear..........................................151 Selecting the driving direction...............................................................151 Selecting the starting gear....................................................................152 5.2.6 Starting.....................................................................................153 5.2.7 Driving and changing gears...................................................................155 In automatic operating mode...................................................................155 In manual operating mode......................................................................156 5.2.8 Changing the driving direction...............................................................157 Quick change ofgear...........................................................................157 5.2.9 Stopping.....................................................................................158 Stopping for along period oftime.............................................................158 5.2.10 On the roller type dynamometer..............................................................158 5.3 Driving and turning off the truck crane............................................................159 5.3.1 Inspections while driving....................................................................159 Immediately after you start to move............................................................159 While driving..................................................................................160 5.3.2 Tempomat.....................................................................................161 Switching on the Tempomat......................................................................161 Driving with the Tempomat......................................................................161 Switching off the Tempomat.....................................................................162 5.3.3 Temposet.....................................................................................163 Switching Temposet on.........................................................................163 Driving with the Temposet......................................................................163 Switching Temposet off........................................................................163 5.3.4 Driving downhill.............................................................................164 Starting.......................................................................................164 Inspections when driving downhill..............................................................164 Downshifting...................................................................................165 Engine retarder................................................................................166 Eddy current retarder..........................................................................167 5.3.5 Driving uphill...............................................................................168 Starting.......................................................................................168 Driving........................................................................................168 5.3.6 Warning submenu..............................................................................169 Opening the submenu...........................................................................169 Meaning of the symbols.........................................................................170 Exiting the submenu...........................................................................173 5.3.7 Error submenu................................................................................173 5.3.8 Parking the truck crane......................................................................174 Securing the truck crane against moving unintentionally........................................175 When stationary for more than 8hours..........................................................176 5.3.9 Folding berth................................................................................177 5.4 Off-road driving...................................................................................179 Adjustments to the transmission....................................................................179 Connections........................................................................................179 Changing the vehicle level.........................................................................179 Rocking the vehicle free andtowing...............................................................179 5.4.1 Operation of the longitudinal differential locks.............................................180 Switching on...................................................................................180 Switching off..................................................................................181 5.4.2 Operation of the transverse differential locks...............................................182 Switching on...................................................................................182 Switching off..................................................................................183 5.4.3 Operation of the level adjustment system.....................................................184 Opening the submenu...........................................................................184 Setting the on-road level......................................................................185 Pre-selecting suspension struts...............................................................185 Changing the vehicle level.....................................................................186 Viewing the current inclination................................................................186 Exiting the submenu...........................................................................187 5.4.4 Freeing the truck crane stuck in terrain.....................................................188 Rocking the truck crane free...................................................................188 Towing free forwards..........................................................................189 Towing free in reverse gear....................................................................189 5.5 Separate steering..................................................................................191 5.5.1 Switching to separate steering...............................................................192 5.5.2 Steering with separate steering..............................................................193 5.5.3 Switching to normal steering mode............................................................194 5.6 Heating and ventilating the driver's cab...........................................................195 5.6.1 Standard heating system......................................................................195 Switching the heating on and off...............................................................195 Setting the temperature.......................................................................195 Setting recirculated / fresh air...............................................................196 Setting the air distribution..................................................................196 Ventilating the driver's cab...................................................................197 5.6.2 Auxiliary water heating system...............................................................198 Preheating the engine..........................................................................198 Preheating the driver's cab....................................................................198 Switching on the auxiliary heater..............................................................199 Switching off the auxiliary heater.............................................................200 Setting the time and weekday...................................................................200 Saving the automatic heating start.............................................................201 Setting the heating period....................................................................202 Switching the automatic heating start on and off...............................................202 Setting the remaining time.....................................................................203 5.6.3 Auxiliary air heater.........................................................................204 Switching on the auxiliary heater..............................................................204 Setting the temperature.......................................................................205 Switching off the auxiliary heater.............................................................205 Additional functions..........................................................................205 5.6.4 Air-conditioning system......................................................................206 Switching on...................................................................................206 Setting the air distribution..................................................................206 Switching off..................................................................................207 For pleasant air conditioning in the crane cab.................................................207 Drying the air in the driver's cab.............................................................208 5.7 Towing a trailer...................................................................................209 Effects on the axle loads..........................................................................209 Coupling the trailer...............................................................................210 Connecting the supply lines........................................................................211 Removing the supply lines..........................................................................212 Uncoupling the trailer.............................................................................212 Checking the braking force........................................................................214 6 Driving modes and rigging for on-road driving............................................................217 6.1 Driving modes......................................................................................217 Information on the axle loads......................................................................217 6.1.1 Information on how to use the tables.........................................................218 6.1.2 Tables for a maximum axle load of 12 t.......................................................219 For 14.00 R25 tyres............................................................................219 For 16.00 R25 tyres............................................................................220 For 20.5 R25 tyres..........................................................................221 6.2 Rigging work for driving with a trailer............................................................223 6.2.1 Switching on the slewing gear freewheel......................................................224 Prerequisites..................................................................................224 6.2.2 Switching on boom floating position..........................................................226 6.2.3 Switching on boom pre-tensioning.............................................................227 6.2.4 Switching the superstructure driving lights on / off.........................................229 Switching off..................................................................................229 Switching on...................................................................................229 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..............................................................238 6.3.4 Removing / attaching the clamp...............................................................239 6.3.5 Hydraulic connection for the lattice extension...............................................240 6.3.6 Switching the pressure relief on / off.......................................................241 6.3.7 Retracting / fitting the derricking cylinder head pin........................................242 Retracting the derricking cylinder head axle..................................................243 Fitting the derricking cylinder head axle......................................................244 6.3.8 Retracting / extending the boom pivot pin....................................................245 Before retracting..............................................................................245 After extension................................................................................245 Retracting / extending the pivot pin...........................................................246 6.3.9 Separate the hydraulic / electrical connection...............................................247 Lifting in front of the turntable..............................................................247 Disconnecting..................................................................................248 6.3.10 Establishing the hydraulic / electrical connection..........................................249 Lifting onto the turntable.....................................................................249 Establishing...................................................................................250 6.3.11 Aligning the connecting points..............................................................251 6.3.12 Securing / releasing the derricking cylinder................................................251 6.3.13 Transporting the main boom..................................................................252 6.3.14 Inspections after main boom mounting........................................................253 7 Malfunctions in driving mode.............................................................................257 7.1 Emergency stop devices.............................................................................257 7.2 What to do when a malfunction occurs in road traffic...............................................259 7.3 Towing the truck crane.............................................................................261 7.3.1 Towing in the event of engine or transmission damage.........................................262 Compressed-air supply..........................................................................262 Electric power supply..........................................................................262 On the transmission...........................................................................263 Axle drives....................................................................................264 Parking brake..................................................................................264 Towing the truck crane out of the danger area..................................................265 7.3.2 Starting to tow..............................................................................266 7.4 Wheels and tyres...................................................................................267 7.4.1 Wheel change.................................................................................267 Removing a damaged wheel.......................................................................268 On the spare wheel holder......................................................................268 Mounting a wheel...............................................................................269 7.4.2 Filling the tyres yourself...................................................................271 Connecting the filling hose....................................................................271 Filling the tyres..............................................................................272 Removing the filling hose.....................................................................272 7.5 Fuses on the carrier...............................................................................273 Notes on changing fuses...........................................................................273 7.5.1 Fuses in the driver's cab....................................................................274 7.5.2 Fuses in the battery box.....................................................................279 7.5.3 Fuses on I/O circuit boards..................................................................280 7.6 Finding and eliminating malfunctions...............................................................281 7.6.1 Malfunctions on the engine for driving.......................................................281 7.6.2 Differential lock malfunctions...............................................................283 7.6.3 Malfunctions on the transmission.............................................................284 7.6.4 Steering malfunctions........................................................................285 7.6.5 Service brake malfunctions...................................................................286 7.6.6 Malfunctions on the suspension...............................................................287 7.6.7 Malfunctions on the level adjustment system..................................................287 7.6.8 Malfunctions in the hydraulic system / hydraulic oil cooler..................................288 7.6.9 Malfunctions on the ECOS carrier.............................................................289 ECOS program version...........................................................................289 General malfunctions..........................................................................289 Error messages.................................................................................290 Exiting the submenu...........................................................................291 Error display on the control units.............................................................292 7.7 Procedure in the event of malfunctions.............................................................293 7.7.1 Switching on emergency operation in coolant circuit..........................................293 7.7.2 Procedure in the event of malfunctions to the transmission and engine........................294 Entries on the transmission display...........................................................294 Transmission emergency program submenu.........................................................296 Switching gears mechanically in emergency mode.................................................299 ID number of the transmission..................................................................303 8 Technical information on the carrier.....................................................................307 8.1 Technical data.....................................................................................307 8.1.1 Dimensions and weights of the truck crane, axle loads........................................308 Dimensions.....................................................................................309 Weight and axleloads..........................................................................309 8.1.2 Dimensions and weights of removable parts....................................................310 Spare wheel....................................................................................310 Outriggers.....................................................................................310 Main boom......................................................................................310 8.1.3 Carrier......................................................................................311 Engine.........................................................................................311 Manual transmission...........................................................................311 Transfer case..................................................................................311 Axle lines.....................................................................................311 Steering.......................................................................................312 Tyres..........................................................................................312 Electrical system..............................................................................312 Tools..........................................................................................312 Towing couplings...............................................................................312 Outriggers.....................................................................................313 Driving speeds.................................................................................313 Climbing ability...............................................................................313 Turning circle radiuses.......................................................................314 9 Index....................................................................................................317 A......................................................................................................319 B......................................................................................................319 C......................................................................................................320 D......................................................................................................321 E......................................................................................................323 F......................................................................................................325 H......................................................................................................325 I......................................................................................................326 K......................................................................................................327 L......................................................................................................327 M......................................................................................................328 O......................................................................................................328 P......................................................................................................329 R......................................................................................................329 S......................................................................................................330 T......................................................................................................332 V......................................................................................................334 W......................................................................................................334 Part 2.........................................................................................................337 Additional pageWind surface of the load....................................................................339 10 Operating elements for crane operation..................................................................345 10.1 Overview of the operating elements................................................................345 10.1.1 On the outside of the truck crane...........................................................346 10.1.2 Crane cab...................................................................................348 10.1.3 Front panel.................................................................................350 10.1.4 Side panel..................................................................................351 Bottom.........................................................................................351 Top............................................................................................352 Standard heating system........................................................................355 Auxiliary water heating system.................................................................356 Auxiliary air heater...........................................................................357 10.1.5 Control panels..............................................................................358 Left-hand control panel........................................................................358 Right-hand control panel......................................................................359 10.1.6 Control lever assignment....................................................................360 Version 1......................................................................................360 Version 2......................................................................................361 10.1.7 ECOS control unit...........................................................................362 10.1.8 ECOS display – main menu....................................................................364 10.1.9 ECOS display – submenus.....................................................................366 Counterweight submenu..........................................................................366 Superstructure lock submenu....................................................................367 Outriggers submenu............................................................................368 Telescoping submenu...........................................................................370 Power unit speeds submenu......................................................................372 Monitoring submenu............................................................................373 Settings submenu...............................................................................374 Operating hours submenu........................................................................376 Warning submenu................................................................................377 Error submenu..................................................................................379 Working range limitation submenu..............................................................380 Driving submenu................................................................................382 10.1.10 SLI control unit...........................................................................384 10.1.11 Hand-held control..........................................................................388 Outriggers control panel......................................................................389 10.1.12 On the Outrigger control units.............................................................390 Outriggers.....................................................................................391 Outrigger pressure display.....................................................................391 Inclination display............................................................................391 10.2 Short description of the operating elements.......................................................393 10.2.1 Definition of positional references.........................................................393 Basic rule.....................................................................................393 Switch.........................................................................................394 10.2.2 General rules for buttons and symbols on the display........................................394 10.2.3 Engine for crane operation..................................................................395 Side panel.....................................................................................395 ECOS display...................................................................................396 10.2.4 Engine for driving..........................................................................397 Side panel.....................................................................................397 Outriggers submenu............................................................................397 10.2.5 Seat contact switch and dead man's switch...................................................398 10.2.6 ECOS crane control..........................................................................399 Control unit...................................................................................399 10.2.7 Outriggers..................................................................................403 Hand-held control..............................................................................403 In the Outriggers submenu......................................................................404 In the Settings submenu........................................................................405 On the Outrigger control units.................................................................406 10.2.8 Inclination displays........................................................................408 10.2.9 Outrigger pressure displays.................................................................409 Outriggers submenu............................................................................409 Outrigger control units........................................................................409 10.2.10 Anemometer displays........................................................................409 10.2.11 Counterweight submenu......................................................................410 Counterweight submenu..........................................................................410 10.2.12 Superstructure lock submenu................................................................413 Turntable lock.................................................................................413 Houselock......................................................................................415 10.2.13 Main hoist.................................................................................416 10.2.14 Auxiliary hoist............................................................................417 10.2.15 Slewing gear...............................................................................418 10.2.16 Derricking gear............................................................................419 10.2.17 Telescoping mechanism......................................................................420 Control panels.................................................................................420 Submenu........................................................................................421 In the Settings submenu........................................................................425 10.2.18 Hydraulic system...........................................................................427 10.2.19 Safe load indicator (SLI)..................................................................429 Input elements with displays...................................................................429 Display elements...............................................................................431 On the front panel.............................................................................434 10.2.20 Electrical system..........................................................................435 10.2.21 Lighting, windscreen wiper / washing system................................................435 Lighting.......................................................................................435 Windscreen wiper/ washing system..............................................................437 10.2.22 Hand-held control..........................................................................438 Sockets on truck crane.........................................................................438 Engine control panel...........................................................................439 Horn...........................................................................................439 Outriggers control panel......................................................................440 10.2.23 Diagnostics................................................................................442 10.2.24 Windows, doors, keys.......................................................................443 Windows........................................................................................443 Crane cab door.................................................................................443 Keys...........................................................................................444 10.3 Short description of the operating elements – driving from the crane cab..........................445 10.3.1 Driving submenu.............................................................................445 10.3.2 Engine for driving..........................................................................446 10.3.3 Transmission................................................................................447 10.3.4 Final drive.................................................................................448 10.3.5 Brakes......................................................................................449 Side panel.....................................................................................449 ECOS display...................................................................................449 10.3.6 Steering....................................................................................450 Normal steering................................................................................450 Separate steering..............................................................................451 11 Starting / turning off the engine – for crane operation................................................455 11.1 Starting the engine – from the crane cab..........................................................455 11.1.1 CHECKLIST: Starting the engine..............................................................455 11.1.2 CHECKLIST: If the temperature is low........................................................458 11.1.3 Refuelling..................................................................................458 11.1.4 Inspections before starting the engine......................................................460 On the hydraulic tank..........................................................................460 Battery master switch..........................................................................460 Checking the hand-held control.................................................................461 11.1.5 Switching on the ignition...................................................................461 11.1.6 Lamp test / equalisation of the switching states............................................462 Lamp test......................................................................................462 Equalisation of the switching states...........................................................463 11.1.7 Adjusting the brightness of the display.....................................................464 11.1.8 Starting the engine.........................................................................465 Without flame start system.....................................................................465 With flame start system........................................................................466 11.1.9 Inspections after starting the engine.......................................................467 11.1.10 Monitoring submenu.........................................................................468 11.1.11 Setting the idling speed...................................................................469 11.2 Starting the engine – with the hand-held control..................................................471 Prerequisites......................................................................................471 Starting the engine................................................................................471 11.3 Turning off the engine............................................................................473 11.3.1 During normal operation, with the ignition lock / with the hand- held control...............473 Hand-held control not connected................................................................473 Hand-held control connected....................................................................473 After parking..................................................................................473 11.3.2 In emergencies, with the emergency-stop switches............................................474 Resetting the emergency stop switch............................................................474 11.4 Air intake inhibitor..............................................................................475 Releasing the air intake inhibitor.................................................................475 12 Crane operation.........................................................................................479 12.1 Before crane operation............................................................................479 12.1.1 CHECKLIST: Inspections prior to crane operation.............................................479 12.1.2 Checking the condition of the truck crane...................................................483 Windscreen washing system.....................................................................483 Visual inspection..............................................................................483 Checking the position of the hoist ropes......................................................484 Checking the electrical system.................................................................484 12.1.3 Adjusting the crane cab seat and front panel................................................485 Crane cab seat.................................................................................485 Front panel....................................................................................485 12.1.4 Checking the safety devices.................................................................486 Safe load indicator............................................................................486 Lifting limit switch...........................................................................486 Seat contact switch and dead man's switch......................................................487 Emergency stop switch..........................................................................488 12.1.5 Earthing the load...........................................................................489 12.1.6 Preheating the hydraulic oil................................................................490 12.1.7 Locking / Unlocking the turntable...........................................................492 Locking points.................................................................................492 Locking the turntable.........................................................................493 Unlocking the turntable........................................................................493 12.1.8 Switching the houselock on / off............................................................494 Switching on the houselock.....................................................................494 Switching off the houselock....................................................................496 12.2 Operation of the safe load indicator..............................................................497 12.2.1 Switching on the SLI........................................................................498 Switching on...................................................................................498 Lamp test on the SLI...........................................................................500 Brightness of the displays.....................................................................500 12.2.2 Entering the rigging mode...................................................................501 Entering the SLI code..........................................................................502 Entering the reeving..........................................................................505 Entering individual components...............................................................506 12.2.3 Inspections prior to crane operation........................................................509 12.2.4 Displays during crane operation.............................................................511 Continuous displays...........................................................................511 Optional displays..............................................................................513 12.2.5 SLI early warning...........................................................................515 12.2.6 SLI shutdown................................................................................516 Shutdown due tooverload.......................................................................516 12.2.7 Error message...............................................................................517 12.2.8 Displaying and entering the time and date...................................................518 Display........................................................................................518 Input..........................................................................................519 12.2.9 SLI override................................................................................520 12.3 Crane operation with main boom....................................................................521 12.3.1 Checks during crane operation...............................................................521 Horizontal alignment..........................................................................521 Safe distances.................................................................................521 Checking the wind speed........................................................................522 12.3.2 Permissible slewing ranges and working positions............................................525 360 slewing range.............................................................................525 0 to the rear working position................................................................525 180 to the front rigging position.............................................................526 Free-on-wheels working position................................................................526 12.3.3 Main hoist..................................................................................527 Switching on the main hoist....................................................................528 Lifting and lowering..........................................................................528 Switching off the main hoist...................................................................529 12.3.4 Auxiliary hoist.............................................................................530 Switching on the auxiliary hoist...............................................................530 Lifting and lowering..........................................................................531 Switching off the auxiliary hoist..............................................................532 12.3.5 Lifting limit switch and lowering limit switch..............................................533 Lifting limit switch...........................................................................533 Lowering limit switch..........................................................................535 12.3.6 Derricking gear.............................................................................536 Switching on the derricking gear...............................................................536 Raising and lowering the boom.................................................................536 Switching off the derricking gear..............................................................537 Lowering the main boom to ahorizontal position...............................................538 12.3.7 Telescoping mechanism.......................................................................539 Overview.......................................................................................540 Telescoping process...........................................................................540 Assignment to display..........................................................................542 Fixed length, intermediate length, telescoping length..........................................544 Telescoping....................................................................................545 Telescoping sequence...........................................................................545 Inspections prior to starting operations......................................................546 Switching on the telescoping mechanism.........................................................547 Function of the control lever..................................................................547 Switching off the telescoping mechanism.......................................................549 Manual telescoping............................................................................550 Checking the initial position.................................................................550 Unlocking the telescoping cylinder...........................................................553 Extending / retracting the telescoping cylinder................................................555 Locking the telescoping cylinder...............................................................556 Unlocking the telescopic section..............................................................557 Telescoping the telescopic section.............................................................559 Locking the telescopic section................................................................560 Locking the telescopic section for on-road driving.............................................561 Telescopic extension with teleautomation......................................................562 Telescoping the main boom inhorizontal position..............................................567 12.3.8 High speed..................................................................................568 Switch onfunction.............................................................................568 Derricking gear / Telescoping mechanism........................................................568 Hoists.........................................................................................569 12.3.9 Slewing gear................................................................................570 Switching on the slewing gear..................................................................570 Slewing........................................................................................570 Braking the slewing movement.................................................................572 Slewing gear freewheel........................................................................573 Switching off the slewing gear.................................................................574 12.3.10 Possible movement combinations.............................................................575 12.3.11 Hydraulic oil cooling......................................................................576 12.4 Settings and displays for crane operation.........................................................577 12.4.1 Limiting the power unit speeds..............................................................577 12.4.2 Setting the characteristic curve for the control levers.....................................579 12.4.3 Inclining the crane cab.....................................................................580 12.4.4 Critical load control.......................................................................581 Function.......................................................................................581 Switching on and off...........................................................................581 12.4.5 Adjusting the stroke interval of the windscreen wiper.......................................582 12.4.6 Operation of the directional spotlights.....................................................583 Switching on / off.............................................................................583 Directing......................................................................................583 12.4.7 Displaying the operating hours..............................................................584 12.4.8 Warning submenu.............................................................................585 Opening thesubmenu............................................................................585 Meaning of the symbols.........................................................................585 Exiting thesubmenu............................................................................588 12.4.9 Error submenu...............................................................................588 12.5 Working range limiter.............................................................................589 12.5.1 Opening the Working range limiter submenu...................................................590 12.5.2 Viewing current settings....................................................................590 12.5.3 Entering limit values.......................................................................592 Overall height / Working radius................................................................592 Slewing angle..................................................................................593 Entering objects...............................................................................595 12.5.4 Entering limit values / objects manually....................................................598 Limit values...................................................................................598 Objects........................................................................................599 12.5.5 Switching monitoring functions on / off.....................................................600 12.5.6 Shutdown by working range limiter...........................................................601 12.6 Work break........................................................................................603 12.6.1 Short work breaks...........................................................................603 12.6.2 Work breaks of more than 8 hours............................................................604 Securing the truck crane against unauthorised use..............................................604 12.7 Heating and ventilating the crane cab.............................................................605 12.7.1 Standard heating system.....................................................................605 Switching the heating system on/ off..........................................................605 Setting the temperature.......................................................................606 Setting recirculated / fresh air...............................................................606 Setting the air distribution..................................................................606 12.7.2 Auxiliary water heater......................................................................608 Preheating the engine..........................................................................608 Preheating the crane cab.......................................................................609 Switching on the heater........................................................................609 Switching off the heater.......................................................................610 Setting the time and weekday...................................................................611 Saving the automatic heating start.............................................................612 Setting the heating period....................................................................613 Switching the automatic heating start on and off..............................................613 Setting the remaining time.....................................................................614 12.7.3 Auxiliary air heater........................................................................615 Switching on the heater........................................................................615 Setting the temperature.......................................................................616 Switching off the heater.......................................................................616 Additional functions..........................................................................616 12.7.4 Air-conditioning system.....................................................................617 Switching on...................................................................................617 Setting the air distribution..................................................................617 Switching off..................................................................................618 For pleasant air conditioning in the crane cab.................................................618 Drying the air.................................................................................619 13 Rigging work............................................................................................623 13.1 Rigging work checklists for crane operation with the main boom....................................623 13.1.1 CHECKLIST: Rigging..........................................................................623 13.1.2 CHECKLIST: Unrigging........................................................................628 13.2 Choosing a suitable site..........................................................................631 13.2.1 Determining the required ground bearing area................................................631 13.2.2 Safe distance from slopes and pits..........................................................634 13.2.3 Earthing the truck crane....................................................................635 13.2.4 Safe distance from electrical lines.........................................................636 13.3 Rigging work after driving with a trailer.........................................................639 13.3.1 Switching off the slewing gear freewheel....................................................639 Prerequisites..................................................................................639 Before slewing.................................................................................640 13.3.2 Switching off the boom floating position....................................................641 13.3.3 Switching off boom pre-tensioning...........................................................642 13.4 Connecting / disconnecting the hand-held control..................................................643 13.5 Starting the engine for driving for rigging work..................................................645 13.5.1 Starting / Turning off the engine with the hand-held control................................645 Prerequisites..................................................................................645 Starting the engine............................................................................646 Turning off the engine.........................................................................646 13.5.2 Starting / Turning off the engine from the crane cab........................................647 Prerequisites..................................................................................647 Starting the engine............................................................................647 After starting the engine......................................................................648 Turning off the engine.........................................................................648 13.6 Outriggers........................................................................................649 13.6.1 CHECKLIST: extending the outriggers.........................................................649 13.6.2 CHECKLIST: retract outriggers...............................................................651 13.6.3 Permissible outrigger spans.................................................................652 13.6.4 Preparing the truck crane...................................................................653 In the driver's cab............................................................................653 Outrigger control units........................................................................653 13.6.5 Setting the outrigger spans.................................................................654 For on-road driving...........................................................................655 13.6.6 Extending / Retracting the outrigger beams..................................................656 From the control units.........................................................................656 With the hand- held control....................................................................658 From the crane cab.............................................................................660 13.6.7 Moving the outrigger pads into working / driving position...................................662 13.6.8 Enlarging the ground bearing area...........................................................663 13.6.9 Extending / Retracting outrigger cylinders..................................................665 From the control units.........................................................................666 With the hand- held control....................................................................667 From the crane cab.............................................................................668 13.6.10 Levelling the truck crane on outriggers....................................................670 Inclination displays..........................................................................670 Prerequisites..................................................................................671 Manual alignment...............................................................................672 Automatic alignment...........................................................................673 13.6.11 Levelling the free-standing truck crane....................................................675 During rigging.................................................................................675 During crane operation........................................................................675 13.6.12 Outrigger pressure display.................................................................677 13.7 Rigging / unrigging the counterweight.............................................................679 13.7.1 Counterweight sections......................................................................679 Basic version..................................................................................679 Additional version1..........................................................................680 Additional version2...........................................................................680 Additional version3...........................................................................681 Additional version4...........................................................................681 13.7.2 Identification..............................................................................682 13.7.3 Slinging points on the counterweight sections...............................................683 13.7.4 CHECKLIST: rigging counterweight............................................................685 13.7.5 CHECKLIST: unrigging counterweight..........................................................687 13.7.6 Assemble counterweight versions.............................................................689 Combinations on the turntable..................................................................690 Setting down the 2.5 t base plate..............................................................691 Combinations for the basic version.............................................................693 Combinations with additional equipment.........................................................698 13.7.7 Counterweight hoist unit....................................................................709 Counterweight submenu..........................................................................709 Extending / retracting the lifting cylinders................................................710 Lock / Unlock counterweight....................................................................712 13.7.8 Removing / installing the counterweight on the turntable....................................713 Installing.....................................................................................713 Removing.......................................................................................715 13.7.9 Assembling counterweight sections for driving the truck crane...............................717 13.7.10 Slewing with rigged counterweight..........................................................719 13.8 Rigging work on the main boom.....................................................................721 13.8.1 Hook block on the bumper....................................................................721 Picking up the hook block......................................................................721 Attaching the hook block.......................................................................722 13.8.2 Hook block on a separate vehicle............................................................723 Picking up the hook block......................................................................724 Setting down the hook block....................................................................724 13.8.3 Reeving and unreeving the hoist rope........................................................726 Fastening the rope end clamp...................................................................726 Reeving the hoist rope.........................................................................728 Unreeving the hoist rope.......................................................................732 13.8.4 Possible reeving methods on the main boom...................................................733 13.8.5 Installing / removing the lifting limit switch..............................................737 Installing the lifting limit switch...........................................................737 Removing the lifting limit switch.............................................................741 13.8.6 Locking / Unlocking the lifting limit switch................................................743 Locking........................................................................................743 Removing the lock..............................................................................744 13.8.7 Installing / removing the anemometer........................................................745 Installing.....................................................................................745 Removing.......................................................................................746 13.8.8 Installing / removing the air traffic control light.........................................747 13.9 Other rigging work................................................................................751 13.9.1 Folding mirrors in and out and adjusting them...............................................751 14 Driving the rigged truck crane..........................................................................755 14.1 Permissible rigging modes and axle loads..........................................................756 14.1.1 With counterweight versions of up to 6 t....................................................756 To drive without a load........................................................................756 To drive with a load...........................................................................757 Axle loads.....................................................................................757 14.1.2 With counterweight versions exceeding 6 t...................................................758 Axle load table................................................................................758 14.2 Route.............................................................................................760 14.3 Before driving the rigged truck crane.............................................................760 14.3.1 Checking the tyre pressure and the wind speed...............................................760 14.3.2 Securing the superstructure against slewing.................................................761 14.3.3 Putting the truck crane on the wheels.......................................................762 14.4 Driving from the driver's cab.....................................................................765 14.4.1 Preparing to drive..........................................................................765 Transmission...................................................................................765 Switching on separate steering................................................................765 Connections....................................................................................765 14.4.2 While driving...............................................................................766 14.5 Driving from the crane cab........................................................................767 14.5.1 Preparing to drive..........................................................................768 14.5.2 Opening / closing the Driving mode submenu..................................................768 Automatically..................................................................................768 Manually.......................................................................................770 Closing........................................................................................770 14.5.3 Starting / turning off the engine for driving...............................................771 Starting the engine............................................................................771 Turning off the engine.........................................................................772 14.5.4 Steering....................................................................................772 Switching on...................................................................................772 Adapt steering direction.......................................................................772 Displays when steering.........................................................................773 Normal steering................................................................................773 Separate steering..............................................................................774 14.5.5 Operating the transmission..................................................................775 Driving direction..............................................................................776 Selecting the transmission mode................................................................776 14.5.6 Starting....................................................................................777 14.5.7 While driving...............................................................................777 14.5.8 Warning messages............................................................................778 14.5.9 Possible connections........................................................................779 Longitudinal differential locks...............................................................780 Transverse differential locks.................................................................781 14.5.10 After driving..............................................................................782 15 Malfunctions during crane operation.....................................................................785 15.1 Emergency stop devices............................................................................785 15.2 What to do when a malfunction occurs during crane operation.......................................787 Load can belowered................................................................................787 Load cannot belowered.............................................................................787 15.3 Fuses on the superstructure.......................................................................789 Notes on changing fuses...........................................................................789 15.3.1 Fuses on the turntable......................................................................790 Fuse groups F1/F2............................................................................790 Fuses on the circuit board....................................................................792 Fuses on I/O circuit boards....................................................................792 15.3.2 Fuses in the crane cab......................................................................793 15.3.3 Fuses in the battery box....................................................................795 15.3.4 SLI fuses...................................................................................796 15.4 Finding and eliminating malfunctions..............................................................797 15.4.1 Malfunctions on the engine for crane operation..............................................797 15.4.2 Malfunctions when operating with the hand-held control......................................799 15.4.3 Malfunctions on the main hoist / auxiliary hoist............................................800 15.4.4 Malfunctions on the derricking gear.........................................................801 15.4.5 Malfunctions on the slewing gear............................................................802 15.4.6 Malfunctions on the counterweight hoist unit................................................803 15.4.7 Malfunctions in the hydraulic system / hydraulic oil cooler.................................804 15.4.8 Malfunctions on the turntable lock..........................................................804 15.4.9 Malfunctions when inclining the crane cab...................................................804 15.4.10 Malfunctions in the telescoping mechanism..................................................805 Telescoping mechanism error messages...........................................................807 15.4.11 Malfunctions when driving from the crane cab...............................................808 15.4.12 Malfunctions on the outriggers.............................................................809 15.4.13 Troubleshooting on the SLI.................................................................811 General malfunctions..........................................................................811 Error messages.................................................................................812 Table of error codes...........................................................................814 Switching off thesensor / tachogenerator.....................................................817 15.4.14 Malfunctions ECOS – superstructure.........................................................818 ECOS program version...........................................................................818 General malfunctions..........................................................................818 Error messages.................................................................................819 Exiting the submenu...........................................................................820 15.5 Emergency operations and programs.................................................................821 15.5.1 Mechanical emergency operation for retracting...............................................822 Check prior to the emergency operation.........................................................822 Procedure......................................................................................822 Mechanical emergency operation.................................................................823 15.5.2 Telescoping emergency program...............................................................825 Starting the emergency program.................................................................825 Determining the type of error..................................................................826 If there is an error on the length indicator..................................................827 If there is an error on a proximity switch.....................................................831 Terminating theemergency program..............................................................832 Tables for approaching the locking points......................................................833 15.5.3 Entering the current telescoping............................................................835 15.5.4 Emergency operation in the event of a failure of the operating elements in the crane cab....837 Preparations...................................................................................837 Operating a power unit.........................................................................838 Stopping movements............................................................................840 Stopping movements in emergencies.............................................................840 Turning off the engine.........................................................................840 15.6 Hydraulic emergency operation.....................................................................841 15.6.1 Important instructions for hydraulic emergency operation....................................841 15.6.2 Operating principle and accessories.........................................................843 For emergency operation........................................................................843 For emergency supply...........................................................................844 15.6.3 Connecting / Disconnecting hoses............................................................845 Establishing connections......................................................................845 Disconnecting..................................................................................846 15.6.4 Activating / deactivating emergency mode....................................................847 15.6.5 Establishing the required hydraulic circuits................................................848 Switching over valves..........................................................................848 For lifting / lowering........................................................................850 For slewing....................................................................................851 15.6.6 Carrying out emergency operation............................................................852 Lifting / Lowering in emergency mode...........................................................852 Slewing in emergency mode......................................................................853 Raising / Lowering in emergency mode...........................................................854 15.6.7 After emergency operation...................................................................855 Switching off emergency operation..............................................................855 Switching over the crane operation.............................................................855 Disconnecting the hoses........................................................................855 15.6.8 Emergency supply of another crane...........................................................856 For emergency supply...........................................................................856 After emergency supply.........................................................................856 16 Technical information for the superstructure............................................................859 16.1 Technical data....................................................................................859 16.1.1 Maximum lifting capacity (DIN / ISO / EN)...................................................859 16.1.2 Dimensions and weights of the truck crane, axle loads.......................................860 16.1.3 Dimensions and weights of removable parts...................................................860 Hook blocks and hook tackle....................................................................860 Counterweight parts............................................................................861 Counterweight versions.........................................................................861 16.1.4 Superstructure..............................................................................862 Engine.........................................................................................862 Main hoist.....................................................................................862 Auxiliary hoist................................................................................862 Slewing gears..................................................................................863 Derricking gear................................................................................863 Main boom......................................................................................863 Lattice extension..............................................................................863 Operating speeds...............................................................................864 17 Index...................................................................................................867 A......................................................................................................869 B......................................................................................................869 C......................................................................................................870 D......................................................................................................871 E......................................................................................................873 F......................................................................................................875 H......................................................................................................875 I......................................................................................................876 K......................................................................................................877 L......................................................................................................877 M......................................................................................................878 O......................................................................................................878 P......................................................................................................879 R......................................................................................................879 S......................................................................................................880 T......................................................................................................882 V......................................................................................................884 W......................................................................................................884
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