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